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Battery performance testing

Comprehensive battery capacity and life tests of battery packs, cells and modules

TÜV SÜD provides professional battery pack, module and cell performance testing, in our global network of state-of-the-art battery testing laboratories to deliver answers to those questions. Our laboratories create precise simulation of electrical, thermal or climatic loads and other conditions that your batteries may be exposed to in real-life use. As an expert in battery performance testing, we can support you throughout the development and manufacturing process to optimise the capacity, reliability and safety of battery packs, cells and modules.

What is battery performance testing?

How do external conditions affect battery cells, modules and packs? What factors impact their capacity and lifetime? Which environmental conditions accelerate ageing? These are the questions addressed by battery performance testing.

Battery performance testing describes electrical testing of battery packs, modules and cells, superimposed by thermal and climate conditioning. By simulating a range of external influences in special testing chambers – such as climatic conditions including arctic temperatures and humid tropical climates – evidence can be collected to the impact of these conditions on your battery; e.g. the impact of mechanical stresses caused by thermal or electrical loads.

At the same time cooling units simulate the cooling cycle. Extensive measurement and simulation equipment further allow the recording of electrical and climatic data as well as simulation and recording of communication between batteries and control devices.

Why is battery performance testing important?

Batteries have become essential parts of our everyday life. The wide use of batteries across industries renders battery pack testing as well as battery cell and module testing essential for the safety of users. And as electric vehicles become more popular, so will the need for electric vehicle battery safety. Conducting life cycle and capacity tests is one crucial step towards validating battery safety and durability.

By choosing TÜV SÜD, you are partnering with our professional team with comprehensive knowledge in battery performance testing, alongside other benefits:

  • Stay ahead of the competition with our experts who are at the forefront of battery testing and support you through the entire value chain from component to final product.
  • During the R&D process our testing services will support you in making technical decisions that serve your design objectives best, while also impacting battery performance in the long run.
  • Uncover possibilities for quality improvement and reduce the risk of product recalls and warranty claims once the product is placed on the market.
  • Access the market faster by reducing your product development time through our effective test programs.
  • Gain advantage from our innovative service offerings: fully automated cutting-edge test process as well as tailored approach to your data measurement, analysis and reporting requirements
  • Ensure battery performance with our battery reliability testing services which can make all the difference between winning and losing - in the commercial sector as well as on the racetracks.

TÜV SÜD supports customers to optimise the performance of battery cells, modules and packs

Our experts have in-depth know-how concerning the technology of lithium-ion batteries, and long-standing experience in automation and in dealing with many different communication protocols. In addition to our wide range of qualifications, we are experienced in testing according to ISO 12405, IEC 62620 and various OEM standards governing the testing of batteries for automotive applications. We also have long-standing expertise in the measurement of swelling forces at various electrical loads, rapid charging profiles and characterisation by means of electrochemical impedance spectroscopy (EIS).

Our battery performance test services for battery cells, modules and packs

Our battery performance tests cover:

  • Battery cell, module and pack testing of all formats and types and several ranges of measurement:
    - Cell: up to 6V; up to 4000A
    - Module and pack: up to 1200V; up to 4000A
  • Testing of cyclic and calendric ageing and of ageing effects caused by realistic driving profiles
  • Battery capacity test and pulse power test
  • Electrical characterisation (e. g. internal resistance /SOC) and electrical tests with parallel thermal tests (-40°C to 80°C)
  • SOC/OCV determination benchmark tests of rapid charging profiles
  • Automation of test series with CAN/LIN signals
  • Automated evaluation of measured data with customer-specific, scalable reporting

The following additional complementary services can also be provided for battery cells and modules:

  • Cycling with cooling systems
  • Parallel mechanical loading using a uniaxial vibration test system
  • Measurement of volume-change effects in cells and modules
  • Single cell voltage measurement on modules
  • Module balancing
  • Electrochemical impedance spectroscopy (0-20V +/- 10A)

For more information about battery performance testing, please contact us today.

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