Electric vehicle battery testing

The traction battery is currently one of the most expensive, if not the single most costly, components of an electric vehicle. It also represents a significant challenge in terms of design and operation for both engineers and end-users. Both the batteries themselves and the materials used in their production must comply with a stringent range of standards and technical requirements.

Key expectations for traction batteries include:

• High operational reliability under diverse conditions;
• Long service life (extended failure-free operation without noticeable degradation of performance characteristics);
• High efficiency and power (maximum energy density and available power to achieve the longest possible range with optimally short charging times);
• Operational safety under all conditions;
• Low environmental impact throughout the life cycle;
• Wide operating temperature range (from -30°C to +65°C);
• Precise monitoring of operating parameters and maintenance-free operation;
• Cost-effectiveness in terms of both production and maintenance.

In practice, these properties are often technically difficult to reconcile.

Temperature has a critical impact on the performance of an electric vehicle, which underscores the importance of battery thermal management systems (TMS). These systems can be active (utilizing liquid cooling or forced air) or passive (relying on heat dissipation through the battery casing). Effective cell cooling allows for sustained high charging speeds, while heating, when necessary, protects the cells from sub-zero temperatures and temporary capacity loss.

The BOSMAL Institute, equipped with state-of-the-art laboratory facilities and a highly specialized engineering team, provides a comprehensive range of testing services for electric vehicles, including detailed assessments of traction batteries and Thermal Management Systems (TMS).

Plug & Test Lab

Our Plug & Test Lab is designed for climate and temperature testing of battery packs and components for electric or hybrid vehicles. Our capabilities include testing electric axles, hybrid transmissions and related components.

The system includes

• Climate chamber with an operating range of -60 to 160°C
• 250kW bidirectional power supply for charging or discharging batteries and powering components
• DUT cooling medium conditioning system
• Data acquisition (analog signals and CAN communication)
• Fire detection and suppression system

Other data

• The dimensions of the workspace are: 2,3 m x 2,2 m x 2,9 m
• The rate of temperature change is: 7 K/min (3 K/min with an 800 kg load)
• The allowable floor load is as follows: 30,000 N/m2
• Cycler: 1000V; +/-1000A; 250kW; max 300kW

Tests of vehicle batteries – REESS (rechargeable energy storage systems).
Testing of automotive batteries at inertial loads that might occur during a vehicle collision.