Battery crash test for electric vehicles

Battery Crash Tests for Electric Vehicles

Dynamic crash tests to demonstrate battery safety performance in simulated accidents

Dynamic crash tests to demonstrate battery safety performance in simulated accidents

TÜV SÜD supports its customers in the area of battery crash tests with long-standing experience, expert know-how and reliable tests. We are able to perform dynamic impact tests for electric vehicle batteries and provide advice on the optimum test design. All tests are conducted at our various crash test facilities, which utilise impactors with variable mass and geometry.


Crash tests simulate realistic accident scenarios to obtain substantiated information about the safety of the batteries when the vehicle body becomes deformed in an accident. The tests are performed in the dedicated crash test facility. Various test methods with different acceleration and speed profiles are used as requested and required by customers. After completion of the tests, a comprehensive technical test report is issued to the client.

This is with an aim to assess how high-voltage batteries in electric vehicles – also known as rechargeable energy storage systems (RESS) – respond in accidents. As electric vehicles pose a potential threat to the safety of drivers and passengers through car accidents, testing rechargeable batteries is essential for automotive manufacturers and suppliers as well as battery OEMs. 

Only crash tests supply substantiated information on how batteries will respond in case of an accident and can deliver various benefits:

  • Gain reliable insights about the safety performance of batteries installed in vehicles with battery crash tests as the only valid source.
  • Discover important information about your product through an established method of dynamic impact tests as early as possible in the development stage to make it more accident-proof.
  • Avoid rework and gain test results that validate your product development, type approval and conformity of production testing (CoP).
  • Obtain consumer confidence through test reports that validate you have completed extensive battery crash test simulations.


TÜV SÜD supports its customers in the area of crash testing with long-standing experience, in-depth know-how and, first and foremost, highly professional and reliable tests. As your globally recognized partner, TÜV SÜD offers electric car battery crash tests according to different test methods depending on customer requirements. At our crash centre in Oberpfaffenhofen, near Munich, Germany, dedicated automotive and battery experts support customers with the development and optimization of their products. This process ensures maximum electric vehicle battery safety.

Our battery crash test center in Oberpfaffenhofen and other global locations offer the following test services:

Non-destructive testing of batteries at speeds of up to 80 km/h

Within the scope of these tests, the batteries are exposed to defined crash pulses or loads as required by the relevant standard, e.g. ECE-R 100. For this purpose, the battery is fastened to a sled, which generates the required shock during deceleration including elements of deformation.

Dynamic loading or deformation of the high-voltage battery structure using an impactor

The deformation of a battery is typically very random in the real world, which increases the difficulty of predicting and determining battery resistance against dynamic loading during actual impact. Simulating a battery loading condition using impactors helps manufacturers to predict the behavior of stress condition sustained by batteries in various impact scenarios.

Sled-testing of batteries and components

  • Velocity: 60-80 km/h
  • Acceleration: 0-60 g with load up to 1000 kg
  • Acceleration: up to 150 g with load up to 300 kg

Additionally to batteries we also offer dynamic crash tests for other components according to the following standards

  • ECE-R11 (door latch)
  • ECE-R16 (safety belts, restraint systems)
  • ECE-R17 (seats)
  • ECE-R44 (child restraint system)
  • FMVSS 201 (occupant protection)
  • EN 1789 (stretcher)
  • ISO 7176-19 standard (wheelchair)

For more information about our battery crash test service, please contact us today.


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