Pack Level (End Item Assembly) Testing

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Presentation transcript:

Pack Level (End Item Assembly) Testing Start Have UN 38.3 Li+ cell level reqts been satisfied? Supplier to satisfy cell testing N Has module assy passed applicable UN tests? N Y If applicable, have UN 38.3 module reqts been met? See module testing flow chart N Y Batteries that are electrically connected to form an assy must be equipped with a system capable of detecting and preventing short circuit, over charge, over discharge, and over heating when operational. Y or N/A Does DUT contain total energy > 6.2 kWhr? Has module assy passed applicable UN tests? Y N Y N Y Meet? N Is DUT mass ≤ 12 kg? Obtain one DUT (@ 25 cycles & SOCfull) N Y Obtain 2 DUTs (@ 1 cycles & SOCfull) & Obtain 2 DUTs (@ 25 cycles & SOCfull) Obtain 4 DUTs (@ 1 cycles & SOCfull) & Obtain 4 DUTs (@ 50 cycles & SOCfull) Test all DUTs to T.1 (Altitude) then T.2 (Thermal) in sequence Test all DUTs to T.3 (Vibration) then T.4 (Shock) then T.5 (External Short Circuit) in sequence Does DUT contain total energy > 6.2 kWhr>? Are DUTs equipped with overcharge protection? Y N N Y Test 4 small/2 large same (undamaged) or different DUTs (@ 1 cycles & SOCfull)* and Test 4 small/2 large same (undamaged) or different DUTs (@ 50 (small) or 25 (large) cycles & SOCfull)*; Or if ≤ 6.2 kWhr, test 1 same (undamaged) or different DUT (@ 25 cycles & SOCfull)* Test to T.7 (Overcharge) *Note: batteries may be run in parallel for T7; 2 or 4 additional batteries would be required (for < 6.2 kWhr, 1 additional battery required) Review test results to determine whether acceptance criteria has been met UN38.3 Flowchart

Module (Sub-assembly) Testing Start Have UN 38.3 Li+ cell level requirements been satisfied? N Supplier to satisfy cell testing Y Are we testing something less than a full assembly? N See pack level testing flow chart Y Is DUT mass ≤ 12 kg? N Y Test 2 DUTs (@ 1 cycles & SOCfull) & Test 2 DUTs (@ 25 cycles & SOCfull Test 4 DUTs (@ 1 cycles & SOCfull) & Test 4 DUTs (@ 50 cycles & SOCfull) Test same DUTs to T.1 (Altitude), T.2 (Thermal), T.3 (Vibration), T.4 (Shock) and T.5 (External Short Circuit) Is DUT equipped with overcharge protection? N Y Test 4 small/2 large same or different DUTs (@ 1 cycles & SOCfull); Test 4 small/2 large same or different DUTs (@ 50 (small) or 25 (large) cycles & SOCfull); Test to T.7 (Overcharge) Review test results to determine whether acceptance criteria has been met UN38.3 Flowchart