Multi station battery short circuit testing system

Power battery short-circuit explosion-proof test box STANDARD FEATURES

Multi-station Battery Short Circuit Test System Design Specification

I. System Overview

This system is designed for high-efficiency, high-volume battery safety testing needs, supporting 2~16 stations parallel testing, applicable to lithium-ion batteries, solid-state batteries, sodium-ion batteries and other types of batteries short-circuit tolerance assessment. Through the modular architecture to achieve high-precision control, real-time data synchronization and centralized control of safety risks.

Core technology architecture

1. Hardware system design

Multi-station cooperative control:

Independent triggering unit: each station is equipped with independent mechanical/electronic short-circuit triggering mechanism (e.g. Ni-Cr alloy sheet contact or probe compression), supporting millisecond response (error ±2ms).

Current Load Matching: Maximum output current per channel is adjustable from 0 to 500A, equipped with independent constant current source module to prevent mutual interference between work stations.

Safety protection system:

Partition isolation design: double-layer explosion-proof glass (impact strength ≥ 50J) and fireproof heat insulation layer, single-station failure does not spread to other areas.

Three-level interlock protection:

① Hardware level: fuse (response time <10ms) + electronic circuit breaker;

② Software level: real-time monitoring of temperature/pressure thresholds (automatic power cut-off when exceeding limits);

③ Mechanical level: emergency pressure relief valve linkage solenoid lock, isolation completed within 3 seconds after triggering.

Shared monitoring network:

Distributed sensors: integrated fiber optic temperature measurement (±0.1℃), piezoresistive pressure sensor (0~30MPa) and voltage acquisition module for each station.

Centralized cooling system: shared liquid cooling circulating pipeline, supporting gradient temperature control (as low as -40℃ for thermal stability test).

2. Software control system

Multi-task scheduling engine:

Supports batch testing (e.g., running 10 groups of short-circuit experiments with different multiplication rates at the same time), with dynamic adjustment of task priority.

Synchronized data recording: Sampling rate up to 10kHz/channel, storage format supports MATLAB, CSV and custom binary.

Intelligent analysis module:

Failure Mode Classification: Identify thermal runaway thresholds based on machine learning algorithms (e.g., determine trends by second-order derivatives of temperature).

Visualization Kanban: Heat map to show the status of each station, and automatic labeling of anomalies (e.g., red blinking warning).

Performance Parameter Comparison Table

Parameter item Single station system Multi-station system (8 stations)

Number of simultaneous tests 1 8

Short-circuit current range 0~300A 0~500A (per channel)

Temperature control accuracy ±0.5°C ±0.3°C

Data synchronization delay - <50ms

Safety Protection Class IP65 + ATEX Zone 1 IP67 + ATEX Zone 2G

IV. Typical Application Scenarios

Mass production battery screening:

Setting up a testing station at the end of the battery production line to conduct 100% short-circuit pressure test on each batch of sampled batteries to eliminate potentially hazardous products.

Material comparison experiment:

Simultaneously test the short-circuit resistance of different diaphragms (e.g., aramid, ceramic coating) to quantify their effect on thermal runaway suppression.

Regulatory compliance verification:

Meet the short circuit test requirements of UN38.3 transportation safety standard for multi-cell components (e.g. simulate the short circuit scenario inside the battery pack).

V. Innovative Function Expansion

Adaptive test protocol:

Automatically adjust the test parameters according to the chemical characteristics of the battery (e.g. 3C short-circuit current for ternary batteries and 5C for lithium iron phosphate batteries).

Wireless remote monitoring:

Integrated LoRa/NB-IoT module supports real-time viewing of test data via mobile APP or Web terminal, applicable to closed environments such as dust-free workshop.

Energy consumption optimization design:

Adopting photovoltaic energy storage to assist power supply, prioritizing the use of stored power during the high power consumption phase of short-circuit testing, and reducing peak power consumption.

Sixth, implementation considerations