• Safe battery testing

    The testing of lithium-ion batteries for electric vehicles must be safe for people, equipment and buildings. More than 12 years’ experience in battery testing makes Weiss Technik a reliable and professional partner.

Battery Testing at Weiss

Standard test chambers and customized solutions

Sophisticated test technology is required to test the safety, reliability and performance of electrical energy storage devices for vehicles under all thermal, climatic and mechanical stresses. That is why we offer automobile manufacturers and suppliers a large selection of tried and tested standard test chambers. In addition, we plan and implement customized test chambers and rooms as a single-source supplier and support the planning of laboratories and the integration of central refrigeration units.

Proven test technology in all dimensions

  • Cells
  • Modules
  • Battery packs
  • Complete drive units
  • Battery Management System (BMS)

Small test chambers, walk-in test chambers and complex test systems

  • Performance and ageing tests
  • Climate tests
  • Environmental simulation tests
  • Vibration tests
  • LV-124 tests

1

Requirement analysis

In joint workshops with our customers, we specify the required test standards, test capacities and other requirements of the planned testing laboratory.

2

Definition of scope of supply

In technical discussions, we clarify which test technology is needed exactly and whether a turnkey solution is applicable. A rough price indication can then be given.

3

Technical definition of subsections of the project

A project team, consisting of weisstechnik experts and customers, defines the technical specifications for all relevant subsections. We then quote a non-binding budget price.

4

Binding quotation

After finalizing and consolidating all subsections, we prepare a binding quotation. Within the framework of final agreements, changes can still be made if necessary.

5

Production of the test systems

After receiving an order, we plan and realize the test systems ordered. Depending on the requirements, we either modify proven standard systems or build completely new customer-specific units.

6

Installation and commissioning

After shipment, our experienced service technicians will install the test systems on site and commission them professionally.

7

Training of employees

In the initial stage, we support our customers with personnel trainings for their employees. weisstechnik Academy also offers online and classroom trainings.

8

After sales service

Customer service is the focus of our thinking and acting. We offer a comprehensive service network with short response times, reliable support by qualified service technicians, preventive maintenance and reliable spare parts supply.

12 years’ experience with battery testing
The market for lithium-ion batteries is growing rapidly - and so is the need for specialized test laboratories. Having been involved in this field of technology from the very beginning, we have been developing test systems for lithium-ion batteries for more than 12 years. Our customers benefit from our experience, regardless of whether they are start-up companies or automobile manufacturers. We will be happy to advise you on what you need for your battery testing system.

Our consulting services:

  • Safety concept
  • Test standards
  • Support in building planning
  • Test capacities
  • Process optimization

LV 124
Automotive Test Standard LV 124 describes the most important standardized tests for energy storage devices in the automotive industry. We would be pleased to inform you about how our solutions can reliably meet the requirements of LV 124.

Tests requested:

  • Vibration
  • Mechanical shock
  • IP tests
  • Condensation and climate tests
  • Temperature shock
  • Splash water test
  • Temperature tests
  • Sun radiation
  • Salt spray test
  • Noxious gas test

UN38.3: Classification in dangerous goods classes
Standard UN38.3 is based on the transport regulations for dangerous goods and describes the tests for classifying energy storage devices in dangerous goods classes. It is a worldwide valid standard that is binding for all manufacturers of electrical energy storage devices.

Tests requested:

  • Vibration
  • Mechanical shock
  • Crush test
  • Altitude simulation
  • External short circuit
  • Overloading
  • Deep discharge
  • High-temperature test
  • Forced unloading

A wide range of standards and test specifications define the type of tests that must be carried out on batteries. In order to achieve reliably comparable results at all times, the prerequisites and the test procedure are precisely defined. We support you in the planning and implementation of a tailor-made solution for your testing task. Of course, we adhere to all relevant standards and specifications and advise you in detail if required.

Battery tests determined according to international standards include tests in the areas of environmental stress, electricity, mechanical stress and performance/ageing.

Safety during battery testing

Assessing dangers correctly

Due to the high energy density of lithium-ion batteries, overloads and malfunctions can occur during tests. If a so-called thermal runaway occurs in a single cell, this uncontrolled chemical reaction can spread to other cells and destroy the entire battery. The potential effects and dangers of a malfunction increase as the storage capacity increases. Safety in the laboratory is therefore a top priority for us.

We advise you on how much safety is needed

We are a TUV*-certified specialist for battery testing technology, and as such adhere to the Machinery Directive and the requirements of the CE Declaration of Conformity. In addition, we comply with the EUCAR hazard standards and the ATEX directives for hazard assessment. We advise our customers in detail which safety standards are relevant for their specific testing tasks and which safety equipment is necessary for their testing systems.

To better assess the hazard potential of tests, EUCAR (European Council for Automotive R&D), a consortium of European car manufacturers, has investigated hazardous situations and divided them into eight risk classes. The development of the safety equipment of our battery test systems is also based on this classification.

The weisstechnik module kit for hazard levels
We have developed a special hazard level module kit for our lithium-ion test systems. For each hazard level, we recommend specific safety devices that can be fitted to our test systems according to customer specifications. This means that tests can be carried out safely in the intended hazard levels. Together with our customers, we assess which safety devices are necessary for the respective test systems.

ATEX directives are valid throughout Europe to ensure the safe operation of industrial plants and equipment in potentially explosive environments or under potentially explosive conditions. They supplement the measures specified in the hazard levels, which only consider the danger of overpressure-induced explosions of housings. ATEX also takes into account the dangers of explosive mixtures that may occur during a battery test if gas is introduced into the test space by the test specimen. Depending on the hazard potential, battery test systems may also require safety measures in accordance with ATEX standards.

Is ATEX protection required? We advise you.
Together with our customers, we analyze the hazard potential of their test projects, also with regard to the risk of gas explosions. Depending on the requirements, we equip our battery test systems with safety devices in such a way that they reliably meet the required ATEX guidelines.

Further information about ATEX

Abuse tests for batteries

Withstand maximum stress

Abuse tests push electrical energy carriers to the limit (of their capability) – and sometimes even beyond. Batteries are exposed to extreme stress such as extremely high or low temperatures, mechanical damage such as crushing or electrical loads such as short circuits or overcharging and deep discharge.

These tests under extreme conditions require particularly high safety standards for test equipment. Weiss Technik is currently developing new test systems for abuse tests.

Test technology for the automotive industry

Accidents during battery tests are dangerous for people, test specimens, test equipment and buildings. This is why the test service provider of a major German automobile manufacturer has been relying on environmental simulation systems from weisstechnik for many years. A large number of accident-free test systems proves our high safety and quality standards.

We plan and equip complete test laboratories

As a full-range supplier, we have contributed our concentrated expertise to the construction of the new large battery test laboratory of a renowned test service provider. The center is one of the largest battery testing laboratories in Germany and is operated exclusively with test systems from us and our partners.

Innovations from Silicon Valley

Because of our well-established global presence, we were able to reliably serve Californian customers who were new to the automotive sector. We supported their innovative approaches in the field of electric cars with our expertise in order to safely implement new ideas on the market.

Electric cars and mobile phones from Asia

We have been working together with customers from Asia for many years. Our test systems have been supplied both to electric car manufacturers in China and to Korean mobile phone manufacturers who use lithium-ion technology.