Everything you can do wrong with batteries, properly tested.
Safe extremes: Controlled abuse testing for modern high-voltage batteries
Abuse and misuse testing are a central component of battery development and a prerequisite for the approval of modern energy storage systems. These tests deliberately expose cells, modules, or packs to overcharging, crushing, short-circuiting, or fire – tests that often lead to thermal runaway and require the highest safety standards.
AIP's battery abuse and misuse test benches offer a completely secure, standard-compliant, and reproducible test environment for this purpose. Extreme scenarios can be recreated in a controlled manner, while fire bunkers, automatic extinguishing systems, and redundant gas and temperature monitoring effectively protect personnel and infrastructure. In this way, AIP creates the basis for reliable, safe, and professionally conducted abuse tests of modern HV batteries.
Advantages
- Maximum safety thanks to fire bunkers, extinguishing systems, and monitoring.
- Reproducible extreme tests under constant conditions.
- A wide range of abuse scenarios such as overloading, crushing, or short-circuiting.
- For all battery sizes – from cells to packs.
- Compliant with national and international safety requirements.
Application
- Type approval of modern batteries.
- Development of new cell, module, and pack designs.
- Analysis of thermal runaway and propagation.
- Quality assurance in production and testing.
- Research into materials and safety concepts.
Safely test what should be safe.
Mechanical battery tests
Mechanical abuse tests show how resistant batteries are to crushing, nail penetration, or deformation. The testing technology provided by AIP enables reproducible loads and clearly reveals structural limits and safety-critical reactions.
Standard reference:
- UN 38.3
- IEC 62619
- IEC 62133
Thermal battery tests
Thermal abuse tests realistically simulate overheating and thermal runaway scenarios. Stability limits, thermal behavior, and critical reaction processes are reliably examined on specially designed AIP test benches.
Standard reference:
- UL 9540A
- IEC 62660
- GB/T 38031
Electrical battery tests
Electrical abuse tests simulate overcharging, short circuits, or deep discharge under strictly controlled conditions. AIP's test solutions clearly identify safety limits and electrical malfunctions – in accordance with standards and reproducible.
Standard reference:
- IEC 61960
- UN 38.3
- SAE J2464