1. Product Name and Purpose

2. Product Features

• Sturdy and EV-Specific Construction
  • The machine is built with a heavy-duty framework, typically made of high-strength steel, to withstand the rigors of battery burning tests. The exterior is designed to be fireproof and heat-resistant, ensuring the safety of the surrounding environment and operators. The interior chamber is lined with a refractory material capable of withstanding temperatures exceeding 1000°C, preventing heat transfer and protecting the machine's structure. The door is engineered for a tight seal, featuring a reliable locking mechanism and a heat-resistant gasket. It also includes a viewing window, usually made of tempered glass with anti-scratch and anti-fog coatings, allowing for clear visual monitoring of the testing process without compromising safety.
• Precision Temperature and Flame Control Systems
  • Temperature Measurement: The machine is equipped with highly accurate temperature sensors that can measure a wide range of temperatures, from ambient to over 1200°C, with an accuracy of ±5°C. These sensors are strategically placed both within the chamber and in direct contact with the battery to provide real-time and detailed temperature data. The data acquisition system records and stores this information, enabling in-depth analysis of the battery's thermal behavior.
  • Flame Generation and Control: Utilizing advanced flame generation technology, the machine can produce a controlled and adjustable flame. The intensity, duration, and direction of the flame can be precisely set according to specific test requirements. This allows for the simulation of different types of thermal runaway events, such as those caused by internal short circuits or overcharging. The control panel offers intuitive controls for adjusting flame parameters, ensuring repeatable and reliable tests.
• Advanced Instrumentation and Data Acquisition
  • In addition to temperature sensors, the machine is outfitted with a comprehensive suite of sensors. Gas sensors detect the release of potentially hazardous gases during the test, providing valuable insights into the battery's chemical reactions. Pressure sensors measure any pressure build-up within the battery and the chamber, helping to assess the risk of explosion. Voltage and current sensors track the electrical behavior of the battery, allowing for a comprehensive understanding of its performance under stress. These sensors are connected to a state-of-the-art data acquisition system that records and stores all the data. The data can be accessed and analyzed in real-time or retrieved later for in-depth studies. The data acquisition system is highly flexible and can be integrated with EV-specific software and databases, facilitating seamless data transfer and analysis. It can also be configured to send notifications and reports automatically, saving time and effort for the users. Additionally, the control panel includes built-in alarms and safety features that alert operators in case of any abnormal temperature, pressure, gas emissions, or equipment malfunctions.
• Enhanced Safety Features and Emergency Shutdown Systems
  • The Battery Burning Test Machine for EV battery testing places a strong emphasis on safety. It is equipped with multiple safety features, such as automatic fire suppression systems that can quickly extinguish flames in case of an emergency. There are also emergency shutdown buttons located in easily accessible positions around the machine, allowing operators to immediately halt the test if any critical parameters exceed safe limits. The machine is designed to vent any potentially harmful gases in a controlled manner, ensuring the safety of the surrounding air quality. It also has a self-diagnostic system that continuously monitors the health of the equipment and alerts operators to any potential issues before they lead to a failure.

3. Specific Parameters

• Chamber Size and Capacity: The machine is available in various chamber sizes to accommodate different electric vehicle battery sizes and configurations. The volume of the chamber can range from a few liters for testing small battery modules to several cubic meters for large battery packs used in commercial EVs. The interior dimensions are optimized for proper air circulation and uniform heat distribution, ensuring that all parts of the battery are exposed to the same thermal conditions.
• Temperature Range: The temperature control system can reach temperatures up to 1500°C, with an accuracy of ±5°C. This wide temperature range allows for the simulation of the most extreme thermal conditions that EV batteries may face, including those caused by high-power charging or severe accidents.
• Flame Characteristics: The flame can be adjusted to have a temperature range of 600°C to 1800°C, with a flow rate that can be varied from a few liters per minute to several tens of liters per minute. The shape and direction of the flame can be precisely controlled, enabling the replication of different types of thermal stress, such as direct impingement or radiant heat.
• Data Acquisition Rate: The data acquisition system can sample sensor data at a high frequency, typically ranging from 20 to 100 samples per second. This ensures that even the most rapid changes in the battery's behavior during the test are accurately recorded and can be analyzed in detail, providing valuable insights for EV engineers and researchers.

4. Product Functions

• Accurate Simulation of EV Battery Thermal Runaway
  • The primary function of this machine is to provide a highly accurate and realistic simulation of battery thermal runaway scenarios specific to electric vehicles. By precisely controlling the temperature and flame parameters, it allows users to evaluate how batteries will behave in the event of a catastrophic failure. For example, it can determine if a battery will explode, release toxic gases, or experience a rapid increase in temperature and pressure that could affect the vehicle's occupants and surrounding environment. This information is crucial for EV manufacturers to design effective safety mechanisms and improve the overall safety of their vehicles.
  • The ability to conduct repeatable tests with different EV battery chemistries and designs is also a valuable function. This helps in comparing the performance of various batteries and identifying the most suitable materials and configurations. For instance, a manufacturer can test different types of lithium-ion batteries with varying cathode and anode materials to determine which combination offers the best thermal stability and safety for a particular EV model.
• Enhanced EV Battery Quality and Research Capabilities
  • Through comprehensive burning tests, EV battery manufacturers can identify and address potential issues in their battery designs. If a battery shows signs of instability or excessive gas release during the test, appropriate measures can be taken, such as modifying the electrolyte composition, improving the separator design, or enhancing the thermal management system. This leads to the development of more reliable and durable batteries, reducing the risk of vehicle fires and enhancing the safety of electric mobility. In the research field, it allows for the exploration of new battery materials and technologies, providing valuable data on their thermal behavior and safety characteristics under EV conditions.
  • The test machine also serves as a valuable tool for quality control. By subjecting EV batteries to standardized burning tests, manufacturers can ensure that their products meet the required safety and performance standards. This helps in building a reputation for quality and reliability in the highly competitive EV market, which is essential for attracting customers and complying with regulatory requirements.
• Compliance with EV Industry Standards and Regulations
  • The electric vehicle industry is subject to strict standards and regulations regarding battery safety and performance. The Battery Burning Test Machine is a reliable tool for ensuring compliance. For example, batteries used in EVs must meet specific thermal runaway and safety requirements set by organizations such as the United Nations Economic Commission for Europe (UNECE) and national regulatory bodies. By using this machine to conduct tests in accordance with relevant standards, EV manufacturers can prove that their batteries are safe and reliable, facilitating market access and enhancing consumer confidence. Regulatory bodies rely on accurate test results obtained from such machines to enforce safety and quality regulations.

5. Production and Quality Assurance

• Stringent EV-Grade Manufacturing Process
  • The Battery Burning Test Machine for EV battery testing is manufactured under strict quality control procedures. Each component, from the refractory lining to the temperature and flame control systems, is carefully sourced and inspected for quality and performance. The assembly process is carried out by highly trained technicians in a clean and controlled environment, ensuring the proper installation and functionality of all parts.
  • The calibration of the temperature, pressure, gas, and other sensors is a critical and regular part of the manufacturing process. It is performed using traceable reference standards to guarantee the accuracy and reproducibility of the test results. Rigorous quality audits and inspections are conducted at various stages of production to maintain the highest level of product quality and compliance with EV standards.
• Quality Certification and Validation for EV
  Our machine has obtained relevant EV quality certifications and has been validated by independent EV testing laboratories. It has been proven to provide accurate and reliable test results, conforming to the relevant international and national EV standards. We also continuously update and improve our product based on the latest technological advancements and customer feedback from the EV industry to ensure its long-term performance and compliance.

6. Application Areas and Success Stories

• Passenger EV Battery Testing
  • A leading EV manufacturer used the Battery Burning Test Machine to test the batteries in their new sedan model. The tests revealed a potential issue with the battery's thermal insulation, which could lead to a thermal runaway event. By improving the insulation material and design, they were able to enhance the battery's safety and performance, ensuring the safety of the vehicle's occupants.
  • An EV research institute used the machine to study the effects of different cooling systems on the thermal stability of passenger EV batteries. The data obtained led to the development of a more efficient cooling solution that reduced the risk of overheating and extended the battery's lifespan, improving the overall performance of the EV.
• Commercial EV Battery Testing
  • A company manufacturing electric buses used the test machine to evaluate the safety of their large battery packs. The burning tests identified a weakness in the battery's structural integrity, which could lead to a rupture and release of hazardous materials in case of an accident. By reinforcing the battery pack's structure and adding additional safety features, they were able to meet the strict safety requirements of commercial EVs and ensure the safety of passengers and the environment.
  • A logistics firm using electric trucks tested their batteries with the Battery Burning Test Machine. The testing helped them optimize the battery's charging and discharging algorithms to reduce the risk of thermal runaway during high-power charging, improving the operational efficiency and safety of their electric truck fleet.
• EV Battery Component Testing
  • A battery component supplier used the machine to test the safety of their new cathode material. The burning tests showed that the material had a higher resistance to thermal runaway compared to previous versions, allowing the manufacturer to produce batteries with improved safety and performance characteristics.
  • An EV battery pack assembler used the Battery Burning Test Machine to evaluate the compatibility of different battery management systems (BMS) with their battery packs. The testing helped them select the most suitable BMS that could effectively monitor and control the battery's temperature and prevent thermal runaway, ensuring the reliable operation of the EV battery pack.

7. Service and Support

• Pre-Sales Technical Consultation for EV
  Our team of EV experts provides in-depth technical consultations to help customers understand the capabilities and suitability of the Battery Burning Test Machine for their specific EV battery testing needs. We offer demonstrations and training, tailored to the EV industry, to familiarize customers with the operation and functionality of the equipment before purchase. We also assist in selecting the appropriate test methods and accessories based on the EV products to be tested.
• After-Sales Service and Maintenance for EV
  We offer comprehensive after-sales service, including on-site installation and commissioning by EV-trained technicians. Our technicians are available for regular maintenance, calibration, and emergency repairs. We provide spare parts and upgrades, sourced from EV-approved suppliers, to keep the test machine operating at peak performance. We also offer service contracts that include preventive maintenance and priority technical support, ensuring the long-term reliability and availability of the equipment for EV applications.
• Training and Technical Support for EV
  We conduct specialized training programs for new EV users to ensure they can effectively operate the Battery Burning Test Machine and interpret the test results. Our technical support team, with EV expertise, is available 24/7 to answer questions, provide troubleshooting assistance, and offer guidance on test method optimization and compliance with relevant EV standards. We also provide software updates and support for the data acquisition and analysis systems, enabling customers to take full advantage of the latest features and technologies in EV testing.