Power battery short-circuit explosion-proof test box

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

Power battery short-circuit explosion-proof test chamber is a special test equipment designed for high energy density batteries (such as lithium-ion batteries for electric vehicles, solid-state batteries, etc.), which is used to simulate the extreme conditions of short-circuit batteries and verify their explosion-proof safety. The following are the core technical points and design specifications:

I. Design Principles

Double safety protection:

Physical isolation: Adopt double-layer explosion-proof shell (inner layer of high-temperature/impact-resistant material, outer layer of anti-static/fireproof structure).

Active inhibition: integrated rapid pressure relief valve, inert gas protection system (such as nitrogen / argon purge).

Strict sealing:

Meets IP67 or higher protection level to prevent electrolyte leakage or explosion shock wave leakage.

Sealed door is equipped with air pressure self-locking device (can not be opened from the outside during the test).

Core Functional Modules

1. Short-circuit trigger system

High voltage and high current output:

Support short-circuit current 0~1000A continuously adjustable (need to be customized according to battery capacity).

Adopting pulse or continuous short-circuit mode to simulate different failure scenarios (e.g. pinprick, diaphragm breakage).

Dynamic triggering accuracy:

Trigger time control error ≤ **±1ms** (e.g. realized by electromagnetic relay or solid state switch).

2. Explosion-proof and safety protection

Pressure relief device:

Built-in multi-stage rupture disk (burst pressure is set at 1.2~1.5 times of the internal pressure of the battery).

The direction of pressure relief is designed to be downward or sideways to avoid flying debris.

Inert gas protection:

Filled with nitrogen to 95% or higher concentration prior to testing to isolate oxygen to inhibit combustion.

Emergency Cooling System:

Integrated liquid nitrogen emergency cooling channel or forced water-cooled circulation, to control the rate of temperature rise ≤ 5 ℃ / s.

3. Real-time monitoring system

Multi-parameter synchronous acquisition:

Temperature: distributed fiber optic temperature measurement (accuracy ± 0.1 ℃) + infrared thermal imaging.

Pressure: piezoresistive sensor (range 0 ~ 50MPa, response time ≤ 10ms).

Voltage/Internal Resistance: High-speed sampling (≥10kHz) to capture short-circuit transient characteristics.

Failure Mode Recognition:

Analyze the data (e.g. voltage dip slope, temperature curve inflection point) through AI algorithm to determine the type of battery failure (thermal runaway, structural damage, etc.).

Key technical parameters

Parameter Technical Requirements

Applicable battery size Maximum diameter × Height × Thickness (Example: 400 × 120 × 20mm)

Short-circuit current range 0~1000A (expandable to higher)

Temperature control range Room temperature ~ 300℃ (±0.5℃ accuracy)

Pressure measurement range Normal pressure ~ 50MPa

Safety protection level IP67 + ATEX Zone 2G (explosion-proof certification)

Typical Application Scenarios

New energy vehicle battery safety certification:

Comply with UN38.3 (transportation safety), GB/T 31485 (thermal runaway test) and other standard requirements.

Battery material R&D:

Evaluation of new diaphragm (e.g. ceramic coating), solid-state electrolyte on the improvement of explosion-proof performance.

Production process validation:

Detect the short circuit risk caused by battery assembly defects (e.g. pole piece burrs, poor welding).

V. Example of test flow

plaintext

1. Pre-treatment: Pre-charge the battery to the nominal voltage and leave it for 2 hours. 2;

2. Sealed box nitrogen replacement: oxygen content is reduced to less than 1%;

3. Trigger short-circuit: set the current value (e.g. 3C multiplier) and start the test;

4. real-time monitoring: record temperature rise, pressure, voltage changes;

5. failure determination: if the temperature > 150 ℃ or pressure exceeds the threshold, automatically terminate the test;

6. post-processing: open the box after the pressure relief to check the battery status (no traces of combustion/explosion).

VI. Precautions

Battery pre-screening:

Insulation resistance testing (>1MΩ) is required before testing to avoid false triggering triggered by residual charge.

Calibration cycle:

Calibrate current sensor (using standard resistance box) and pressure sensor quarterly.

Personnel protection:

Operators need to wear anti-static clothing and goggles, the test area is equipped with fire blankets and fire extinguishers.