Electric Vehicle Battery Vibration Test Standard for Different Market and Applications

Lithium-ion batteries are gaining popularity as the most commonly used battery type for electric vehicles. During their service life, these batteries experience various vibrations and temperature changes. Some common test standards have been developed to simulate the long-term environmental impact on these different size classes of cells (e.g. cells, modules, packs).

Among the many EV battery testing standards, this article will focus on four well-known standards for vibration and temperature: SAE J2380, SAE J2464, IEC 62660-2, and UN 38.3. Crystal Instruments Spider system can provide solutions for random, sine, shock vibration testing, and temperature control.

SAE J2380

The SAE J2380 standard vibration target spectrum is based on actual road measurement data and is designed to simulate the impact of driving 100,000 miles on battery packs and modules. The standard calls for a series of random vibration target spectra to be applied on three vertical axes, with test durations ranging from 9 minutes to 38 hours.

SAE J2464

The SAE J2464 standard evaluates the abuse tolerance of cells and battery packs and is used to measure the response of any RESS (Rechargeable Energy Storage System). Abuse refers to the excessive use of the battery contrary to the design intent of the battery due to negligence, accidents, poor training, etc.

Of all the test types listed, there are two specified test types for thermal shock cycling and shock vibration testing. The thermal shock cycle consisted of 5 cycles, including hot and cold temperatures (70°C to -40°C), with a duration of 1 hour for the battery and 6 hours for the battery pack. In the shock vibration test, 3 half-sine shocks in positive and 3 negative directions are applied on three vertical axes.

IEC 62660-2

The IEC 62660-2 standard (related to ISO 12405) specifies reliability and abuse testing of lithium-ion batteries for electric vehicles for use in various battery systems. Vibration testing requires 8 hours of random vibration testing on each plane of the battery, as well as mechanical shock testing (half-sine) in six spatial directions. The temperature test is to start the battery at room temperature, increase the temperature at a rate of 5K/min until the final temperature reaches 130°C, and keep it within 2K of the target temperature for 30min. Thermal cycling testing requires 30 test cycles (85°C to -40°C).

UN38.3

The UN38.3 Manual of Tests and Criteria provides information on testing procedures for the transport of dangerous goods, and section 38.3 discusses lithium-ion batteries. Li-ion batteries must pass these tests before they can be shipped.

Of the 8 test types listed in the standard, there are 3 specified heat, vibration and shock test types. Thermal testing consists of 10 cycles of hot and cold temperatures (72°C to -40°C), followed by storage at ambient temperature (20°C) for 24 hours. Vibration testing simulates the typical vibrations of shipping batteries and involves sweeping sine tests over 3 hours for three possible vertical mounting positions. In the impact test, 3 positive and 3 negative half-sine impacts are applied to each of the three vertical installation positions (a total of 18 impacts).