ZL-3210 Power Battery Squeezing Test Machine

Standard:

GB/T 31485-2015     Safety requirements and test methods for power batteries for electric vehicles

 UN38.3             Test standard and regulation of lithium battery and battery pack

GB/T 18287 -2013     External short circuit requirements of General specification for lithium

                               ion batteries for cellular telephones

QC/T743-201X        Lithium ion battery for electric vehicle

GB/T 21966-2008     Safety requirements for lithium primary batteries and batteries in transit

UL 2054: 2012         Household and commercial storage battery

IEC 62281: 2004      Safety requirements for lithium primary batteriy and battery pack in transit

 

Principle details of equipment:

Test objective:This tester is used to simulate all kinds of power lithium battery in the course of being squeezed.It presents different possible situations when the battery is under strong external pressure.When the battery explode or burn during the test,the equipment shall guarantee the personal safety and does not harm the test environment absolutely . In the squeezing test,the battery shall not explode or burn.

 

Test method

The single cell battery is tested according to the following conditions:

Squeezing direction: pressure should be perpendicular to the battery plate (Refer to figure 1 below)

Squeezing plate form: the half cylinder’s length is 650mm,diameter of 75mm, its size is larger than the battery

Squeezing rate: （5±1）mm/s

Squeezing level:When the voltage reaches 0V or deformation reaches 30% or the extrusion pressure reaches 30kN, stop squeezing.Observe for 1 hour.

 

The battery module is tested under the following conditions:

 

Squeezing plate form:the half cylinder’s length has a diameter of 75mm, its length is longer than the size of battery,but no more than 1m.

Squeezing direction:it is the same as the most likely direction to be squeezed of the battery module in the vehicle layout. Pressure should be perpendicular to the battery plate or monomer arrangement.

Squeezing rate: （5±1）mm/s

Squeezing level:deformation of battery module reaches 30% or the pressure reaches 1000 times the weight of the battery module and larger values in the following sheet.

Keep it for 10min,observe for 1 hour.

 

Diagrammatic sketch of squeezing and module extrusion plate

 

Squeeze pressure selection sheet

 

compressive plane contact number/ n	Extrusion force/kN
1	30
2~5	100*n
>5	500

 

Main feature and function

Equipment safety explosion-proof function,

convenient and environmental protection performance

 

The equipment should be tested in a separate compartment, surrounded by a solid wall .Compartment door is explosion-proof .There should be 2-3 meters of space around the compartment.For test safety,controller and testing section should be separated.

Tester type:four column vertical structure,maximum extrusion force 30kN

Remote control the main part of the equipment and console extension.Operators stay away from the test area, guarantee the safety of test personnel.

 

Inner box, middle layer, outer box are three parts of testing machine:

Inner box material: stainless steel plate (SUS#304 thickness: 3.0mm), stainless steel welded, and  all affixed with high temperature resistant and flame retardant Teflon tape. Not only protect the inner box , it is easy to clean after the test, easy to replace Teflon tape.

Outer box material: cold-rolled plate stoving varnish (3.0mm thick), the middle layer has buffer insulation effect, when tank pressure is too large, it can effectively alleviate the pressure impact on outer box.

Meanwhile, inside the box,when the burning tempertureof the test sample is too high,it can effectively interrupt the transmission of temperature, protect the safety of the test personnel.

 

The rear part of the box is equipped with an explosion-proof door, with explosion-proof door lock. When the inner pressure intensity is too large (about 30kgf), explosion-proof door will open, which is helpful to pressure relief and explosion venting.Explosion-proof door is easy to open and close, easy to operate, good sealing and connection.There should be no sundries within two meters of open space around the explosion-proof door , ;

 

Front door:single door on left.The front door is equipped with a safety power-off induction switch. When the door is opened, the control part of power equipment can not be started, unable to carry out follow-up operation. Only when the door is closed, the tester can start the control program for subsequent operations, play a protective role in a true sense.

 

Air smoke exhaust and outfire system

 

The rear part of the box is equipped with an exhaust fan,has a diameter of 300mm, and an exhaust duct which can connect to external exhaust fan.While the air inlet at the left side of the box can be opened at the end of the test t. Flue gas can be discharged quickly. In the test,exhaust fan should be opened at first.

 

Smoke alarm and outfire system design: As for battery explosion may occur, first smoke alarms should be installed in the test area.When the test sample lets out smoke, smoke alarm can automatically detect it, the fan would start automatically (you can also start it at the begining). Remind testers manually open the external exhaust fan, smoke would be discharged through the exhaust duct .

 

Equipped with a fire extinguisher: if the battery is on fire, the fire extinguisher can be operated on the integrated control panel

 

Lighting design:The top of the test box is equipped with a three-proofings lamp, dustproof,explosion-proof ,fire-proof,explosion proof lamp housing can be replaced easily.

 

The power battery extrusion test machine has the “emergency stop” button, which is convenient for the emergency treatment in the critical situation, and the emergency stop button is used to stop all the actions of the squeezing testing machine under the critical condition to prevent the occurrence of harm

 

Equipment strength support section:the bottom of the device is equipped with a fixed universal roller and an adjustable supporting foot for fixed position

 

The tester is equipped with an independent camera to observe and record, and the camera can capture the image clearly, as part of the test report.Photographic data can be reserved.

 

The power battery tester is equipped with special tools, which can be used in fixed battery and battery module.

 

Safety protection system

Emergency stop function on the control panel ; limited conditions of protection

Input protection: undervoltage 、overvoltage、 overcurrent 、lost phase、overload、

Over temperature shutdown alarm

Output protection:overvoltage、 overcurrent、overload

 

Working conditions and environmental requirements

Ambient temperature :roomtemperature～35℃

Ambient humidity:≤20%～ 65±5%R.H

Atmospheric pressure:86～106kPa

No strong vibration around

No direct exposure to sunlight or other heat sources

Power supply: AC380V（＋15%，-10%）three phase 50Hz±2%

 

Functions and features of control and operation part:

 

According to the monomer battery test requirements,keep squeezing until the battery shell rupture,then stop extrusion test .That is, induce the pressure change through the force sensor to fulfill thedestruction  closing down test, while maintaining the maximum power value on the computer operating screen.

 

According to the test requirements of modular battery, the test system can manage to squeeze the battery module to 30% of its’ dimensions (i.e., deformation ratio); or setting a certain pressure value (such as the extrusion pressure is 1000 times the weight of the battery module or larger value in 20~30kN). When the extrusion test pressure value is reached ,the test could be ended after the set pressure duration (1 – 9999s) .

 

Through the built-in high precision encoder, multiple steps and stages of the extrusion test could be set and programmed in the test software freely . In the test with a stroke control variable settings,at the end of the test，extrusion plate does not move, it can avoid the expansion of the battery which would lead to fixture shift.It also can be set that extrusion plate back to the initial position after extrusion, two ways for selection.

 

All kinds of test requirements included:

 

It can be tested according to one of these three conditions such as pressure, stroke (variable can be a numerical value or a percentage), voltage.

 

It can be tested by arbitrary combination conditions of three test modes as control variables. For instance, set up three or two test conditions, meet any one of these conditions, then stop the test. This is in accordance with all the latest domestic and foreign single cell or battery module extrusion test requirements.

 

The test system can test the speed at the same time, and testing speed can be set up in the computer software as required. unit:mm/min

 

The main features of extrusion test software

 

Operation settings are handled by the windows dialog box.It can plan the form mode automatically, record the test data at the full scale, and provide the complete planning of preservation, comparison and tracking.

 

Extrusion special test main control board, can record the power,the displacement (stroke), voltage at the same time.It can directly monitor the battery voltage and sends instructions to the equipment. It can real-time record and monitor the extrusion pressure, pressure, battery temperature, test speed, test deformation value and curve at the computer control interface . It is easy to generate a report or derived directly, the interface is easy to operate.

 

Test system voltage acquisition and control :it can control the extrusion test by collecting the voltage during the testing in the battery during the test .During the battery test, the voltage will change. Input a specified magnitude of voltage in the test system, and the test can be stopped when the output signal of the system reaches the set voltage value.

 

Control of experimental conditions: to set pressure, constant deformation (can be numerical or percentage), constant voltage test, can set pressure at the same time, fixed deformation, multi stage voltage control procedures and maintain procedures for each test process can keep the time within 0 ~ 9999S; It can continuously set multi steps of test procedures in one experiment.

 

Test condition termination: the software can terminate the test conditions and termination, it can also terminate the extrusion plate back to the initial state, the termination conditions can be custom set according to any single termination condition or any combination of custom settings: such as pressure, battery, pressure holding time, deformation, hold time test under one condition.

 

Other test options can be displayed: test speed, deformation, peak pressure display, etc.

 

All the test methods are storaged in the independent test method file, which can be added and modified easily by user, and be shared in different instruments. All test data display name can be customized, modified and stored in the test method file respectively, to meet the needs of different customers.

 

 

Introduction to the main interface of remote extrusion test software

(as shown in figure 2)

 

4 regions (curve area, real-time acquisition of data area, control panel area and test data area) at a glance; this system display force, stroke (displacement), voltage which summaries in a test interface: 

Data area can be hidden

Test settings, curve selection and report print storage

Test settings include: sample information, control plans, test completion criteria and other common information

The movement speed can be set quickly on the test board (applicable to the test of speed requirements)

               You can use shortcut keys to control the movement of the machine

The data in the database can be removed manually

The data in the database automatically calculates the statisticl values, the maximum, minimum, average, standard deviation, coefficient of variation of each column

 

Main technical specifications of the equipment

Extrusion parameters:

Drive mode: hydraulic system drive

Pressure control: solenoid proportional valve control

Maximum extrusion pressure: 30kN  can be customized

The largest test space: 700 x 700 x 700mm (W x D x H) can be customized, can be tested for a variety of power batteries and modular batteries

Max stroke: 650mm

Extrusion speed: (5 +. 1) mm/s

Power display: high precision pressure sensor and display through the computer

Sensor accuracy: level 0.5   sensor resolution: 1/10000

Squeeze pressure control accuracy: + + 1%

Unit conversion: KGF, LBF, N, kN;

Displacement resolution:0.001 mm

Displacement control accuracy: ±1%

Voltage display accuracy: ±0.1%FSR

Data sampling frequency: 50 times / sec

Pressure holding time: within the range of 0 ~ 9999s can be set arbitrarily

Signal transmission mode: RS serial port or USB 2 232 high speed serial port

Extrusion direction: extrusion plate from right to left or left to right

Extrusion plate configuration details:

Single cell extrusion head: a half cylinder with a radius of 75mm, the length of the half cylinder (L) is larger than the size of the squeezed cell

Module battery pack plate: half cylinder of diameter 75mm, the length of the half cylinder 650mm is larger than the size of the extruded battery, but not more than 1m.

Number of extruded plates: 1 set of single cell extrusion plate , 1 set of module battery extrusion plate

The extrusion plate is made of high hardness A3 steel plating, surface attached with flame resistant Teflon tape; the under flat reserves diversion groove, which is convenient for leakage of electrolyte outflow;

The monomer battery is squeezed to the voltage 0V or the deformation reaches 30% or the extrusion pressure reaches 30kN after the extrusion (base on which reaches first). Observe for an hour.

For the battery pack, the deformation of the battery module is up to 30% or the pressure is up to 1000 times the weight of the battery module and the larger values are listed in the table below.

 

Extrusion selection sheet

contact numbers of extrusion surface n	extrusion force/kN
1	30
2~5	100*n
>5	500

 

Equipped with 1 sets of 300mm thickness of intermediate bearing plate, so that applys to small size cell extrusion testing machine.

Data collect voltage, temperature, pressure, velocity, displacement (cell deformation) and other parameters can be output and record the data storage, leading out as EXCEL format and generate curve chart.

High definition video monitoring system a set of (5 million pixels), can keep records of image data, and can be observed in real time on the computer;

Outer size: about 1600*1470* 1240mm  （L*W*H）(Hydraulic oil source and control box volume are not included)

Weight: about 1.8 ton

Power supply:380V， 50HZ， 20kW；

One set of extrusion test software    independent R&D           Dongguan