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www.intertek.com1
UN 38.3 Shock Test Data Collection
Rich Byczek, Intertek
Oct 2013
1http://www.psessymposium.org/
www.intertek.com2
T4: Shock
• Small Cells/Batteries = 150g/6ms = consumer battery specs
• Large Cells/ Batteries= 50g/11ms = automotive OEM Specs
• Large Cells -> Small Batteries: Cells at 50G, Battery at 150G
www.intertek.com3
Measurement Methods
Shipping of Representative shipments and packaging.
• OEM selected Samples
• OEM selected Methods
• Small, Medium, Large sample shipments
www.intertek.com4
Measurement Methods
INTERTEK RECOMMENDATIONS
Pallet (LTL) and Small (UPS, FEDEX, etc)
Assume small parcels have the roughest handling.
Measure at package, not at device (do not assume dampening)
www.intertek.com5
Measurement Methods
Measurement Equipment
EDR-3C by IST
- 3axis internal accelerometer
- Use 2 to test both package and
battery.
- Set minimum G threshold, to collect primarily shock pulse data (i.e. 3G, 5G)
www.intertek.com6
Measurement Methods
May require multiple runs per shipment size and type.
• Set realistic thresholds to maximize data collection
• Potential variation from shipment to shipment
• Variation based on sample and packages size and method.
www.intertek.com7
Measurement Methods
Measurement Analysis
- Convert recorded data to time history
- Cursory review of peaks and durations
- Data “reduction” based on revised threshold
- Statistical calculation of Peak G and Duration
www.intertek.com8
Measurement Methods
Resultant Shock Pulse ASSUMPTIONS
• Half Sine Pulse
• Small/ Large have separate parameters
• Peak G level: based on max for each shipment size, regardless of method
• Duration: based on average pulse width above threshold
• Pulse Count: TBD, based on average pulses per shipment
www.intertek.com9
Measurement Methods
NOTE on PEAK and NUMBER of PULSES:
Increasing number of pulses may be a way to reduce test peak levels.
Typical 1-3 pulse per direction is an ACCELERATED TEST, and therefore peak G level may not be representative of actual accumulated stress.
Alternate is realistic G level, with representative test duration (number of pulses seen in a typical or multiple shipments)
www.intertek.com10
Vibration and Shock
• “Test cells and batteries shall be secured to the testing machine by means of a rigid mount”
• Fixturing:
• Support the product
• May simulate packaging
• May simulate mounting in position
• Not well defined currently.
• Cannot assume package dampening
www.intertek.com11
Vibration and Shock
• CONSIDER WHAT IS BEING SHIPPED!
• CONSIDER HOW IT IS SHIPPED!
• CONSIDER HOW IT IS TRANSPORTED AFTER INITIAL SHIPMENT
www.intertek.com12
THANKYOU
Mike WellsVibration Test Department Manager
Rich ByczekIntertek Global Technical Lead
Electric Vehicle & Energy Storage248-219-1099