What Are the Safety Tests for Lithium Batteries?

As a highly efficient energy supply, lithium batteries are widely used in various scenarios in modern society, including electric vehicles, energy storage systems, and consumer electronics. Safety testing for lithium batteries is a crucial step to ensure their safe and reliable operation. So, what are the main testing items? The following is a detailed introduction:

Core Safety Testing Items

1. Overcharge Test

Aimed at evaluating the safety performance of the battery under overcharging conditions. Under overcharge conditions, batteries may experience issues such as temperature rise, gas generation, and capacity degradation. For example, the ul 2054 standard requires that the battery must not exhibit hazardous conditions such as fire or explosion when overcharged.

2. Over-discharge Test

Used to evaluate the safety performance of the battery under over-discharging conditions. Under over-discharge conditions, batteries may experience a voltage drop, temperature rise, and capacity loss. For example, the iec 62133 standard requires that the battery must not catch fire or explode during over-discharge.

3. Short Circuit Test

Used to simulate accidental short circuits and evaluate the battery's ability to withstand short-circuit current impacts. The battery should not catch fire or explode during the short circuit, and the open-circuit voltage after the short circuit should not be less than 90% of its nominal voltage.

4. Temperature Test

Used to evaluate the performance and safety of the battery under different temperature conditions. This includes testing the battery's capacity, voltage, and cycle life in high and low-temperature environments. For instance, the IEC 62133 standard mandates that the battery must not catch fire or explode under extreme high and low temperatures.

5. Mechanical Shock Test

Used to simulate the safety of the battery when subjected to mechanical shocks (such as drops, collisions, etc.). During the test, parameters like the battery's deformation degree and voltage changes are recorded, and it is observed whether phenomena like fire or explosion occur.

6. Battery Pack Safety Test

For battery packs, a series of system-level tests are required, including overcharge, over-discharge, short circuit, temperature, and mechanical shock tests for the entire pack. For example, the IEC 62619 standard requires that battery packs must not catch fire or explode under various extreme conditions.

7. Battery Packaging and Transportation

Batteries must also meet specific safety requirements during packaging and transportation, including moisture resistance and shockproofing. For example, the UL 2054 standard requires that batteries must not catch fire or explode during packaging and transit.

8. Thermal Abuse Test

Evaluates the safety of the battery under high-temperature conditions (usually 130°C). The battery must not rupture, catch fire, explode, or present other hazards.

9. Low Pressure (Altitude) Test

Simulates the safety performance of the battery in low-pressure environments, such as high altitudes.

10. Internal Short Circuit Test

Used to verify whether the Battery Management System (BMS) can effectively prevent internal short circuits, thereby ensuring the safe use of the battery.

11. Thermal Propagation Test

Used to evaluate whether thermal runaway will propagate to the entire battery system if a single cell experiences thermal runaway.

12. Laser-Induced Thermal Runaway Propagation Test

Used to simulate the safety performance of a battery under extreme high temperatures, requiring that adjacent cells must not ignite.

13. Battery Management System (BMS) Functional Test

Includes evaluating functions such as overcharge voltage protection, overcharge current protection, over-temperature protection, and resistance to thermal runaway propagation, ensuring the BMS works effectively under abnormal battery conditions.

14. Vibration Test

Simulates the vibration environments the battery may encounter during transportation or use, evaluating its performance and durability under these conditions.

15. Nail Penetration Test

Evaluates the puncture resistance of the battery separator by piercing the battery with a sharp object. This test is vital for improving battery safety.

16. Drop Test

Simulates a scenario where the battery is dropped from a certain height onto a hard surface to evaluate its structural integrity and safety. After the test, the battery must be observed for damage, leakage, or fire.

17. Crush Test

Evaluates the safety of the battery when subjected to mechanical crushing, simulating the pressure the battery might face during actual use. Deformation, voltage changes, and any signs of fire or explosion are recorded.

18. Battery Separator Puncture Test

Evaluates the puncture resistance of the battery's internal separator film, which is crucial for enhancing overall battery safety.

Technical Specifications & System Requirements

19. Technical Specifications for Battery Module Testing Systems

Specifies the terminology, technical requirements, and test methods for lithium-ion battery module testing systems. This applies to lithium-ion traction battery packs and systems for electric vehicles.

20. Electrical Performance Test Methods for Lithium-ion Traction Battery Packs and Systems for Electric Vehicles

Specifies the electrical performance test methods for EV lithium-ion battery packs and systems, including test procedures for high-power and high-energy applications.

21. Safety Requirements and Test Methods for Lithium-ion Batteries for Electrical Energy Storage

Specifies the safety requirements and test methods for lithium-ion batteries used in electrical energy storage, including safety performance tests for individual cells and modules.

22. Safety Requirements for Moving Parts of Battery Systems

Includes anti-pinch and anti-misoperation measures to better suit scenarios involving forklifts, AGVs (Automated Guided Vehicles), etc.

23. Electromagnetic Compatibility (EMC) Requirements

The battery system should comply with the iec 61000 standard to avoid functional abnormalities caused by electromagnetic interference.

24. The Battery System Must Be Equipped with a "Key" or "Lock" Device

To prevent accidental operation by non-professionals.

25. Live Parts (Terminals, Wires) Must Have Reliable Insulation and Protective Measures

To avoid the risk of accidental electric shock.

Through the corresponding safety tests listed above, the safety and reliability of lithium batteries in various application scenarios can be ensured, providing standard guidance for lithium battery safety assessments.

Testing Services Provided by JJR Laboratory

JJR Laboratory provides a comprehensive suite of services including: un38.3, IEC 62133, GB 31241, ul 1642, UL 2054, cb certification, ce marking, pse certification, kc certification, BMS Testing, Altitude Simulation, Low Pressure Simulation, Thermal Cycling, Thermal Shock Test, Vibration Test, Mechanical Shock, External Short Circuit, Heavy Impact, Crush Test, Nail Penetration Test, Overcharge, Overcharging Test, Forced Discharge, Drop Test, Thermal Abuse Test, Heating Test, Thermal Runaway, Washing Test, Projectile Test, Insulation Resistance, Flame Retardancy Test, Fire Resistance Test, Over-discharge Protection, Over-current Charging Protection, Over-temperature Protection, Molded Case Stress Relief, Battery Cell Safety Test, Battery Pack Safety Specification, Class 9 Dangerous Goods Transport, SoC Limit, Capacity Verification, Internal Resistance Test, and Explosion-proof Test.