Reliability Abuse Testing Machine for Electric And Hybrid Electric Vehicle Rechargeable Energy

Governments around the world continue to make regulations that require automakers to improve the average level of fuel economy, So automakers turn to gas-electric hybrid vehicles. In 2015, China’s sales of new battery electric vehicles accounted for nearly one-third of the global total, and it is expected that 5 million zero-emission vehicles will be on the road by 2020. Germany and the U.K. have also said they will stop selling gasoline and diesel cars in 2030 and 2040 respectively. With the rapid development of the electric vehicle industry, the electric drive system industry has also made great progress.

The technical level of products continues to improve, The scale of industrial development is further expanded, new materials and new processes continue to emerge, and the development trend of integration is obvious. It is also for this reason that Wewon Tech continues to increase research and development efforts for reliability abuse testing machine for electric and hybrid electric vehicle rechargeable energy.

Due to the complex driving requirements and working conditions of electric vehicles, the performance of traditional electric drive systems has been unable to meet the needs of electric vehicles. High-voltage, high-speed, and high-efficiency electric drive systems have become the main characteristics of electric drive systems for electric vehicles. In order to ensure the use performance and safety performance of the electric drive system for electric vehicles and improve the technical level of the products, China has established a relatively complete drive motor standard system, which has played an important role in promoting the technical improvement of motor products, accelerating the improvement of safety, and ensuring effective testing. to the role of norms and guidance.

reliability abuse testing machine

Equipment ModelWEW-RATS-8000L
Temperature Range-70℃~+150℃
Temperature Fluctuation≤±0.5℃ (at constant temperature)
Temperature Deviation±2.0℃
Temperature Uniformity≤±2.0℃
Time Setting Range1~60000 Minutes
Humidity Range20%RH~98%RH
Humidity Fluctuation+2.0~-3.0%(>75%RH),±5%(≤75%RH)
Humidity Deviation≤±3.0%RH
Heating Rate≤15℃/min (-60℃~+150℃; load 5KW calorific value, 1000KG Aluminum Ingot)
Cooling Rate≤1.2℃/min (+100℃~-55℃; load 5KW calorific value, 1000KG aluminum ingot, Mechanical Refrigeration)
≤1.2℃/min (+20℃~-55℃; load 10KW calorific value, 1000KG aluminum ingot, Liquid Nitrogen Refrigeration)
Heating and Cooling Overshoot≤±2.0℃
Lifting PlatformLifting platform way, adjust the height of the test box
Equipment Noise≤65 ~ 68dB (A sound level, when constant, 1 meter in front of the device)
Nominal Internal Volume8 m3
Inner Test RoomW2000mmxH2000mmxD2000mm
Machine AppearanceW24000mmxH4880mmxD4460mm
Sinusoidal Thrust≥2200 kN
Random Thrust≥2200 kN
Shock Thrust (6ms)≥4400 kN
Frequency RangeDC~3000 Hz
Continuous Displacement45 mm (p-p)
Impact Displacement45 mm (p-p)
Maximum Speed1.5~2.5m/s
Maximum Acceleration950m/s2
First-order Resonant Frequency2600Hz
Allowable Eccentric Moment>500N×m
Load Connection Point16 Connection Points
Axial Vibration Isolation Frequency≤3Hz
>Table Size600mm×600mm
Maximum Load300 KGS
Inner Test RoomSUS304 Stainless Steel Plate
Machine AppearanceCoating anti-corrosion treatment cold-rolled steel surface spray
Sealing StripImported Silicone Seal
InsulationThick polyurethane foam and fiberglass
Heating SystemNickel-chromium alloy heating wire heater
Cooling SystemGerman Bitzer cascade semi-hermetic compressor, water-cooled refrigeration method, environmentally friendly refrigerant R404A/R23
Vibration SystemSingle vertical shaking table or vertical shaking table + horizontal sliding table (can be customized)
DisplayTFT true color LED touch screen, Chinese/English menu, touch input
Operation ModeProgram Control, Fixed Value Control
Program Editing120 Groups of Programs Can Be Edited
Sensor Input TypeTwo-way PT100 Input (Optional Electronic Sensor Input)
Temperature Measurement Range And Accuracy-90.0℃~200.0℃ (-90.0℃~300.0℃ can be customized) Error ±0.2℃
Humidity Measurement Range and Accuracy1%RH~100%RH, error ±1%RH
Communication InterfaceEquipped with USB interface, support RS-485, LAN access
Power SupplyAC 380, 440V (1±10%) V (50±0.5) Hz three-phase four-wire + Protective Earth Wire

The electric and hybrid vehicles testing equipment’s main body shell is made of high-quality A3 steel plate and is treated with plastic spraying, the inner tank is made of SUS high-grade stainless steel mirror panel, and the insulation medium is ultra-fine glass wool.Equipment Structure
Circulation Mode: Top centrifugal fan for air supply, bottom return air. Double-layer high-temperature-resistant high-tensile sealing strips are used between the door and the box to ensure the airtightness of the test room.
The electric and hybrid vehicle testing machine adopts non-reaction door handle for easier operation. The observation window is made of multi-layer hollow tempered glass, and the inner side is glued with a conductive film (the test process can be clearly observed)
The power on test hole (left side of the storage system (ress) safety and abuse testing machine) can be used for external test power cord or signal line (diameter 100mm) There is a guide rail under the working room for the shaking table body to move in and out (the shaking table body is moved out when the vibration test is not performed)
The connection between the vibration table and the lower part of the studio is sealed with multi-layer epoxy resin and high temperature resistant silicone rubber. The reliability abuse testing machine’s heating system adopts finned stainless steel heater, and the heating core is far-infrared nickel alloy wire.
There has two systems are independently controlled and do not interfere with each other and provide testing and certification programs for large batteries used in electric vehicles (evs) to help foster safety. Air supply circulation system Xiangming motor (low noise), multi-wing centrifugal wind wheel, single cycle.

Reliability abuse test equipment produced by Wewon Environmental Chambers Co., Ltd. are suitable for various applications such as electric vehicles, stationary batteries, railway and marine applications, two-wheeled vehicles, grid storage, grid balancing, backup applications, uninterruptible power supplies (UPS), electric bicycles, Off-Road and Aerospace. The reliability and abuse testing machine simulates extreme environmental conditions and scenarios to test whether the battery is beyond its limits. Battery safety testing ensures the safety and reliability of batteries used in growing applications such as transportation, renewable energy, grid storage, grid balancing, backup applications and uninterruptible power supplies (UPS). The safety and reliability of electric vehicles, rail and marine applications, and air transport also depend on the quality of their batteries.

related page logoReliability Abuse Testing Machine’s Installation and Commissioning Photos for Electric And Hybrid Electric Vehicle Rechargeable Energy–Secondary Lithium Cells and Batteries 1
related page logoReliability Abuse Testing Machine’s Installation and Commissioning Photos for Electric And Hybrid Electric Vehicle Rechargeable Energy–Secondary Lithium Cells and Batteries 2
related page logoReliability Abuse Testing Machine’s Installation and Commissioning Photos for Electric And Hybrid Electric Vehicle Rechargeable Energy–Secondary Lithium Cells and Batteries 3
related page logoReliability Abuse Testing Machine’s Installation and Commissioning Photos for Electric And Hybrid Electric Vehicle Rechargeable Energy–Secondary Lithium Cells and Batteries 4
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related page logoReliability Abuse Testing Machine’s Installation and Commissioning Photos for Electric And Hybrid Electric Vehicle Rechargeable Energy–Secondary Lithium Cells and Batteries 6

reliability abuse testing machine for electric and hybrid electric vehicle rechargeable energy

Competition in the automotive industry and the pace of development of hybrid technology have prompted manufacturers to invest in battery research and development. Time-to-market is critical, and comprehensive product testing of batteries should not be overlooked, as recalling vehicles can be costly. Batteries and their sub-systems (such as connections, cooling, etc.) are prone to failures over long periods of time, which can range from battery performance degradation to complete failure.

SAE J2464Surface Vehicle Recommended Practice|(R) Electric And Hybrid Electric Vehicle Rechargeable Energy|Storage System (RESS) Safety And Abuse Testing
IEC 62660-2Secondary Lithium-Ion Cells For The Propulsion Of Electric Road Vehicles – Part 2: Reliability And Abuse Testing|Electric Vehicle Systems Architecture and Standardization Test
IEC 61960-3 Secondary Cells And Batteries Containing Alkaline Or Other Non-Acid Electrolytes – Secondary Lithium Cells And Batteries For Portable Applications – Part 3: Prismatic And Cylindrical Lithium Secondary Cells, And Batteries Madefrom Them
IEC 60086-4Primary Batteries- Part 4: Safety Of Lithium Batteries To Guarantee Its Safe Operation Under Intended Use And Reasonably Foreseeable Misuse.
UN 38.3Lithium Metal And Lithium Ion Batteries|UN 38.3 Testing Procedure Will Help To Ensure The Safety Of Lithium Ion Or Lithium Metal Batteries During Transport.
IEEE 1625IEEE Standard For Rechargeable Batteries For Multi-Cell Mobile Computing Devices|IEEE Power & Energy Society Sponsored By The Stationary Batteries Committee
IEEE 1725IEEE Standard For Rechargeable Batteries For Cellular Telephones|IEEE Power & Energy Society Sponsored By The Stationary Batteries Committee

Because batteries used in electric and hybrid vehicles come in a variety of sizes, shapes, weights, and chemistries, different test methods are critical to verifying durability. The three main battery types are battery cells, battery modules, and battery packs. In order to comply with major regulations and standards for hybrid and electric vehicle batteries, such as ISO, MIL and USABC, mechanical, electrical, environmental and chemical testing of battery cells, battery modules, battery packs and subsystems is necessary. Wewon Tech is well aware of this and strictly respects the advice and guidance of prismatic and cylindrical lithium secondary cells international standards.

For reliability abuse testing system for electric and hybrid electric vehicle rechargeable energy, The chiller adopts the French original “Tecumseh” fully enclosed compressor and Germany BOKE semi-hermetic compressor.Refrigeration System
The refrigeration system is designed with a unit or binary cryogenic loop system. American “Aigao” filter drier, UK United Kingdom “Uniqema” oil separator, Germany Schneider solenoid valve.
The multi-wing blower is used to provide strong air supply circulation to avoid any dead angles, which can make the temperature and humidity distribution in the test area evenly.
The air circuit circulates the air return air design, the wind pressure and wind speed meet the test standards, and can make the temperature and humidity stabilization time of the opening moment fast.
The heating, cooling, and humidification systems for storage system (ress) safety and abuse testing are completely independent to improve efficiency, reduce test costs, increase life, and reduce failure rates.
Vibration Generator: Choose the adhesive for the circle winding of the Labtone company, the stainless steel mesh plate for the moving circle of the LABTONE manufacturing company, and the low-noise fan.Vibration System
Switching Power Amplifier: Use Siemens switch, contactor, Japan Sanyo Electric power module, American Motorola power amplifier, Japan Fuji Electric power module to protect ultra-fast fuse
Main Configuration of Digital Vibration Controller: DSP interface box (built-in 2-channel charge amplifier), industrial computer CPU PIV2.0G, memory 256MB, 60GB hard disk, optical drive 52X, 17-inch flat-screen display. Piezoelectric acceleration sensor (CGJ- Type 1)
Reliability and Abuse Testing Systems Software: Sinusoidal vibration control system, random vibration control system, classic shock vibration control system color inkjet printer accessory cable.
Intelligent dual-channel high-precision digital display PID microcomputer control instrument (can directly display the percentage value of humidity, without temperature and humidity conversion control).Control System
Membrane KEY BOARD|Electric vehicle (ev) battery testing machine has the function of power failure memory, and the remaining test process can be continued when the power is restored.
Reliability abuse testing for electric and hybrid electric vehicle rechargeable energy’s temperature control adopts P I . D +S . S . R system channel coordination control, can improve the stability and life of the control components and interface use.
Touch settings, digital and direct display|Battery module and pack testing for manufacturers with P. I . D The function of automatic calculation can reduce the inconvenience caused by artificial setting|In operation or setting, if an error occurs, an alert signal is provided. Blackout records can be stored for five years.

storage system (ress) safety and abuse testing machine

New energy vehicles refer to the use of unconventional vehicle fuels as the power source (or the use of conventional vehicle fuels, the use of new vehicle power units), and the integration of advanced technologies in vehicle power control and drive. New technology, new structure of the car. New energy vehicles include four types of hybrid electric vehicles (HEV), pure electric vehicles (BEV, including solar vehicles), fuel cell electric vehicles (FCEV), and other new energy vehicles (such as supercapacitors, flywheels and other high-efficiency energy storage) vehicles etc.

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Power batteries are the heart of electric vehicles and the key to the development of the new energy vehicle industry. In 2004, China proposed to actively carry out research and industrialization of new types of power such as electric vehicles and vehicle power batteries; In 2009, it was proposed to include the “lithium-ion battery/supercapacitor” hybrid system into the scope of subsidies for new energy vehicles; In 2012, it was proposed to formulate management methods for power battery recycling and utilization, and establish a cascade and systematic power battery recycling and utilization management system; From 2017 to 2025, the specific energy of power battery cells will reach 500 Wh/kg. According to the plan from 2021 to 2035, China will implement battery technology breakthrough actions, build a power battery recycling system, and speed up legislation on power battery recycling.


Power lithium-ion batteries must pass a series of safety tests before they can be used in electric vehicles. These safety tests are designed to understand and identify potential weaknesses and vulnerabilities of batteries under abnormal conditions and to determine how batteries will perform under severe and severe conditions. Compared with other types of batteries, lithium-ion batteries have the advantages of green environmental protection, high voltage, long storage and cycle life, strong charge retention ability, and no memory effect. They have been widely used in power systems, microgrids, ships, etc. , aerospace, rail transit and many other industrial fields.

Lithium-ion battery is an important energy storage element, and its performance and safety indicators are directly related to the reliability and economic benefits of the equipment. Therefore, a storage system (ress) safety and abuse testing is needed to achieve accurate testing and evaluation of lithium-ion batteries. Electric vehicles are developing rapidly and have become a must-have model for gasoline and diesel vehicle manufacturers to a certain extent.

Currently, There are many naming conventions for various vehicle technologies. The main types include Pure Electric Vehicles (BEV) and Hybrid Electric Vehicles (HEV) with Internal Combustion Engine (ICE). The main difference between traditional conveyor system testing and HEV/BEV testing is the addition of one or more electric motors to HEV/BEV, including variable frequency technology, battery cooling and transmission design. Compared to internal combustion engines, Reliability abuse testing for electric and hybrid electric vehicle rechargeable energy presents us with new challenges.

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