Battery Testing Facility (KTAC)

Battery Testing

In order to confirm that test samples work under irregular conditions and in abnormal environments, the battery testing facility is equipped with state-of-the-art test equipment ensuring highest safety standards. With the test chambers installed, we aim to support battery energy technologies in a fast developing industry. Testing services are offered for a wide variety of products, ranging from batteries used in electric and hybrid electric vehicles, industrial / household stationary energy storage systems and portable applications.

Why TÜV Rheinland (KTAC)?

  • Safety of KTAC insured by our abuse chambers
  • State-of-the-art facility
  • ISO 17025/ KBA/ SII Accreditation
  • Technical service offered at own laboratory
  • Wide range of services (please refer to the following list)
  • Expertise in national and international regulations and standards (participation of working groups under UN, WP29)
  • Largest laboratory which is designated only to ESS (Energy Storage System) in Japan
  • Major OEM & TIER I companies are our customers
  • Offering flexible and creative service to meet your needs ( design, development and implementation of customized testing systems)

Major testing services

Mechanical Tests Vibration, Impact, Penetration, Crush, Drop, Free-fall test
Electrical Tests Internal short circuit, external short circuit, overcharge, forced discharge test
Environmental Tests Immersion: LLC, Salt Water, Temp. & Humidity cycle, Heat shock, Altitude test, Thermal stability, Thermal abuse test using Calorimeter
Other Services X-ray/CT scanning service, Gas Chromatography, Stone Chipping

Testing Equipment in KTAC

Battery testing facility in KTAC is equipped with state-of-the-art test equipment ensuring highest safety standards.
For pictures and the details, please refer to Testing Equipment .

Major standards we handle

  • Legal regulation: Electrical Appliance and Material Safety Law (DENAN Act)
    Related standard: JIS C 8712, JIS C 8713, JIS C 8714, etc
  • UN38.3 (Recommendations on the transport of dangerous goods - UNECE)
  • R100.02 (Safety regulation of REESS for electric power train)
    *KBA Accreditation (Federal Motor Transport Authority in Germany)
  • SBA S1101 (Subsidy for stationary rechargeable energy storage system)
  • Others (e.g.):
    • CB report can be issued upon following IEC standards.
      IEC61959, IEC61960, IEC62133, IEC62281, IEC62660-1, IEC62660-2, IEC60086-4
    • UL1642, UL2054, UL Subject 2580, SAE J2464, FreedomCAR
    • BATSO 02

For more details, please send us your inquiry from the "Contact" button.

Abuse Test Chamber

Abuse Test Chamber

Destructive Test Areas for battery
CO, H2, 3IR and Temperature Sensor
Filter (Scrubber) System for emitted gas
Inner size: W 4000 x D 4000 x H 3500mm - 4 Chambers


• Automatic Argonite Fire Extinguisher System and safety structure which can withstand explosions of large batteries.
• Created gas during test will be released after cleaned up through dry and wet scrubber

Vibration System

Vibration System

Frequency:5~2000Hz
Rated Force:60kN
Max Velocity:1.8m/s
Max displacement:63.5 mmp-p
Table size at Horizontal:W 900 × D 900mm
Table size at Vertical: W 700 × D 700mm

• Shock test available

Example of test standard:
ISO 12405-1 IEC 62133 IEC 62660-2 JIS C 8712 JIS C 8713
UN3480 – 38.3 T3 UL1642 QC/T 743 PSE

Free-Fall Shock Tester

Free-Fall Shock Tester

Max Acceleration:1000G
Max sample mass:181kg
Table size:W 610 × D 610mm

Example of test standard:
ISO 12405-1 IEC 62133 JIS C 8714 JIS C 8712 JIS C 8713
QC/T 743 UN3480 – 38.3 T4 UL1642 PSE

Overcharge / Force Discharge Tester

Overcharge / Force Discharge Tester

Max current: 600A
Max voltage: 80V
Ambient temperature during test: 25~80℃
Inner size of test box:
W 700 x D 700 x H600mm (for cell)
W 1000 x D 1000 x H 750mm (for module and pack)

• Special test out of above condition can be performed.

Example of test standard:
ISO 12405-1 IEC 62133 IEC62660-2 JIS C 8712 JIS C 8715-2 SBA S 1101
UN3480 - 38.3 T7 UN3480 – 38.3 T8 UL1642 QC/T 743 PSE

Crush Tester / Penetration Tester

Crush Tester / Penetration Tester

Max Force: 250 kN
Speed: 0.1~10mm/sec
Ambient temperature during test:25~80℃
Inner size of test box: W 600 x D 600 x H 700mm

• Compliant with a various standard replacing jigs.

Example of test standard:
ISO 12405-1 IEC 62133 IEC62660-2 JIS C 8712 JIS C 8713
JIS C 8714 UN 3480 – 38.3 T4 UN 3480 – 38.3 T6 UL 1642 QC/T 743
SAND 2005-3123 SAE J 2464 PSE

External Short Circuit Sytem

External Short Circuit Sytem

External resistance: 2m to 100mΩ
Test capability: 12.500A
Ambient temperature during test: 25~80℃
Inner size of test box:
W 700 x D 700 x H 600mm (for cell)
W 1000 x D 1000 x H 750mm (for module and pack)

Example of test standard:
ISO 12405-1 IEC 62133 IEC62660-2 JIS C 8712 JIS C 8714
JIS C 8715-2 SBA S 1101 UN3480 – 38.3 T5 UL1642 QC/T 743

Performance Test System

Performance Test System

For cell: 5V/980A (Max)
For module: 100V/600A (Max)

• More than 100 channels available

Example of test standard:
ISO 12405-1 IEC 62660-1 JIS C 8711 QC/T 743 JIS C 8715-1 UN3480 – 38.3
サイクル劣化

Temperature Chamber

Temperature Chamber

Temperature: -40℃~100℃
Inner size: W 1000 x D800 x H 1000mm
W 700 x D 700 x H 950mm
W 600 x D 800 x H 850mm
W 500 x D 390 x H 600mm

Example of test standard:
ISO 12405-1 IEC 62660-1 JIS C 8711 QC/T 743 JIS C 8715-1 UN3480 – 38.3
サイクル劣化

Temperature and Humidity Chamber

Temperature and Humidity Chamber

Temperature: -40℃~100℃
Humidity: 20~98%RH
Inner size: W 600 x D 500 x H 600mm

Example of test standard:
ISO 12405-1

Thermal Cycle Chamber

Thermal Cycle Chamber

Temperature: -40℃~100℃
Rapid Temperature Change: Between -40℃ to 80℃ within 30 minutes
Max sample mass: 100kg
Inner size: W 1000 x D 800 x H 1000mm

Example of test standard:
ISO 12405-1 IEC 62133 IEC 62660-2 JIS C 8712 JIS C 8715-2
UN3480 – 38.3 T2 UL 1642 UL 1973 SAE J 2464 SBA S 1101

Calorimeter

Calorimeter

Temperature: 25℃ ~ 250℃
Temperature rise rate: 5℃/min steps (depends on battery size)
Inner size: φ 350 × H 325mm

Example of test standard:
IEC 62133 IEC 62660-2 JIS C 8712 JIS C 8714 UL1642
QC/T 743 SAND 2005-3123 PSE

Heat Shock System

Heat Shock Chamber

Hot temperature: 200℃ (Max)
Cold temperature: -65℃ (Min)
Inner size: W 650 x D 400 x H 500 mm

Example of test standard:
IEC 62133 IEC 62660-2 JIS C 8712 JIS C 8714 JIS C 8715-2
SBA S 1101 UL1642 C/T 743

Altitude Simulation Chamber

Altitude Simulation Chamber

Temperature: 10~80℃
Air pressure: 101.3~10.1kPa
Inner size: W 800 x D 700 x H 800mm

Example of test standard:
IEC 62133 JIS C8712 UN3480-38.3 T1 UL 1642 PSE

PEC Performance system (for Cell―Type SBT0550)

battery performance test system (PEC for cell Type)
5V/50A 24ch (max 600A 2ch possible)
charge/discharge system (PEC for cell Type ACT0550)
5V/50A 40ch (max 2000A 1ch possible)
reduce testing time by chamber temperature control, automatically control each cell SOC
Characteristic test based on practical amount of each cell
High accuracy

・control current / voltage by ±0.03% (full scale)
・rise rate of current 1msec (no over shoot)
・sampling 1msec

Gas Analysis system (Pressure Vessel + GC/Agilent Tec-made (7820A))

Fraunhofer ICT-made
Max pressure: 30bar
Inner size: Φ508mm (150L)
Test item: Overcharge, Forced discharge, External short circuit(max.900A)
Measurable gas: H2/CO/CO2/Others
Sampling method: Sampling bags, max 8 times in 1 test

DC load

High voltage high capacity DC electric load system (NHR-4760-24)
600V/1200A/24kW
For high voltage battery pack discharge, capacity check
For lead-acid battery cranking test by high current

Forced Internal Short Ciruit test

Forced Internal Short Ciruit test
This test assumed that a conductive foreign matter is mixed into the battery.
Simulating such situation by mixing L-shape small Nickel piece into disassembled battery.
Then crush a battery until internal short circuit occur.
Disassemble a battery in a glove box purged with argon gas and put nickel piece into a battery.

Example of test standard: JIS C8714, JIS C8715-2

IMV vibration machine + Temperature/Humidity chamber

Vibration machine:
Frequency: 5~3000Hz
Rated Force: 16kN
Max Velocity: 2.2m/s
Max displacement: 51 mm p-p
Table size at Horizontal: W 630 × D 630 mm
Table size at Vertical: W 500 × D 500 mm

Temperature/Humidity Chamber:
Size: W 1000 x D 1000 x H 1000
Temperature Range: -40 ~ +150 ℃
Humidity Range: 20%~95% RH
Temperature change rate:-40 ~ +150 ℃ =  within 190min (for cooling and heating, not linear gradient)