Battery Crush & Nail Penetration Test Equipment

Lithium-ion Battery Crushing Test Machine China Manufacturer and Supplier

Lithium-ion Battery Crush & Nail Penetration Test Equipment is used to simulate the mechanical abuse, including the crushing and nail penetration exerted on the lithium-ion cells/batteries, to determine their safety performance when subjected to the same conditions in practical applications.

In particular, the crush test is essential for battery safety testing, and you can almost see it in all mainstream lithium-ion battery safety testing standards.

AMADE TECH lithium-ion battery tester is a 2-in-1 dual-purpose testing equipment thanks to the replaceable test fixtures and attachment inside the chamber. Before the test, it allows you to mount crushing plates or crushing heads in different sizes and shapes to perform the crushing test or mount the corresponding needles and fixtures to perform the nail penetration test. The whole disassembly and assembly process is effortless and convenient.

Pressing plates for crush test

Needle for nail penetration test

AMADE TECH has designed different types of crush & nail penetration test machines according to international test standards for cells, modules, and battery packs.

20 kN cell crush & nail penetration tester

200 kN battery module/pack crush & nail penetration tester

1000 kN battery pack crush & nail penetration tester

Our conventional crush & nail penetration test equipment has a common feature: the test space adopts an enclosed box structure. It is because unqualified battery samples may be encountered during testing, which means that an internal short circuit may occur and cause a fire or explosion. This box-type structure can effectively isolate the testing area from the external laboratory environment. In the event of a fire or explosion, it can control and limit the flame, smoke, and shock waves within the box as much as possible, thereby protecting surrounding people or equipment from hurt. Apart from this, we have also equipped the equipment with safety features such as pressure relief vents, explosion-proof chains, smoke vents, and even fire extinguishers if necessary.

For the crushing test of large-volume battery packs, we can also supply unconventional horizontal open-type testing machines to provide greater crushing force and test space.

Crushed cells

Crushed battery pack

Battery pack crush test

Penetrated cells

Control System

We configure each battery crush & nail penetration test equipment with a computer pre-installed with specialized testing software. With the support of PLC, precise control and real-time data display of parameters such as applied pressure, specimen deformation, specimen voltage, and specimen surface temperature can be achieved. You are allowed to preset the desired parameter values based on the standard’s requirements. The machine automatically ends the test when the test conditions reach any of the preset values.

Attachments & Fixtures

Test Types

Regular Auxiliary Devices

Crushing test

150 mm diameter flat plate

R75 mm semi-circular bar

Hemispherical head with a diameter of 150 mm

Crush plate composed of 3 pcs of R75 mm half cylinders

R75 mm round bar

Nail penetration test

Tungsten steel needles in corresponding sizes

PARAMETERS

Model	AT-L5001
Force Applied Range	0 ~ 20 kN
Crushing Speed	1.5 cm / s, the speed range: 0.01 ~ 900 mm / min adjustable (0.01 ~ 1.5 cm / second)
Drive Method	Servo motor and driver
Crush Travel	0 ~ 300 mm
Test Space	More than 300 × 300 × 300 mm (W x D x H)
Force Accuracy	+/- 0.5%
Crush Retention Time	0 ~ 9,999 Sec adjustable
Control Mode	Controlled by professional testing software on the computer
Battery Crush Test Conditions	During the test, as long as any one of the following conditions is met (whichever comes sooner), the device relieves pressure and ends the crush test (based on UN38.3 & IEC 62133-2): 1) Applied crushing force reaches (13 ± 0.78) kN; 2) The voltage of battery drops by at least 1/3 or 100 mV; 3) The cell is deformed by 1/10 or 50% of its original thickness.
Test Software Features	a) It owns 1 channel of voltage acquisition Voltage acquisition resolution: 5 mV Voltage acquisition range: 0 ~ 10 V b) The test software can monitor the voltage change, the pressure on the sample and the deformation of the sample in real time. c) The function for battery surface temperature acquisition is optional with additional cost.

TEST PRINCIPLE

The cell/module/battery pack sample is placed on an electrically insulating platform, and then a specific force is applied to the sample through the moving crushing head. The conditions for releasing the pressure are different according to different test standards. Mainly as follows:

The initial size of the specimen is reduced to a specified percentage by crushing.
The applied pressing force reaches a specified value (kN). (and maintained for a specified duration if required.)
The voltage of the specimen drops to a specified value.
The surface temperature of the specimen drops to a specified value (if required).

These conditions can be controlled individually or in combination.

TEST STANDARDS

UN 38.3
IEC 62133
IEC 62660-2
IEC 62660-3
UL 1642
EN 50604-1
ISO 12405-3
SAE J2462
GB/T 38415, etc.

Li-ion Battery Crush & Nail Penetration Tester Features

The box is divided into three layers: the material of the outer box is cold-rolled steel plates. The inner box is made of stainless steel, and the intermediate layer plays the role of buffering and heat preservation.
The computer control unit is separate from the test box.
Support a variety of different machine styles to meet your testing requirements.
Equipped with various safety features, such as explosion-proof chains, pressure relief port, smoke detector, web camera, etc.
Fitted with a piece of tempered glass at the front of the chamber for easy observation during testing.
The inner chamber is equipped with explosion-proof lighting.
The servo motor and drive system enhance the control accuracy.
Support free selection and collocation of test conditions such as pressure, voltage, deformation, etc., as variables.
Thanks to the built-in PLC unit, and the pre-installed professional software, the monitoring and execution of all parameters are controlled by the computer. When the test conditions are reached, it will automatically stop.
Test results can be stored and exported for further editing.

Learn More about the Crush Test

Why do Li-ion Battery Crush & Penetration Tests?

With the wide application of lithium-ion batteries, it has become the power source of much industrial equipment and electric vehicles from its initial use as a power source for consumer electronics products. Due to lithium-ion batteries’ special material and chemical characteristics, their safety hazards still exist when subjected to extreme situations. Especially in the event of an electric vehicle crash, the battery pack will inevitably be crushed and deformed in the accident. If these power units fail the crush or needle tests, there may be dangerous consequences.

The crush or nail penetration test for the lithium-ion cell, module and battery pack is an essential safety test item. In order to test the safety of lithium-ion cells and batteries, many international organizations have formulated and promulgated regulations and standards for different applications. The process of the crush and nail penetration tests is described in the test methods.

Summary on Core Parameters of the Crushing Test Machine

Crushing force: The maximum crushing force exerted on the cell is usually 13 kN, but the crushing force applied to the electric vehicle battery is required not to exceed 1000 times that of the tested object. Usually, the upper limit of crushing force is 200 kN, 500 kN even 1000 kN.
Drive mode: The drive mode of the battery crushing test equipment depends on the upper limits of the required crushing force. Generally, we choose servo drive for conventional models or electro-hydraulic servo drive for models needing large crushing forces.
Crushing head: We configure different crushing heads according to the type of test samples(cells, modules or battery packs) and the test standards to be followed.
Data acquisition: The crushing test is usually controlled by three variables simultaneously: the sample’s voltage, the sample’s deformation, and the maximum pressing force. The test can be stopped if any one of these conditions is met. After the test, it is sometimes required to observe the sample for a period of time or until the surface temperature of the sample drops to a specified value. Therefore, acquiring voltage, sample deformation, pressing force, and sample surface temperature is essential.

Pressing forces	20 kN, 100 kN, 200 kN, 500 kN
Drive modes	Servo system, electro-hydraulic servo system
Crushing heads	150 mm diameter round flat plate R75 mm semi-circular bar Hemispherical head with a diameter of 150 mm Crush plate composed of 3 pcs of R75 mm half cylinders R75 mm round bar
Data acquisition	The voltage of the battery sample under test The deformation of the battery sample under test The force applied to the battery sample under test The temperature of the battery surface under test

Summary on Test Conditions to End Crush Test (only partially listed)

Test Standards	Test Conditions (for Cells/ Battery Modules or Packs)
UN38.3	Applied force = 13 kN±0.78 kN The voltage drop ≥ 100mV A cell deformation of its original thickness ≥ 50%
IEC 62133	Applied Force = 13 kN ± 0.78 kN An abrupt voltage drop of 1/3 of the original voltage
UL 1642	Applied force = 13 kN
IEC 62660-2/3	An abrupt voltage drop of 1/3 of the original voltage A deformation of the initial cell dimension ≥ 15% Applied Force = 1000 x (the weight of the test sample)
EN-50604-1	Applied Force = 1000 x (the weight of the test sample) Deformation = 50%
ISO 12405-3	Applied Force = (100 -0/+5) kN
SAE J2464	Applied Force=1000 x (the weight of the test sample)

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