Beyond Battery Cycling

As automotive battery technologies continue to advance, battery testing is a critical step in the process of bringing a vehicle to market, particularly for hybrid and battery electric vehicles. Lifecycling is an important benchmarking test for batteries. As a battery is cycled and used, the capacity decreases. This diminished capacity and the drivers behind it are critical factors to pack longevity in the automotive market. As the infamous million-mile pack is sought after, this testing is vital to achieving that goal.

In addition to longevity requirements, however, modern battery designs need to incorporate strong thermal management, shock and fatigue resistance, durability, fire resistance, and more while optimizing cost and offering long ranges and fast charging capability. With all of these requirements, battery testing today needs to cover much more than cycling testing.

This white paper explores today’s requirements in battery testing as well as how the battery tests interact with testing routines across the vehicle. These tests ensure that batteries are safe, reliable, compliant with all standards and regulations, and suitable for demanding new technical applications such as hybrids and BEVs. For example, as packs have increased in size, more packs are integrated as part of the chassis and frame and must maintain structural integrity. The primary way to verify this prior to production is through durability, shock, and fatigue resistance testing. These tests verify for mechanical systems working in tandem with electrical systems that no compounding factors are found.

The importance of both subcomponent and full vehicle testing with real-world inputs is vital to proper operations. This white paper will include the latest testing requirements, procedures, and best practices in areas of battery testing you may not have considered.

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