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21/11/2013 TÜV SÜD 1
TÜV SÜD TÜV SÜD
An introduction to
Battery Testing and
Certification
Presented by:
Timothé Frealle Test Engineer
Matthew Larkin Battery Certification Services
21/11/2013 Introduction to Battery Testing and Certification Slide 1 TÜV SÜD
Contents
Introduction to Battery Testing and Certification
Battery testing
Battery safety
Support
Typical test plans
Directives and regulations
21/11/2013 Slide 2
TÜV SÜD
Testing Services
TÜV SÜD Product
Service
Slide 3
13-11-29
Electrical Performance Testing
Environmental
Testing Abuse Testing UN 38.3
Performance tests
according to
different
standards (e.g.
IEC-61960) or
customer-specific
test protocols.
Environmental
tests according to
different
standards (e.g.
EN 62133), or
customer-specific
test protocols.
Abuse tests
according to
different
standards (e.g.
IEC-62660-2,
ISO-12405), or
customer-
specific test
protocols.
TÜV SÜD
Certification
Mark is a
combination of
performance,
safety and
abusive tests +
engineering
know-how.
Safety test
protocol
mandatory for
transport of
cells, batteries
and battery
packs.
Cell
Certification
TÜV SÜD
Safety Testing
• Mould stress (temperature)
• Continuous charge
• External Short-circuit
• Overcharge (time)
• Overcharge (voltage)
• Over discharge
• Drop test
• High temperature
Abuse Testing
• Crush tests
• Nail penetration
• Shock test
• Impact test
• Vibration test
• Immersion
• Fire
• Gas analysis
Safety and Abuse Testing
21/11/2013 Introduction to Battery Testing and Certification Slide 4
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Background: Electrochemical Window
21/11/2013 Introduction to Battery Testing and Certification Slide 5 TÜV SÜD
Safety tests – How to be safe ?
21/11/2013 Introduction to Battery Testing and Certification Slide 6
- Temperature
- Charge
- Discharge
21/11/2013 TÜV SÜD 2
TÜV SÜD Slide 7 21/11/2013 Introduction to Battery Testing and Certification
Safety tests – The main risk
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Safety tests – Control the risk
21/11/2013 Introduction to Battery Testing and Certification Slide 8
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Safety tests – How avoid problems ?
21/11/2013 Introduction to Battery Testing and Certification Slide 9 TÜV SÜD
Example overcharge test
21/11/2013 Introduction to Battery Testing and Certification Slide 10
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Abuse testing facilities
21/11/2013 Introduction to Battery Testing and Certification Slide 11 TÜV SÜD
Battery Transport
• Essential to aid the transportation of Lithium metal or Lithium ion cells and batteries by land, sea & air.
• Required by such organisations as: IATA (International Air Transport Association)
IMO (International Maritime Organisation)
ADR (Road) & RID (Rail)
• Demonstrates your cell/pack is safe for transportation.
• Applies to both Primary & Secondary cells and batteries .
• Recommended to source cells already tested to UN Manual of Test to
minimise testing of your pack.
• Applicable to a variety of applications from coin cells to EV modules.
TRANSPORT OF DANGEROUS GOODS
UN Manual of Tests and Criteria - Section 38.3 Lithium Batteries ST/SG/AC.10/11/
21/11/2013 Introduction to Battery Testing and Certification Slide 12
21/11/2013 TÜV SÜD 3
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UN Manual of Test & Criteria
Test
• T1 Altitude Simulation
• T2 Thermal
• T3 Vibration
• T4 Shock
• T5 External Short Circuit
• T6 Impact
• T7 Overcharge
• T8 Forced Discharge
Cell
Battery Pack , Module, Battery Assemblies
T7 test only applies to secondary batteries.
Introduction to Battery Testing and Certification 21/11/2013 Slide 13 TÜV SÜD
Performance Testing
21/11/2013 Introduction to Battery Testing and Certification Slide 14
Discharge performance at 20°C
IEC capacity
Discharge performance at -20°C
High rate discharge
Charge retention and recovery
Storage Endurance in
cycles
Internal resistance
Electrostatic resistance
+ specific test
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What’s a good battery ?
21/11/2013 Introduction to Battery Testing and Certification Slide 15
Adapted to an application
Lasting
Effective Reliable
Battery
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Parameters influencing the capacity/performance
21/11/2013 Introduction to Battery Testing and Certification Slide 16
• Electrochemical composition
• Battery size
• Battery’s internal resistance
• Temperature and relative humidity
• Frequency of use, usage pattern and ageing
• Battery discharge type (constant current/resistance/power)
• End-use application
o In the case of secondary batteries, their technology allows having low internal resistance,
leading to lower variation of the capacity depending on the end-use application: a single rated
capacity can be determined
o For general purpose primary batteries, the comparison of the performances of two distinct
batteries can therefore only be established regarding a specific end-use application that will
impose the discharging rate through its resistance
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Discharge performance
21/11/2013 Introduction to Battery Testing and Certification Slide 17
Discharge at different rate Rated capacity 6.6 Ah
Pulse test / difference
between chemistry
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Application testing
21/11/2013 Introduction to Battery Testing and Certification Slide 18
21/11/2013 TÜV SÜD 4
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Battery life
21/11/2013 Introduction to Battery Testing and Certification Slide 19
That batteries have a finite life is due to
occurrence of the unwanted chemical or
physical changes to, or the loss of, the active
materials of which they are made. Otherwise
they would last indefinitely. These changes
are usually irreversible and they affect the
electrical performance of the cell
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Storage performance
21/11/2013 Introduction to Battery Testing and Certification Slide 20
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Cell qualification Approach
21/11/2013 Introduction to Battery Testing and Certification Slide 21
Review qualification requirements
Construct qualification
test plan
Review and validation
Execute test plan
Confirm results and
submit report
Through review of
program
requirements and
what tests may be
required to ensure
compliance.
Test cell quantity
Testing resources
Schedule, test flow
Cell is qualified for
use in the
customer’s
application.
Present plan to
customer for
approval.
Revise as
necessary
Execute according
the customer test
plan.
TÜV SÜD
Qualification testing
21/11/2013 Introduction to Battery Testing and Certification Slide 22
Performances tests
Capacity Cell cycle life
Environmental
Temperature Humidity Shock
Safety
Overcharge Over-
discharge External short
circuit Heat to vent Drop test
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Comparatives tests
21/11/2013 Introduction to Battery Testing and Certification Slide 23
Example : Discharge performance at -20°C (mAh)
Cell A Cell B Cell C Cell D Cell E Cell F
For the cells in green, the results are superior than the minimum required.
For the cell in orange, the results are satisfactory but with restriction.
For the cells in red, the results are not satisfactory and would be not used for the application.
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Comparatives tests
21/11/2013 Introduction to Battery Testing and Certification Slide 24
0
1
2
3
4
5
6
7
8
9
10Capacity at +20°C
Capacity at -20°C
High rate discharge capacity
Charge retention
Charge recovery after storage
Endurance in cycles
Battery 1
Battery 2
Global comparaison between 2 batteries
21/11/2013 TÜV SÜD 5
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Battery testing info needed
21/11/2013 Introduction to Battery Testing and Certification Slide 25
Basic information needed to quote your test program:
- Nominal Voltage and Capacity (Ah) rating
- Maximum charging current and voltage
- Maximum discharge current and voltage
- Normal discharge current
- Cutoff voltage (voltage at which output is cut off or battery is considered)
- Cutoff voltage (voltage at which output is cut off or battery is considered "dead")
- Fully charged current/voltage (current and voltage points where battery is considered fully charged)
- Schematics of battery packs and protection circuitry (if applicable)
- For UL 2054 Limited Power Source test on Request only
- Existing certifications on cells or packs
- Chemistry used (MSDS, Shipping requirements)
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General Product Safety Directive (GPSD) 2001/95/EC
Introduction to Battery Testing and Certification
This directive covers all products not already covered by a specific EU Directive and applies to consumer
products. The LVD (Low Voltage Directive) is not applicable for the majority of consumer batteries as the
voltage is less than 75Vdc.
The purpose of the GPSD is to ensure that all products intended for or likely to be used by consumers
under normal or reasonably foreseeable conditions are safe.
This directive allows the national enforcement authority to take action in order to protect consumers from
unsafe products.
The common way to demonstrate compliance to the majority of the requirements is to assess the battery
against harmonised standards such as :
Consideration shall be given also to the end product safety standard if known.
Standard Title Chemistry
EN 62133 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
Lithium-ion
Nickel
EN 60086-4 Primary batteries - Part 4: Safety of lithium batteries Lithium
EN 60086-5
Safety of batteries with aqueous electrolyte Alkaline
Slide 26 21/11/2013
TÜV SÜD
Batteries & Accumulators & Waste Batteries & Accumulators
2006/66/EC Overview
The “Battery Directive” can be broadly split into 2 UK Statutory Instruments:
The Waste Batteries and Accumulators Regulations S.I. 2009 No.890
Main objective relates to the collection, treatment and recycling of waste batteries.
The Batteries and Accumulators (placing on the market) (Amendment)
Regulations S.I 2012 No.1139 (S.I 2008 No.2164)
Main objective relates to material prohibition, labelling to aid recycling, capacity labelling,
placing on the market and removal of batteries.
“Battery Directive” applies to all batteries and accumulators regardless of shape, volume,
weight, material composition or use. Some exceptions exist such as batteries/
accumulators that's end use is for military or space applications.
21/11/2013 Introduction to Battery Testing and Certification Slide 27 TÜV SÜD
The Batteries and Accumulators (placing on the market)
Regulations Overview
Came into effect 31st May 2012 (update) and applies to any person/company placing Batteries and products containing or incorporating such Batteries onto the EU market. The regulation is enforced by the National Measurements Office (NMO) on behalf of the Secretary of State for Business Innovation and Skills (BIS). Material Prohibitions Battery/Accumulator shall not exceed the below limits : Mercury - ≤ 0.0005% by weight of battery, for button cell ≤ 2% of weight. Cadmium - ≤ 0.002% by weight of portable battery. The Cadmium requirement does not apply for portable batteries intended for use in Emergency& alarm systems including lighting, medical equipment and cordless power Tools.
21/11/2013 Introduction to Battery Testing and Certification Slide 28
TÜV SÜD
The Batteries and Accumulators (placing on the market)
Regulations Overview
Labelling to aid recycling
All batteries shall be labelled with the crossed out wheeled bin symbol.
Dimensions :
≥ 3% of area of the largest side of battery, with maximum size of 5 x 5cm.
≥ 1.5% of surface area for Cylindrical cells , with maximum size of 5 x 5cm.
If the symbol would be less than 0.5 x 0.5 cm the symbol can instead be located on the
packaging ≥ 1 x 1 cm.
The symbol shall be visible, legible and indelible.
Use of Mercury, Cadmium & Lead symbols The chemical symbol shall be placed below the wheeled bin symbol under the following circumstances :
The chemical symbol shall cover at least ¼ the size of the wheeled bin symbol.
Chemical Requirement
Mercury Hg ≥ 0.0005% by weight button cell only
Cadmium Cd ≥ 0.002% by weight
Lead Pb ≥ 0.004% by weight
21/11/2013 Introduction to Battery Testing and Certification Slide 29 TÜV SÜD
Capacity labelling
The requirement to detail the capacity of the battery applies to portable rechargeable batteries and
Automotive batteries.
The requirement however does not apply to embedded batteries that are not user replaceable in end
application.
The below standards shall be used to determine the capacity of a battery:
The Batteries and Accumulators (placing on the market)
Regulations Overview
Standard Chemistry
EN 61951-1 Nickel-Cadmium
EN 61951-2 Nickel-Metal Hydride
EN 60622 Nickel-Cadmium (Prismatic)
EN 61960 Lithium-ion
EN 61056-1 Lead Acid (portable)
EN 60095-1 Lead Acid (automotive)
EN 50342-1 Lead Acid (automotive)
21/11/2013 Introduction to Battery Testing and Certification Slide 30
21/11/2013 TÜV SÜD 6
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The Batteries and Accumulators (placing on the market)
Regulations Overview
Introduction to Battery Testing and Certification
Capacity labelling The capacity shall be expressed in either mAh or Ah including if applicable cold cranking current. The size of the label shall be as follows :
If the Individual Batteries, accumulators or battery pack are small and cannot have labelling of this size , the packaging shall detail the capacity with a size of 5.0 x 12.0 mm.
Type of battery Location & Dimensions (height x length)
Individual Batteries & Accumulators On Battery: 1.0 x 5.0mm.
On Packaging Front: 5.0mm x 12.0mm
Battery Packs On Battery:
when the largest side is less than
70cm2 = 1.0 x 5.0mm.
when the largest side ≥ 70cm2 = 2.0 x 5.0mm.
Button Cell On Packaging front: 5.0 x 12.0mm
Automotive Batteries & Accumulators On Battery: ≥ 3% of area of largest side, up to 20 x
150mm
21/11/2013 Slide 31 TÜV SÜD
Removal of batteries
The “Battery Directive” requires that battery powered appliances are not to be placed on the
market unless :
- The design allows end of life batteries to be readily removed from the appliance.
- Instructions showing how the battery can be removed safely and where appropriate details of the
type of battery shall be available to the end user.
This does not apply where for safety , performance , medical or data integrity reasons continuity
of power supply is necessary and permanent connection between battery and appliance is
required.
Consideration to end user safety shall also be given. Some product safety standards may
not allow access by end user only qualified personnel in this case the information shall be made
available to the recycling facility.
For embedded batteries the manufacturer shall ensure they have considered the lifetime of both
the battery and product.
The Batteries and Accumulators (placing on the market)
Regulations Overview
21/11/2013 Introduction to Battery Testing and Certification Slide 32
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The Waste Batteries and Accumulators Regulations
Came into effect during 2009 – 2010 and applies to any person/company placing
Batteries and products containing or incorporating such Batteries onto the EU market
as well as battery distributors/retailers and waste battery collectors, recyclers and
Exporters.
The regulation is enforced by :
Agency Responsibility
BIS (Department for Business Innovation & Skills)
Waste Industrial and Automotive
Batteries
Environmental Agency (EA,SEPA,NEIA)
Waste Portable Batteries
VCA (Vehicle Certification Agency)
Distributors
Take-back of Waste Portable
Batteries
21/11/2013 Introduction to Battery Testing and Certification Slide 33 TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 34 Introduction to Battery Testing and Certification 21/11/2013
Battery Categories
Portable :
• Sealed
• Can be hand carried by an average person without difficulty
• Does not meet the definition of the other categories
TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 35 Introduction to Battery Testing and Certification 21/11/2013
Battery Categories
Industrial :
• Designed exclusively for industrial or professional uses
• Used as a power source for the propulsion in an electric vehicle including Hybrid
• Unsealed but is not an Automotive battery.
• Sealed but is not an Portable battery.
TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 36 Introduction to Battery Testing and Certification 21/11/2013
Battery Categories
Automotive :
Battery solely used for the starting or ignition of a engine for a road going vehicles including
providing power for lighting.
21/11/2013 TÜV SÜD 7
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The Waste Batteries and Accumulators Regulations
Who is a Producer ? “producer” means any company/person in the United Kingdom that, irrespective of the selling technique used, including by means of distance communication(website etc) places batteries including those incorporated into appliances or vehicles onto the market for the first time in the United Kingdom on a professional basis. Who is a Distributor ? “distributor” means that they provide batteries and accumulators on a professional basis to an end user You may be both a Producer and Distributor in which case you need to meet the obligations of both.
21/11/2013 Introduction to Battery Testing and Certification Slide 37 TÜV SÜD
The Waste Batteries and Accumulators Regulations
Portable Battery Producer Obligations “Small Producer” = ≤ 1 tonne of batteries (1,000 kg). Register on the NPWD(National Packaging Waste Database) Registration System. Pay annual charge typical £30 a year. Record the amount (weight) of batteries sold (UK) including chemistry. If you sell more than 1 tonne of batteries Register with a Battery Compliance Scheme (BCS) who will notify the environmental agency of your joining. Provide BCS with comprehensive details of your company. Provide quarterly data reports of the amount (weight) of batteries sold (UK) including Chemistry to BCS. Pay applicable fee to BCS for the service they provide you.
21/11/2013 Introduction to Battery Testing and Certification Slide 38
TÜV SÜD
The Waste Batteries and Accumulators Regulations
Portable Battery Distributors Obligations
“Small Distributor” = ≤ 32 Kg
Record the amount (weight) of batteries sold (UK) including chemistry.
If you sell more than 32 Kg of batteries :
Must implement a take back scheme for waste (end of life) batteries.
The scheme must be free to the end user and accept all types of portable batteries not just
ones you sell.
Record the amount (weight) of batteries sold (UK) including chemistry and location of sale.
Arrange collection with a BCS.
Publicise / make available information to end users relating to cost of collection, treating and recycling
waste when selling new batteries to end users.
The requirement for a take back scheme is not required if you only sell equipment that contains batteries i.e you do
not sell batteries separately
21/11/2013 Introduction to Battery Testing and Certification Slide 39 TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 40 Introduction to Battery Testing and Certification 21/11/2013
Portable Battery Distributors Obligations
The weight limit, what does this mean in real terms?
Year Directive Target UK Actual
2012 25% 28.3%
2016 45% ??
Directive Targets for collection, treatment and recycling
National Packaging Waste Database Summary of Portable Batteries Data for the 2012 Compliance Period - as at 18 July 2013
TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 41 Introduction to Battery Testing and Certification 21/11/2013
Industrial Battery Producer Obligations
Register company details with BIS.
Register on the NPWD (National Packaging Waste Database) Registration System. A BPRN (Battery Producer Registration Number) will be allocated to producer. Take Back & Collection (1) Provide free take back & collection on request if the end user is buying a replacement battery. (2) Provide free take back & collection on request if the end user cannot return the waste battery to there
original producer (supplier) if it is the same chemistry type as the Producer has placed on the market currently or in the last 3 years.
(3) Provide free take back & collection on request if the end user is unable for any reason to return the
waste battery to the producer under entitlement (1) & (2). Alternative commercial arrangements with end users is permitted relating to meeting of costs of collecting, treating and recycling waster industrial batteries but it is the responsibility of the Producer to meet the directive requirements.
TÜV SÜD
The Waste Batteries and Accumulators Regulations
Slide 42 Introduction to Battery Testing and Certification 21/11/2013
Industrial Battery Producer Obligations Publicise to Industrial Battery end users the take back scheme. Publicise chemistry of the batteries the producer has placed on the market currently and in the last 3 years. Compile yearly report s that are available to the Environmental Agency covering: • Amount and chemistry of batteries placed on the market. • Amount and chemistry of batteries received as part of the take back scheme .
• Amount and chemistry of batteries delivered to an approved Battery Treatment Operator for recycling
• Amount and chemistry of batteries delivered to an approved Battery Exporter for recycling outside the UK. • Records shall be kept for a minimum of 4 years.
When selling/supplying industrial batteries the producer must declare the BPRN number to their client. Illegal to dispose of waste Industrial Batteries in landfill or to incinerate them.
21/11/2013 TÜV SÜD 8
TÜV SÜD Slide 43 Introduction to Battery Testing and Certification 21/11/2013
Automotive Battery Producer Obligations
Register company details with BIS.
Register on the NPWD (National Packaging Waste Database) Registration System. A BPRN (Battery Producer Registration Number) will be allocated to producer.
Collect waste Automotive Batteries from Final Holders free of charge, no requirement to collect from individual consumers. Publish waste battery collection to Final Holders. Compile yearly report s that are available to the BIS (Department for Business Innovation & Skills) covering: • Amount and chemistry of batteries placed on the market.
• Amount and chemistry of waste batteries collected.
• Amount and chemistry of batteries delivered to an approved Battery Treatment Operator for recycling or Battery Exporter for recycling outside the UK.
• Estimated tonnage of batteries that will be exported before use.
Illegal to dispose of waste Automotive Batteries in landfill or to incinerate them.
The Waste Batteries and Accumulators Regulations
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Thank you for
listening!
For more information contact:
+44 (0)1489 558100
www.tuv-sud.co.uk
TÜV SÜD
Slide 44
Introduction to Battery Testing and Certification 21/11/2013