Electric Vehicle Battery Testing Systems

Sentek Dynamics provides complete systems for electric battery durability testing. Contract testing services are also available from the Sentek Dynamics Lab in Charlotte, North Carolina. Contact the Sentek Dynamics team to learn more.

Sentek Dynamics Vibration Testing Systems

Electric vehicle battery testing with CAN bus

THV Environmental Testing Systems

Vibration Testing Systems

Environmental Testing Systems

Electric Battery Vibration Testing with CAN bus request

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	Single Axis Vibration Testing Options Electric battery vibration testing is required to verify the battery's durability against harsh conditions resulting from shipping and everyday usage to ensure their safe operation. Environmental hazards can range from extreme temperatures to repeated shocks and vibrations resulting from transportation.
	Electric Vehicle Battery Testing Standards Perform electric vehicle battery abuse & durability tests according to MIL-STD, SAE, UL, ISO, & more. Contact the Sentek Dynamics team to set up testing projects. Dedicated application engineers are available to assist projects from 6:00 AM to 6:00 PM Pacific time.
	BATSO 01 Manual for Evaluation of Energy Systems for Light Electric Vehicle (LEV) – Secondary Lithium Batteries MIL-STD-810H - Released with Method 520.5 added to cover the testing of components in combined environments. IEC 62133 - Safety Requirements for Portable Sealed Secondary Cells and Batteries Made from them IEC 62660-2:2016 - Secondary Lithium-ion Cells for the Propulsion of Electrical Road Vehicles Reliability and Abuse Testing IEC 62113-2:2017 - Secondary Cells and Batteries Containing Alkaline or other Non-Acid Electrolytes – Safety Requirements for Portable Sealed Secondary Cells, and for Batteries Made from Them, for Use in Portable Applications. IEC 62660-3:2016 - Secondary Lithium-ion Cells for the Propulsion of Electrical Road Vehicles – Safety Requirements ISO 12405-1 - Lithium-ion traction battery packs & systems SAE J2464 - Electric Vehicle Battery Abuse Testing SAE J2464:2009 - Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing SAE J2380 - Single battery durability testing UL 2054 - Testing & Certification for Battery Packs UL 2202 - Standard for Safety Electric Vehicle (EV) Charging System Equipment UL 2231-2 - Standard for Safety Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: Particular Requirements for Protection Devices for Use in Charging Systems UL 2271 - Batteries for Use in Light Electric Vehicle (LEV) Applications UN 38.3 - Transport of dangerous goods UN38.3:2015- Recommendations on the Transport of Dangerous Goods – Manual of Tests and Criteria – Section 38.3 Lithium Batteries GMW16390 - General Motors manufacturer standard
	Random Vibration Testing - Random is the most popular type of excitation. Gaussian or non-Gaussian random signals are generated by the Spider controller to create a broadband excitation to the shaker. Feedback control signal meets most stringent requirements defined by aerospace or military testing standards. Input channels can be set as control, monitor, or limit.
	Swept Sine Vibration Testing - Swept Sine Vibration Control provides precise real-time multi-channel control. It provides a spectrally pure and undistorted sine wave and a control dynamic range of up to 100 dB. As many as 512 channels can be enabled for control, notching, or monitoring, while supporting time-data recording.
	Multi Sine Vibration Testing - Multi-Sine control enables multiple sine tones sweeping simultaneously and ensures that multiple resonant frequencies of the structure can be excited. With multiple sine tone excitation, the required time duration of sine testing can be reduced significantly.
	Classical Shock Control - Classical Shock Control provides precise, real-time, multi-channel control and analysis of a transient motion in the time domain. Classical pulse shapes include half-sine, haversine, terminal- peak sawtooth, initial-peak saw tooth, triangle, rectangle, and trapezoid. Applicable Test Standards include MIL-STD-810F/G/H, MIL-STD-202F, ISO 9568 and IEC 60068 (plus user-defined specifications).
	Shock Response Spectrum (SRS) Synthesis & Control - The SRS synthesis and control package provides the means to control the measured SRS of the DUT to match a target SRS, the Required Response Spectrum (RRS). The necessary drive time history is synthesized from damped-sine or sine-beat wavelets. Damped Sine Parameters include frequency, amplitude, critical damping factor, and delay. Waveforms may be automatically synthesized from a user-specified SRS reference profile.
	THV Environmental Test Systems The industry trend demands environmental testing conducted in fully integrated environments. Various physical parameters, including vibration (acceleration, velocity and displacement), temperature, humidity, pressure, torque, and electrical signals such as those from CAN bus should be monitored and controlled by one system.
	The Spider-101i is designed to perform tests subjecting the DUT to simultaneous temperature cycling and variable humidity. The Spider-101i controls both temperature and humidity in a chamber system, which includes external heating/cooling and humidification/dehumidification systems. PTP time synchronization technology and Ethernet connectivity allows all Spider hardware to be accessed and configured as one integrated system. When vibration control is required along with temperature and humidity control, users are able to conveniently access the parameter and schedule setup between all combined physical quantities from one fully integrated user interface. If a THV (temperature, humidity, vibration) system (chamber + shaker) is equipped with a Spider-101i controller, the controller software allows the addition of a Spider vibration controller and operates the two systems as one while providing an integrated user interface. Users can execute vibration tests such as Random, Sine, Shock, SoR, RoR, and other types together with various cycle settings of temperature and humidity. One user interface for setting up run schedules for temperature, humidity, vibration, etc. Fully networked allowing users to connect multiple hardware devices through Ethernet which allows one PC to control all devices at the same time Ability to extract battery information through a CAN bus and take various actions including emergency shutdown. Access and control with one software application Data acquisition is accurately time-synchronized One combined test report - If test reports are generated separately from several apps, the time clock and schedules will not be coordinated, unlike the integrated test report generated by Crystal Instruments’ EDM THV Software
	Contract Testing from Charlotte, North Carolina Our in-house team provides expert assistance for battery testing projects and are available to provide affordable contract testing services.
	Testing services include but are not limited to the following list. Combined environmental testing Single axis vibration testing (Random, Sine, & Shock vibration testing) Structural testing Electric battery reliability testing Electric battery durability testing Temperature and/or Humidity testing HALT/HASS testing Temperature and/or Humidity testing MIL standard testing
	Combine Electric Battery Environmental Testing with CAN bus Support CAN bus alarm and abort rules can be configured during a vibration test with a customer’s DBC file and a custom-built Crystal Instruments USB CAN adapter. For example, a user running vibration tests on an EV battery can configure the software to monitor the battery’s temperature and stop or pause the test in response to the temperature matching or exceeding a particular value. Read case study here.
	The THV system software supports the custom-built Crystal Instruments USB CAN adapter as well as the PCAN-USB adapter developed by Peak Systems. While performing vibration or THV (temperature/humidity/vibration) tests on a battery pack, the accelerometers, temperature, and humidity sensors can measure the external environment of the battery pack. The Battery Management System (BMS) monitors the internal battery pack status and communicates with external components using CAN bus. The integrated CAN bus support allows EDM to monitor the internal and external status of a battery pack and take actions according to pre-defined conditions. Supports multiple CAN Bus channels and records data simultaneously to a solid-state drive. Expand data storage to 2 TB with the addition of a Spider-NAS.
	EDM Cloud Online Status Monitoring Provided for users to monitor the status of vibration tests across multiple Spider controllers. Allows access to multiple users according to customized account privileges to view data and status of Spider systems. Lab administrators can simultaneously monitor multiple tests from anywhere in the world using EDM Cloud. Supports EDM Vibration Testing and EDC Temperature/Humidity Testing.
	EDM Cloud can also be deployed on local servers within an organization’s network. This allows an organization to limit the scope of information exchange and data sharing to users within their network to ensure data security. This feature is useful for monitoring the progress and status of environmental tests with classified information. Visit https://cloud.go-ci.com/ to register and log on. EDM Cloud allows users to: Create email address accounts and invite others to form a team with groups underneath. Share tests among members of the same group after configuring the upload parameters in the EDM VCS application. Save and share several aspects of the test, including Status, Run Log, and Test Reports.
	Data Acquisition During Environmental Battery Testing Record CAN bus data, peak CAN data, time data, dynamic measurements (APS, FRF, frequency domain data, etc.), cycling data logging (voltage, current, battery, etc.)
	Combine a Spider vibration controller with a Spider-80SG unit to acquire data from a strain gage or a wide range of sensors. With the help of precision excitation voltage, the Spider-80SG/SGi can support strain gage based sensors, MEMS sensors, IEPE and DC sensors (to name a few) thus expanding the scope of the Spider-80Xi hardware platform to support the synchronized acquisition of a wide range of measurement quantities including Force, Torque, Pressure, Acceleration, Velocity and Displacement. It can be used for strain measurement and many other types of sensors that requires external power. The Spider hardware platforms (including the Spider-80X/Xi and the Spider-80SG/SGi) share the flexibility of scaling up in channel count and functionality. The Spider-80SG/SGi can combine with any Spider-80Xi device to create a high channel count system with up to 512 channels to perform data acquisition during vibration tests. A dedicated massive storage hard disk (a 250 GB solid-state drive) allows the time signals of all input channels to record at up to 256 kHz/channel. Accurate time synchronization results in excellent phase match in the frequency domain between all channels, either on the same Spider front-end or across different front-ends.