Intertek offers abuse tests of batteries for electric and hybrid vehicles - tests for the European and North American market from one source

22 May 2012

Stuttgart/Kaufbeuren - Intertek, a leading provider of quality and safety solutions for a number of industries worldwide as well as a long-term partner for research, development and testing for component manufacturers and the automotive industry, continues to expand its service portfolio for the automotive industry at its location in Kaufbeuren (Bavaria) with the construction of an on-site e-mobility test laboratory. As of now, the laboratory also offers abuse tests and lifetime tests for batteries and battery packs for electric vehicles as well as hybrid vehicles. Thereby batteries and battery packs could be cycled with a power up to 320 kW. The electrical parameters of the battery can vary between 0-1000 VDC and 0-1200 A.

"Abuse" can be interpreted as misuse or abnormal use. Abuse tests of vehicle batteries and battery packs allow the targeted and controlled regulation of known or suspected abnormal operating conditions or misuse. The test portfolio includes the simulation of critical conditions in transport and shipping, assembly/installation, maintenance works and in the operation of the vehicle. In the tests, the battery experts run the test samples to their absolute specification limits. The energy stores are mostly destroyed after the test runs. These special stress tests simulate the effects of maximum mechanical, chemical and thermal forces as well as further environmental forces (e.g. height simulation). The knowledge gained leads to constructive changes which should significantly reduce the risks to people, the environment and material, during transport and use of the batteries.

The following, among others, are included in the demanding abuse tests by Intertek:
Overcharge: This test seeks to simulate the overcharging of a battery with charging equipment or charging a battery with defective charging equipment.
Short Circuit: What happens if a short circuit takes place between both poles, or conducting material or a conducting tool falls onto the battery? The trigger for the laboratory short circuit is a switch which is designed for short circuit currents of at least 4,500 Amps.
Penetration Test: This test regulates the consequences of a foreign body penetrating the cells. In doing so the battery shall be fully penetrated with a needle.
Crush Test: Intertek regulates the mechanical crushing of batteries which can occur inter alia during transport or accidents.
Impact Test: Here, the experts simulate targeted risk situations which are encountered by the cells, for example, during the packaging of the battery or during transport.
Further Tests: The modern test equipment also allows for battery testing according to various customer-specific requirements.

The heart of the abuse laboratory in Kaufbeuren, which covers more than 150 m², is a special bunker with 27 m³ chamber volumes and a special, chemical-resistant floor pan. Since all the tests mentioned can result in the test samples catching fire or bursting, Intertek test engineers conduct the tests from a control room which is fully isolated from the test bunker. During testing, they are supported by a digital thermal test sample monitor. If a battery does burst, equalisation valves as well as combustible gas removal and cleaning is automatically activated. All of this allows battery stress tests to be simulated without risk to people and the environment.

Contact:

Roger Grumpelt, Business Development Manager E-Mobility, Intertek Germany
Tel. +49 8341 9556 301
Email: roger.grumpelt@intertek.com

Metin Saglam, Key Account Manager, Intertek Deutschland GmbH
Tel. +49 171 8870273
Email: metin.saglam@intertek.com

Christian Kleinert, Marketing Director, Intertek Holding Germany
Tel. +49 711 27311449
Email: christian.kleinert@intertek.com

About Intertek

Intertek is a leading provider of quality and safety solutions serving a wide range of industries around the world. Through our services, we help our clients to minimise the adverse health and environmental impact of their products and processes for the benefit of society as a whole. From auditing and inspection, to testing, quality assurance and certification, Intertek people are dedicated to adding value to customers' products and processes, supporting their success in the global marketplace. Intertek has the expertise, resources and global reach to support its customers through its network of more than 1,000 laboratories and offices and over 30,000 people in more than 100 countries around the world.

Please visit www.intertek.com for further information.