Battery Test Campaign: Structured Summary
This post summarizes the comprehensive series of tests performed on the battery, covering mechanical, electrical, waterproofing, and fire protection aspects. Each section includes a brief description, success criteria, results, and links to video evidence for further reference.
Mechanical Tests
Vibration of the Battery
Category: Mechanical
- Description: Battery in 10s1p configuration vibrated from 7Hz to 200Hz while discharging, monitoring for voltage drops.
- Success Criteria: No voltage drop
- Result: OK
- Video: Watch on YouTube
Click image for video at 0:30
Vibration of the Pack
Category: Mechanical
- Description: Same vibration test applied to the battery pack only.
- Success Criteria: No voltage drop
- Result: OK
- Video: Watch on YouTube
Click image for video at 0:25
Drop Test
Category: Mechanical
- Description: Battery dropped from 1m on concrete from various angles.
- Success Criteria: Battery still works
- Result: OK
- Video: Watch on YouTube
Click image for video at 0:15
Fits on the Bike
Category: Mechanical
- Description: Battery should fit and be held firmly on the bike.
- Result: OK
- Remark: Do we need to modify the tool for the little movement?
BMS (Battery Management System) Tests
BMS Power Consumption
Category: BMS
- Description: Current logger used to measure BMS consumption in different modes.
- Success Criteria: Sleep consumption should be lower than 2mA
- Result: OK
- Video: Watch on YouTube
Click image for video at 0:20
BMS Review (ARTS ENERGY)
Category: BMS
- Description: Review of schematics and routing.
- Success Criteria: No issues found on components or isolation
- Result: OK
BMS Review (SERMA)
Category: BMS
- Description: Review of schematics, routing, and manufacturing quality of first batch.
- Success Criteria: No major issues, minor solder quality improvements suggested
- Result: OK
Waterproofing & Environmental Tests
Internal Air Pressure
Category: Waterproof
- Description: Battery casing filled with air to test pressure resistance.
- Success Criteria: Only leak at breathing valve
- Result: OK, pressure up to 8 bars
- Video: Watch on YouTube
- Remark: No venting valve present, breathing valve exploded under pressure.
Click image for video at 0:40
Fire Protection & Abuse Tests
BMS Salt Spray Test
Category: Fire protection
- Description: 10% saline solution sprayed on BMS (not tropicalized) to spot hot points and spark propagation.
- Success Criteria: No sustained spark, no propagation to contacts
- Result: OK
- Video: Watch on YouTube
- Remark: With coating, there should be no spark at all.
Click image for video at 0:35
Nail Penetration
Category: Fire protection
- Description: Nail inserted into one cell to trigger thermal runaway.
- Success Criteria: Other cells do not enter thermal runaway
- Result: OK
- Video: Watch on YouTube
- Remark: OK after redesigning venting valve
Click image for video at 0:50
Complete Thermal Runaway of the Pack
Category: Fire protection
- Description: Nail inserted through multiple cells to trigger global thermal runaway.
- Success Criteria: Pack should withstand flames/explosions as long as possible
- Result: OK (10 min without flames, flames at the back at the end, easy to control with water)
- Video: Watch on YouTube
- Remark: OK after redesigning venting valve
Click image for video at 1:00
Conclusion
The battery has successfully passed a rigorous series of mechanical, electrical, waterproofing, and abuse tests. Results indicate robust design, with only minor improvements suggested for future iterations. For detailed visual documentation, refer to the linked videos and suggested timestamps.
