Battery crash tests for electric vehicles

Battery crash tests simulate realistic accident scenarios to evaluate electric vehicle battery safety when exposed to dynamic impact. This ensures that the battery structure can withstand real-world crash conditions. To enhance vehicle safety and consumer trust, manufacturers and suppliers must use crash tests to ensure high-voltage battery safety. 

Comprehensive battery crash testing provides crucial insights into product development, performance, and safety. Manufacturers can use crash test results to optimise battery design for improved safety and durability. Safety performance validation minimises the risk of electric vehicle battery failures during accidents by ensuring they perform safely under crash conditions, preventing hazards such as fires or explosions. Battery crash tests also support compliance with global safety standards, such as ECE-R 100 and FMVSS 201, to enable access to markets worldwide.

TÜV SÜD has long-standing crash testing experience, with a focus on electric vehicle battery safety that is aligned with international regulatory requirements. Our customer-centric testing solutions are always customised according to specific client needs and product specifications. Specialist crash test centres use sophisticated testing apparatus, and our advanced testing capabilities support a wide range of dynamic tests This delivers dependable test results that support global standards compliance to ensure market readiness.

Our global battery crash test centres offer the following test services:

Non-destructive testing of batteries at speeds up to 80 km/h
Batteries are exposed to defined crash pulses or loads as required by the relevant standard, e.g. ECE-R 100. 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 behaviour 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.

Dynamic crash tests for other components, in addition to batteries, to the following standards

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