Battery Testing Solutions. - Fhi · 2020-02-14 · 17 With Security Installations: EUCAR Hazard...

Battery Testing Solutions.Wesley Witteveen – Weiss Technik B.V. Tiel

Weiss Technik Battery Testing Solutions.

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Future Visions with Batteries.

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Requirements on energy storages.

✓ Long duration.. Much power..

✓ Rechargeable

✓ Fast charging!

✓ Light

✓ Small

✓ Long Lifecyle / infinite number of rechargeability

✓ No heat development

✓ Long-term warehousing (with no further checks)

✓Weather-resistant (Warm, Cold, moisture, …)

✓ Low price

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Many different chemical combinations:

Which one is the best?

It always depends on your application…

Most popular in media worldwide is Li Ion.

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Highest requirements lead to a higher failure risk.

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Highest requirements lead to a higher failure risk.

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Mistakes and dangers with energy storages.

Top 3 most done mistakes with batteries:

• Too long in stock (with no control)

• Stock in wrong environmental conditions (Temperature, Humidity)

• Wrong charging (wrong charger, charging process, charging time)

Top 3 most dangerous mistakes with batteries:

• Overload or wrong loading

• Mechanical damage

• OverheatingNo chance for not testing...

(Only Li-Ion batteries have over 40 different test specifications)

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Several Test Categories for Li-Ion Batteries.

Humidity

Temperature

Thermal-Shock

Temp.-Changes

Vibration

Gas

Saltspray / Corrosion

…

Visual Inspection

Leakage

Connectors

Geometry

Weight

…

ElectricalTests

Capacity, Power, Resistence

Lifetime

Self discharge

Cold start

Safety

Short circuit

Power interrupt

Plug interrupt

Reset

Abusetests

Bruise / Squashing

Fall

Deep discharge

Overload

Reversed Polarity

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Necessary Security Topics.

Batteries with high energy level und huge performance level.

→ Potential dangers during test processes are increasing dramatically.

Safety First with test systems:

1) People

2) Buildings

Different possibilities and opinions regarding the security installations:

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Without Security Installations:

Advantages

• Lower investment / costs

• Possible damage of test equipment is accepted / acceptable

• Let the test equipment burn down and buy a new one

Disadvantages

• Environmental harms

• Stop of company processes / possible lost of money

• Maybe lost of important and expensive prototypes

• Danger for workers in the test area

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Energy Storage Checklist

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With Security Installations: EUCAR Hazard Level

Hazard Level

Description Security Level and results

0 No effects. No effect, no functional limitation

1 Start of passive security system.

No damage, no leakage, no gas leak, no fire, no explosion, no reaction, no thermal runaway.

Cell broken reversible, repairs of security installations necessary.

2 Damage No leakage, no gas leak, no fire, no explosion, no reaction, no thermal runaway.

Cell broken irreversible, repairs of security installations necessary.

3 Leakage

(Weight loss < 50%)

No gas leak, no fire, no explosion.

Leakage of electrolyte <50%.

4 Gas leakage

(Weight loss > 50%)

No fire, no explosion.

Leakage of electrolyte >50%.

5 Fire No explosion, no flying parts.

6 Fraction No explosion, but flying parts of the active mass.

7 Explosion Decomposition of battery cell.

External influences, internal topics with results on the Li-Ion battery

With Security Installations: EUCAR Hazard Level

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Test Equipment INDOOR or OUTDOOR

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Indoor• Security installation on the building in some cases

necessary

• Personal protection has to be guaranteed

• Necessary approval procedures

• Security to other facilities in the neighborhood has

to be clarified

• Existing space can be used.

07.02.2020 Weiss Battery Testing Solutions

Test Equipment INDOOR or OUTDOOR

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Outdoor• Container, bunker, seperat building etc.

• Security installations only focused on this

• Easier and faster approval processes

• Shorter installation time in many cases

• Laws of fire protection are easer in realization

• Disadvantage: Need more space…

07.02.2020 Weiss Battery Testing Solutions

Customized test equipment for batteries

¬ Customized, tailor-made complete solutions

for testing Li-Ion batteries

¬ Lots of application solutions

¬ Hazard-Level security levels

Branch: Electronics & Automotive – Li-Ion

Feature

¬ Risk of deflagration, explosion etc.

¬ Leakage of harmful gases

Test Equipment in all sizes.

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These customers use our battery testing solutions:

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Customized test equipment for batteries

¬ Customized, tailor-made complete solutions

for testing Li-Ion batteries

¬ Lots of application solutions

¬ Hazard-Level security levels

Branch: Electronics & Automotive – Li-Ion

Feature

¬ Risk of deflagration, explosion etc.

¬ Leakage of harmful gases

Test Equipment in all sizes.

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Our huge experiences: Project Examples

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• Prototype Testing (Temperature cycles)• 12 Cells in one chamber• Cell size of 200-400mm length, 20mm

depth• Central master control→ no control

panel on the chambers


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2-Level installation

Power electronics / Battery tester

Exhaust air with smoke detection

Kratzer control unit

Touch panel with special customer user interface

Weiss technik chamber ClimeEvent withHazard Level


26Plumm; Gotthardt // Battery Testing: Weiss References

Temperature chamber with 4 drawers Fully filled tray in test space

Drawer with 3 customized connection ports – One Wire ID

For internal trainings only!



• Testing unit for smaller cells



• Temp. Testing for whole systems

• About 2.5m weidth

• Chamber size 6-9m2

• No big height needed



• Lift truck used for bringing packages in

• Double bottom

• Cables layed in lower level

• Temp. and Humidity testing



• Temp. and Humidity

• Chamber size between 6 and 9 m2

• CO and O2 controlled

• Hazard Level 7



• System is in a container outside

• Gas sensors with two switching thresholds:

• Pre-alarm activates exhaust air

• Main alarm calls fire department



• Cooperation for Battery + Control unit

• Hazard Level Container with standard chambers

• HL7

• 6 Chambers (3x 600l; 3x 1500l)



• Water in- and outlet

• 22 Bar flooding with water



• Battery X-Ray solution

• First of its kind during temp. cycles..

2700 liter climatic chamber HL 6

Plumm; Gotthardt // Battery Testing: Weiss References 35

2700 liter climatic chamber HL 6


2700 liter climatic chamber HL 6 Interior


Gas detection


Pressure resistant cableports


Nitrogen purging


Burst disc


Cable penetrations


07.02.2020 Plumm; Gotthardt // Battery Testing: Weiss References 43

Chamber 16 m3 HL 6

Optic and acoustic alarm

Pressure release flap

Fire detection via CO gas sensor

Gas and pressure resistant syphon

InertisationAccess ports with retaining clamps

Air purging unit

Burst Disc

Electrical door lock

A 3-Axis Vibration System is also called Multi-Axial Simulation Table or short: MAST system.

3-Axis Vibration System


Possibilities for installation of a MAST system to a climatic test bench:

3-Axis Vibration System


Test chamber with integrated MAST systemhas a flexible sealing at the actuators and

the hydraulic cylinders are positioned outsideof the chamber

Test system with flexible wall elementsincl. motor-driven raise and sink of the wall

Questions ?

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Weiss Umwelttechnik GmbHGreizer Straße 41 - 4935447 Reiskirchen ¬ GermanyTel +49 6408 [email protected]

Battery Testing Solutions. - Fhi · 2020-02-14 · 17 With Security Installations: EUCAR Hazard...

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