Ever Wonder How EV Batteries Are Tested?

EV batteries are part of the newest technology in the automotive world and these things are tested under tough and adverse conditions that replicate American roadways.

Why is this necessary? Driving on the roads in America can cause a vehicle to face some treacherous conditions that are relatively unpredictable when it comes to how a vehicle will react. Because EV batteries have several chemicals and elements that could cause these items to catch fire, it’s important for these items to be tested under some of the toughest conditions possible. Let’s see how this testing takes place.

Thus, the Torture Test Lab Was Built

The Volkswagen ID.4 is made in Chattanooga, TN. This is where VW invests its money into the American automotive market, and now a new facility is part of the plant to make sure the batteries can be tested under some of the toughest conditions. The $22 million, 32,000-square-foot lab created conditions for testing the batteries that simulate all types of conditions these batteries might face in America. These conditions include floods, dust storms, temperature shocks, and earthquakes. These conditions create the various weather storms and conditions that emulate American roadways.

A Table that Shakes the Entire System

One of the coolest pieces of equipment to see how these EV batteries are tested is the Electric Multi-Axial Shaker Table. This table is placed over a 90 x 90-foot pit that’s 20 feet deep. At the bottom is a four-foot thick concrete slab with an eight-foot pedestal that is what the equipment is bolted to. This entire system weights 600,000 pounds and it helps to isolate the rest of the building from the incredible forces that come from shaking one of these battery packs in an extremely violent manner in this massive space.

Can this Device Truly Replicate and Earthquake?

Aside from the massive road damage that can come from an earthquake, this incredible machine can create the forces that replicate an earthquake pretty well. The six actuates are arranged in a hexapod to create motion in a variety of directions. Each of these actuates can generate up to 16,000 pounds of force. The test chamber for the EV batteries is 12 x 12 x 9 feet in size. This amazing machine allows us to feel confident that the EV batteries in VW models are truly tough enough and rugged enough to get the job done.

The Shaker Table Pushed the Limits

The shaker table tests the durability of the batteries to an extreme level. A 13-minute test is repeated 800 times over the course of a week. This test simulates 9,000 miles of driving and includes charging to 800 amps and discharging to 350 amps. The table also tests these batteries at a wide range of temperatures ranging from -40 and 150 degrees. The clamps holding the batteries create a clamping force of 1,000 psi but this pressure can suddenly be increased to 5,000 psi to show how the batteries react to extreme sudden pressure changes.

Individual EV Batteries Are Also Tested

This amazing facility has a Mini Shaker Table to test individual battery chambers as well. These chambers are about three cubic feet in size and weight about 220 pounds. This is a multi-axis shaking devices that use eight actuators and the temperature controls reach up to 480 degrees. This allows testing of the individual cells to determine whether or not they can withstand the challenges created within this testing facility. This testing allows VW to know the batteries work right and handle the extreme roads of America.

A Thermal Shock Chamber to Test Extreme Temperatures

The thermal shock chamber at the facility is made to ensure batteries work well when changing from one extreme temperature to another very quickly. A person starting an EV when the temperatures are extremely cold will shock the system a little because the batteries and motors will then heat up extremely quickly. The thermal shock chamber is a two-chamber test area that mimics these extreme conditions. The left and right sides are made to take batteries from -40 to 150 degrees quickly to replicate the conditions a vehicle would face when starting up in the extreme cold.

A Shuttle Does Some Extra Testing

A shuttle with insulated end plates is part of what’s needed when EV batteries are tested at this facility. These plates help the battery cells receive a thorough testing to allow the batteries to be moved from one side to the other in only 15 seconds. The chamber shuttle moves across different cells and it takes 3 days to run 40 thermal-shock cycles which simulates two entire winters. This test used to take 20 days when the cells had to be moved by hand and the shuttle wasn’t available to get the job done.

You’ll Face Water and So Will Your Batteries

This VW facility also tests the batteries using a water immersion tank which could be a challenge for any car. If you face puddles and wet roads, your batteries could get wet and you need to know your batteries will handle the challenge. The test facility created an immersion tank to plunge the batteries into a 2100 gallon tank of 40-degree water to make sure these items will survive. The chiller ensures the water stays at the right temperature throughout 20 test cycles that VW realizes these batteries need to endure to be used.

This Facility Uses Lots of Dust to Test the Batteries

Driving through Arizona when its dusty out can be damaging to many parts of a car including the batteries and motors. To replicate this, the EV batteries tested at this facility go through a ton of testing with dust flying around in a chamber. Each test involves 20 cycles of 20 minutes each replicating an amazing dust storm. Some empty battery packs are also tested to ensure the cases can survive tough weather and damaging storms.

The various EV batteries tested at this facility go through torture to ensure you know they will work great in your car when you buy a VW EV in the near future.