What Are The Mechanical Shock Tests For Battery?

Batteries are the lifeblood of countless modern devices, from smartphones and electric vehicles to critical medical equipment. Their ability to withstand the rigors of their intended environment, including sudden impacts, is paramount for safety and reliable operation. Mechanical shock testing for batteries is therefore a crucial aspect of quality assurance. At Dongguan Precision Test Equipment Co., Ltd., we understand the significance of these tests and adhere to relevant standards to ensure battery integrity under forceful transient events.

So, what specific mechanical shock tests are typically applied to batteries? While the exact tests and their severity depend on the battery type, application, and relevant industry standards, here are some common categories and specific standards to be aware of:

Common Categories of Mechanical Shock Tests for Batteries:

• Drop Tests: Simulating accidental drops that portable devices or batteries might experience during handling or use. The drop height, impact surface, and orientation of the battery are carefully controlled.
• Impact Tests: Assessing the battery's resistance to localized impacts, such as those that might occur from collisions or external forces. These tests can involve dropping a weight onto the battery or striking it with a pendulum.
• Shock Machine Tests: Utilizing specialized machines to generate controlled shock pulses with specific waveforms (e.g., half-sine, sawtooth), amplitudes (G-levels), and durations. These tests can simulate shocks experienced during transportation, handling, or in specific operational environments.
• Crush Tests: Although sometimes categorized separately, crush tests involve applying a controlled force to the battery to evaluate its resistance to mechanical deformation, which can be relevant in scenarios involving significant external pressure or impact.

Key Mechanical Shock Testing Standards for Batteries:

Several standards outline specific mechanical shock test procedures and requirements for batteries, depending on their intended application and market:

1. UN 38.3 (Recommendations on the Transport of Dangerous Goods – Manual of Tests and Criteria):

• Application: This is a crucial standard for the transportation of lithium batteries by air, sea, and land.
• Shock Test: UN 38.3 includes a specific mechanical shock test (T4) designed to simulate the shocks that batteries might experience during transportation. The test involves subjecting fully charged batteries to three half-sine shock pulses in each of the positive and negative directions of the three orthogonal axes. The peak acceleration and pulse duration depend on the battery's mass (e.g., 150 G for 6 milliseconds for cells and small batteries, 50 G for 11 milliseconds for larger batteries and battery packs).

2. IEC 62133 (Secondary cells and batteries containing alkaline or other non-acid electrolytes - Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications):

• Application: Focuses on the safety of rechargeable lithium-ion and nickel-based batteries used in portable electronic devices.
• Mechanical Test (Shock and Vibration): IEC 62133 includes a mechanical test (clause 7.3.8 for batteries) that encompasses both vibration and shock. The shock test typically involves subjecting the battery to three half-sine shock pulses in each of the positive and negative directions of three mutually perpendicular axes. The peak acceleration is typically 50 G with a pulse duration of 11 milliseconds.

3. IEC 62660-2 (Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 2: Reliability and abuse testing):

• Application: Specifically for lithium-ion batteries used in electric vehicles.
• Shock Test: This standard includes a shock test to evaluate the battery's ability to withstand mechanical shocks encountered during vehicle operation. It typically involves subjecting the battery to 10 half-sinusoidal pulses in all six spatial directions. The specific G-levels and pulse durations are defined within the standard.

4. MIL-STD-810 (Environmental Engineering Considerations and Laboratory Tests):

• Application: Primarily for military and aerospace equipment, but its methods are often adapted for commercial applications requiring high reliability.
• Shock Test (Method 516): MIL-STD-810 outlines various shock test procedures (e.g., functional shock, transportation shock, transit drop) that can be applied to batteries depending on their intended use and the expected shock environment. The specific test parameters (waveform, G-level, duration, number of shocks) are tailored to the application.

5. SAE J2464 (Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing):

• Application: Focuses on the safety and abuse testing of rechargeable energy storage systems (RESS), including batteries, for electric and hybrid vehicles.
• Mechanical Abuse Tests (including Shock): SAE J2464 includes mechanical abuse tests such as shock, drop, and crush to evaluate the RESS's ability to withstand physical stresses without compromising safety. The shock test typically involves three half-sinusoidal pulses on all three axes in both positive and negative directions with specified G-levels and durations.

Importance of Adhering to Standards:

Compliance with these mechanical shock testing standards is crucial for battery manufacturers to:

• Ensure Safety: Verify that batteries can withstand potential impacts without causing hazards like leakage, fire, or explosion.
• Guarantee Reliability: Demonstrate that batteries will maintain their performance and structural integrity after being subjected to mechanical shocks.
• Meet Regulatory Requirements: Comply with transportation and safety regulations in various markets.
• Build Customer Confidence: Provide assurance that their batteries are robust and dependable.

At Dongguan Precision, we provide comprehensive mechanical shock testing equipment and services to help battery manufacturers evaluate their products against these critical standards. Understanding the specific requirements of the relevant standards for your battery application is the first step towards ensuring a safe and reliable power source.