Battery and Sensor Test Center (BST)

Since 2014, the Fraunhofer HHI in Goslar has been operating a test center to characterize and validate the thermal and electrical behaviour of lithium-ion battery systems under various operating conditions. The focus is on scientific investigations into battery safety, extinguishing agents, fireproof materials and innovative sensor technology and diagnostics. The test center also offers services for industrial partners - for example, long-term cycling of cells, modules and systems in climate chambers, thermal fuse tests of battery systems with capacities of up to 150 kWh or extinguishing agent tests under defined conditions. The Fraunhofer HHI offers unique diagnostic options such as fiber optic temperature and strain measurement. Certifications can be carried out with appropriately accredited partners if required. The test center is ISO 9001 certified and TISAX certification is currently being processed.

All tests and investigation methods for lithium-ion batteries (NMC or LFP chemistry) can be easily transferred to new types of batteries such as sodium-ion batteries and are already being successfully carried out at the test center.  

Another focus of the Fraunhofer HHI is the development and subsequent provision of sensor systems for reliable characterization and early identification of safety-critical conditions. In addition, safety concepts such as energy-consuming separation layers, extinguishing systems, gas neutralization filters and emergency shutdown systems based on active and passive components in a controlled environment are being developed to application maturity in order to provide the necessary safety features for critical infrastructures, 2nd life energy storage systems and prototype batteries.

Equipment overview

Scienlab Battery Test System

SL60/600/36kW

  • Module test bench (4 channels; up to 60V and 600 A)
  • Impedance spectroscopy
  • Parallelizability

SL60/200/12BT4C

  • Module test bench (4 channels; up to 60V and 200 A)

SL60/300/18kW

  • Module test bench (4 channels; up to 60V and 300 A)
  • Impedance spectroscopy
  • Parallelizability

AVL - Power test bench for electrical load tests

  • up to 1000 V and 1200 A
  • two sub-channels
  • 320 cell channels
  • BMS integration
  • (CAN bus) possible
  • Current rise times from 10 to 90
  • percent in less than 3 ms

Electrodynamic Shaker Data Physics V13-33/DSA5-15K

  • Max. Sine Force(pk): 10,930 N
  • Max. Random Force(rms): 10,000 N
  • Max. Shock Force(half sine at 6 mSec): 23.171 N
  • Max. Acceleration(Sine): 845 m/s²
  • Mac. Velocity: 2.2 m

Fuelcon Evaluator-B

  • Cell test bench
  • 17 channels
  • max. 5 V and 25 A
  • 1 channel can be interconnected, max. 400 A
  • Impedance spectroscopy
  • Can be air-conditioned

Sécheron short-circuit tester
HSCB UR26-81S

  • 115 kA
  • up to 1.6 kV
  • switchable in 30 ms

Cycling stands

  • Single-cell cycling stands
  • Round cells (type 18650/21700)
  • 600 channels

Module test stand

  • up to 70 V and 100 V
  • 4 channelsImpedance spectroscopy
  • Cell test bench max. 5 V 10.7 A; 16 channels
  • Cyclization system 20 single cells

Abuse test chambers

  • Large high-temperature test chamber (dimensions: 3 x 2.5 x 3m³)
  • Small high-temperature test chamber (dimensions: 1.5 x 1.2 x 2.5 m³)
  • Container test chamber with extinguishing and flooding function (dimensions: 5.9 x 2.4 x 2.4 m³)
 

Services

In addition to research and development work on battery safety and condition characterization, Fraunhofer HHI provides the following services:

VDE-AR-E 2510-50:2017-05 

  • 6.2.2 Iso-Test**
  • 6.2.3 HV-Test**
  • 6.2.4 Propagation test
  • 7.3 BMS voltage test
  • 7.4 Switching elements test
  • 7.5 Line test
  • 7.7 Derating
  • 7.8.1 Overcharge
  • 7.8.2 Deep discharge
  • 7.8.3 Current monitoring
  • 7.8.4 Over-temperature
  • 7.8.5 Under-temperature
  • 7.9.1 Current measurement
  • 7.9.2 Temperature measurement
  • 7.10.1 Communication failure
  • 7.10.2 Component failure
  • 7.10.3 Cell failure
  • 8.1 Ext. short circuit
  • 8.2 Drop test
  • 8.4 Th. mishandling
  • 8.4.1 Overcharge
  • 8.4.2 Forced discharge

ECE R100

  • A) Vibration test *
  • B) Thermal shock and cycling test **
  • C) Mechanical shock *
  • D) Mechanical integrity **
  • E) Fire resistance
  • F) External short circuit protection
  • G) Overcharge protection
  • H) Over-discharge protection
  • I) Over-temperature protection

UN 38.3

  • T.1 Altitude simulation **
  • T.2 Thermal test **
  • T.3 Vibration *
  • T.4 Shock *
  • T.5 External short circuit
  • T.6 Impact **
  • T.7 Overcharge
  • T.8 Forced discharge

* Up to approx. 150 kg resp. 25 kg

** Can be realized short-term after consultation

Reference

  • TÜV Rheinland
  • Brandschutz Voß GmbH
  • Power Innovation GmbH
  • Volkswagen Aktiengesellschaft
  • Porsche Engineering Services GmbH
  • FLN Feuerlöschgeräte Neuruppin Vertriebs GmbH / Johnson Controls
  • REMONDIS Industrie Service GmbH & Co. KG
  • Hoppecke Batterien GmbH & Co. KG
  • Intilion GmbH
  • ElringKlinger AG
  • VoltaLabs GmbH
  • FOGTEC Brandschutz GmbH