EV Battery Testing Solutions

Electric car battery testing proves that your batteries comply with the required standards and regulations

Electric car battery testing proves that your batteries comply with the required standards and regulations

What is electric vehicle battery testing?

The development of electric cars has accelerated enormously in recent years. Thereby, electric vehicle (EV) batteries are considered the most essential component of an electric vehicle. The battery’s performance and reliability are critical to ensure the quality of the whole electric vehicle. So, it is important that manufacturers focus on optimal quality, safety performance, and efficiency. Electric car battery testing and certification services ensure that your batteries, cells, chargers, and electrical components for use in e-mobility, comply with global safety requirements and performing reliably.

Why is EV Battery Testing important?

Over the course of their service life, batteries and their subsystems such as connections and cooling systems will deteriorate. The consequences of this can vary from loss of battery performance to total failure. In addition, batteries in electric and hybrid vehicles come in a wide variety of sizes, shapes, weights and chemical compositions. This makes it essential to carry out EV battery testing to verify durability, safety and reliability.

TÜV SÜD is your trusted partner for electric vehicle battery testing

TÜV SÜD is your trusted, independent, and neutral technical service provider for electric car battery testing. Our holistic approach and commitment to safety will ensure the safety and reliability of your electric vehicle batteries. We support our customers from their initial design with a strong focus on R&D testing to Two automotive engineers are working on a structure for an electric car where the batteries will be located.ensure our customers develop safe EV batteries, and we provide safe and clean testing conditions – even for abuse and destructive testing.

Our global team of experts have already tested thousands of batteries in our laboratory network where we provide various tests on cells, modules, and full-scale systems. Within our state-of-the-art testing facilities, we can perform critical battery abuse tests for battery packs in a manner that is safe and environmentally friendly. We run tests at extremely high-power levels of more than 1000kW for qualifying high-power batteries and charging systems.

We test according to various global EV battery testing standards to ensure maximum performance, durability, and safety of your electric vehicle batteries, including:

Standard

Content

IEC 62619

Safety requirements for secondary lithium cells and batteries, for use in industrial applications

IEC 62660

Secondary lithium-ion cells for the propulsion of electric road vehicles

ISO 12405

Electrically propelled road vehicles

ISO 6469-1

Electrically propelled road vehicles - safety specifications - part 1: on-board rechargeable energy storage system (RESS)

GB 38031

Electric vehicles traction battery safety requirements

GB/T 31484-2015

Cycle life requirements and test methods for traction battery of electric vehicle

GB/T 31486-2015

Electrical performance requirements and test methods for traction battery of electric vehicle

 SAE J2288

 Life cycle testing of electric vehicle battery modules

SAE J2464

Electric and hybrid electric vehicle Rechargeable Energy Storage System (RESS) safety and abuse testing

 SAND 2005-3123 

Electrical energy storage system abuse test manual for electric and hybrid electric vehicle applications

UN 38.3

Recommendations on the transport of dangerous goods - manual of tests and criteria part III 38.3

UL 2580

Standard for safety - batteries for use in electric vehicles

UN ECE R100

Uniform provisions concerning the approval of battery electric vehicles with regard to specific requirements for the construction and functional safety

TÜV SÜD’s EV battery testing services

At TÜV SÜD we take a holistic approach within our range of solutions to support customers right from the start to develop safe EV batteries. Our experts support you with:

  • Battery testing in all performance classes
  • Further customised testing procedures according to your individual needs
  • Battery testing in the car / white body directly
  • Failure analysis after the test
  • Additional services in the same location, e.g. EMC

We offer the following EV battery testing services:

Battery performance and lifecycle testing

Among our EV battery testing services, we offer professional battery performance testing. Our laboratories create an accurate simulation of thermal, climatic loads and other conditions your batteries might be exposed to in real life. As experts in battery performance testing, we support you along your development and manufacturing process to optimise your product capacity, reliability and safety. 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

With our experience and in-depth knowledge, we can also support you with battery testing according to various environmental conditions to verify the product durability. As part of this service, we perform the following battery tests:

  • Vibration and shock testing under different climatic conditions (temperature, humidity)Image of a person working on batteries of an electric vehicle.
  • Dust and salt fog testing
  • Altitude simulation
  • IPXX, immersion splash water testing
  • Electromagnetic compatibility testing
  • Chemical influence analysis

Battery safety and abuse testing

We also offer battery safety and abuse testing services to help you design and manufacture EV batteries that meet the highest levels of safety and quality. These will keep your batteries in line with global industry standards such as SAE J2464, SAE J2929, UN 38.3 and ISO 12405. With our fully equipped and advanced facilities, we can 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

Get in touch with our battery testing experts

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