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What is electric vehicle battery testing?
As the core component of electric vehicles (EVs), batteries dictate their performance, reliability, and safety. Demonstrating battery safety and efficiency through standardised testing is crucial for manufacturer credibility and consumer trust. TÜV SÜD’s comprehensive testing services ensure these batteries meet rigorous EV battery regulations and standards.
Why electric vehicle battery testing is important
Testing against international standards assure safety, performance, and durability. Optimising battery performance balances battery life, capacity, and efficiency to meet your expectations and regulatory demands. Compliance with international safety regulations reduces the risk of failures and ensures global market access. Our comprehensive electric vehicle battery testing services address all potential safety risks associated with EV batteries, from thermal propagation to electrical integrity.
How TÜV SÜD can help you with electric vehicle battery testing
TÜV SÜD’s global network of experts leverage years of battery testing experience and have a deep understanding of EV technologies. They are supported by advanced testing facilities that are equipped with state-of-the-art technologies. Our holistic testing approach and customised solutions offer a complete suite of tests. These can be tailored to meet specific industry needs and the requirements of electric vehicle battery safety standards. Our certifications are recognised globally, facilitating smoother global market entry.
What our electric vehicle battery testing services include
TÜV SÜD supports you along your development and manufacturing process to meet EV battery specifications and optimise your product capacity, reliability, and safety. We offer the following EV battery testing services:
Battery performance and lifecycle testing
Our laboratories create an accurate simulation of thermal, climatic loads, and other conditions that your batteries might be exposed to in real life. We provide:
• Cycle testing under different climatic conditions (temperature, humidity).
• Parameter determination.
• High performance cycling.
• Lifecycle simulation.
• Validation of cooling systems.
Battery environment and durability testing
We verify product durability according to various environmental conditions to, performing the following battery tests. We provide:
• Vibration and shock testing under different climatic conditions (temperature, humidity).
• Dust and salt fog testing.
• Altitude simulation.
• IPXX, immersion splash water testing.
• Electromagnetic compatibility testing.
• Chemical influence analysis.
Battery safety and abuse testing
We help you to design and manufacture products that meet the highest levels of safety and quality, keeping them in line with global electric vehicle battery safety standards. Our advanced facilities simulate extreme conditions and scenarios to put your battery to the ultimate test. We provide:
• Propagation.
• External short circuit.
• Overcharge.
• Overdischarge.
• Nail penetration.
• Static and dynamic crush.
• Roll-over.
• Drop and impact.
• Water intrusion and leakage.
• Fire resistance.
Electromagnetic Compatibility (EMC) testing solutions
Our global laboratories conduct a comprehensive range of EMC tests and can provide you with EMC certifications.
Frequently Asked Questions (FAQs)
What EV battery testing standards does TÜV SÜD test against?
We test according to various global EV battery testing standards to ensure maximum performance, durability, and safety of your electric vehicle batteries, including:
• IEC 62619
• IEC 62660
• ISO 12405.
• ISO 6469-1
• GB 38031.
• GB/T 31484-2015
• GB/T 31486-2015
• SAE J2288.
• SAE J2464
• SAND 2005-3123
• UN 38.
• UL 258.
• UN ECE R10.
• IEC 62619
• IEC 62660
• ISO 12405.
• ISO 6469-1
• GB 38031.
• GB/T 31484-2015
• GB/T 31486-2015
• SAE J2288.
• SAE J2464
• SAND 2005-3123
• UN 38.
• UL 258.
• UN ECE R10.
What are the different types of EV battery?
Depending on performance, cost, and energy density requirements, different types of battery are used. This includes:
• Lithium-Ion (Li-Ion) – The most commonly used battery in EVs. Includes subtypes like Lithium Iron Phosphate (LFP), Nickel-Cobalt-Aluminium (NCA) for high energy density, and Nickel-Cobalt-Manganese (NCM) for balanced performance and cost-efficiency.
• Sodium-Ion (Na) – A developing technology using sodium ions as charge carriers is an emerging alternative to lithium-ion batteries.
• Nickel-Metal Hydride (NiMH) – An older technology usually used in hybrid vehicles.
• Solid-state – A technology still in development, it replaces the liquid electrolyte in traditional batteries with a solid electrolyte.
• Lithium-sulfur (Li-S) – A developing technology using sulfur as the cathode material.
• Zinc-air – Generate electricity through the oxidation of zinc with oxygen from the air.
• Lead-acid – One of the oldest battery technologies, mostly used in EV auxiliary systems.
• Lithium-Ion (Li-Ion) – The most commonly used battery in EVs. Includes subtypes like Lithium Iron Phosphate (LFP), Nickel-Cobalt-Aluminium (NCA) for high energy density, and Nickel-Cobalt-Manganese (NCM) for balanced performance and cost-efficiency.
• Sodium-Ion (Na) – A developing technology using sodium ions as charge carriers is an emerging alternative to lithium-ion batteries.
• Nickel-Metal Hydride (NiMH) – An older technology usually used in hybrid vehicles.
• Solid-state – A technology still in development, it replaces the liquid electrolyte in traditional batteries with a solid electrolyte.
• Lithium-sulfur (Li-S) – A developing technology using sulfur as the cathode material.
• Zinc-air – Generate electricity through the oxidation of zinc with oxygen from the air.
• Lead-acid – One of the oldest battery technologies, mostly used in EV auxiliary systems.
What is an EV battery management system?
This consists of both hardware and software elements, which contribute to vehicle safety and performance. The hardware generally includes current sensing capabilities for state of charge (SoC) estimation and for safety. It must also detect leakage current faults, which could render the vehicle chassis “live” and therefore highly dangerous, if not lethal.
The software in a battery management system (BMS) enables communication with the vehicle and provides critical control over the battery’s safety and performance. It continuously monitors the state of charge (SoC) to prevent undercharging or overcharging, which supports vehicle range estimation and safety. Additionally, it tracks the state of health (SoH) to assess battery degradation and predict end of life. Key functions include managing electrical isolation, thermal control, charge/discharge cycles, and cell balancing, ensuring safe and efficient operation throughout the battery’s life.
5G will be a driver of smart battery maintenance. Using “Data Over the Air” and “Software Over the Air”, real-time data can be used to optimise batteries and support predictive maintenance and failures, as well as remote troubleshooting.
The software in a battery management system (BMS) enables communication with the vehicle and provides critical control over the battery’s safety and performance. It continuously monitors the state of charge (SoC) to prevent undercharging or overcharging, which supports vehicle range estimation and safety. Additionally, it tracks the state of health (SoH) to assess battery degradation and predict end of life. Key functions include managing electrical isolation, thermal control, charge/discharge cycles, and cell balancing, ensuring safe and efficient operation throughout the battery’s life.
5G will be a driver of smart battery maintenance. Using “Data Over the Air” and “Software Over the Air”, real-time data can be used to optimise batteries and support predictive maintenance and failures, as well as remote troubleshooting.
What are some of the EV battery design considerations?
Single battery cells typically come in three styles, cylindrical, prismatic, and pouch.
When these individual cells are connected in series / parallel combinations (depending on end use requirements) the resulting modules deliver increased voltage and capacity. Although the individual cells are now mechanically “protected” with a mechanical support / enclosure, care must be taken due the potentially high voltages and high currents presented.
For EVs, large battery packs connect to the vehicle’s electric powertrain. These packs are constructed by connecting modules together, adding sensors and a battery management system. They deliver an extremely high voltage and can be moulded to fit the host vehicle and may also form part of its structure.
Safety tips for module and pack designs include:
• Use physical partitions and fire breaks to minimise fire propagation.
• Employ good thermal management.
• Use pressure vents / relief mechanisms to safely deal with excessive pressures.
• Utilise sensors and a battery management system to identify abnormal behaviours.
• Use materials appropriate for foreseeable temperatures.
• Use constructions with adequate mechanical strength appropriate for the real world.
When these individual cells are connected in series / parallel combinations (depending on end use requirements) the resulting modules deliver increased voltage and capacity. Although the individual cells are now mechanically “protected” with a mechanical support / enclosure, care must be taken due the potentially high voltages and high currents presented.
For EVs, large battery packs connect to the vehicle’s electric powertrain. These packs are constructed by connecting modules together, adding sensors and a battery management system. They deliver an extremely high voltage and can be moulded to fit the host vehicle and may also form part of its structure.
Safety tips for module and pack designs include:
• Use physical partitions and fire breaks to minimise fire propagation.
• Employ good thermal management.
• Use pressure vents / relief mechanisms to safely deal with excessive pressures.
• Utilise sensors and a battery management system to identify abnormal behaviours.
• Use materials appropriate for foreseeable temperatures.
• Use constructions with adequate mechanical strength appropriate for the real world.
