Battery Vibration Testing

Change Log

Battery Vibration Testing Change log

Required Tools

Torque wrench calibrated to 195 lb-in (22 N-m)
inch pounds (YYY Newton Meters)
Digital camera (or phone camera if permissible)
Multimeter with mV precision
EQUIPMENT NEEDED TO ATTACH ACCELEROMETER

Required Parts and Hardware

Battery Vibration Testing Required Hardware

Pass/Fail Criteria

The pass/fail criteria for this test is that there shall be less than 0.1% change in the OCV and less than 5% change in capacity before and after vibration tests and throughout the remainder of the test procedures.

Pre-Test Confirmation (To be Completed by UMSTARLab)

Confirm that the following tests have been completed:
1. Ensure that charge cycling has been completed and recorded.
2. Confirm that all cells have been discharged to less than 10% SOC before shipping.
3. Record the OCV for each cell before shipping the cells for testing.
Assemble the UMS-0445 Battery Vibration Jig as per the assembly instructions here.

Open Circuit Voltage (OCV) Measurement Procedure

The OCV needs to be recorded in 4 stages. Pre-vibe, post-x-axis-vibe, post-y-axis-vibe, post-z-axis-vibe (or post-vibe). The results of the OCV for each cell shall be recorded in the table below. A multimeter with mV precision is used to measure each cell's OCV by connecting the meter's probes to the cell's terminal. Red probe to the positive terminal and black probe to the negative terminal as shown in the Figure below.

vibration OCV test results (Table C-11*)

Figure 1: UMS-0445 Battery Vibration Jig with Accelerometer Mounting Locations

Test Procedure (To be Completed by the CSA)

NOTE: If the CSA vibration table is currently in the z-axis test orientation, z-axis testing can be performed before x and y axes testing.

Measure the open circuit voltage (OCV) of each battery using the procedure in the previous section.
X-Axis Testing
1. Mount the Battery Vibration Jig to the vibration table using four 3/8"-16 fasteners and 3/8" washers at mounting locations indicated in Figure 2.
2. Ensure all four 3/8"-16 fasteners are torqued to 195 lb-in (22 N-m).
3. Attach accelerometer to the X-axis location shown in Figure 1, using the CSA's standard accelerometer mounting procedure.
4. Take a picture of the test setup.
5. Run the vibration table using the vibration profile shown in Figure 3 for 60 seconds.
6. Once the profile has been run, visually inspect the vibration jig for damage.
7. Measure the open circuit voltage (OCV) of each battery using the procedure in the previous section.
Y-Axis Testing
1. If no damage was observed after X-Axis testing, remove the four 3/8"-16 fasteners
2. Rotate the Battery Vibration Jig by 45 degrees
3. Re-attach the jig to the vibration table using the same four mounting locations shown in Figure 2.
4. Ensure all four 3/8"-16 fasteners are torqued to 195 lb-in (22 N-m).
5. Attach accelerometer to the Y-axis location shown in Figure 1, using the CSA's standard accelerometer mounting procedure.
6. Take a picture of the test setup.
7. Run the vibration table using the vibration profile shown in Figure 3 for 60 seconds.
8. Once the profile has been run, visually inspect the vibration jig for damage.
9. Measure the open circuit voltage (OCV) of each battery using the procedure in the previous section.
Z-Axis Testing
1. If no damage was observed after Y-Axis testing, remove the four 3/8"-16 fasteners
2. Change the vibration table configuration for Z-axis testing.
3. Re-attach the jig to the vibration table using the four mounting locations shown in Figure 4.
4. Ensure all four 3/8"-16 fasteners are torqued to 195 lb-in (22 N-m).
5. Attach accelerometer to the Z-axis location shown in Figure 1, using the CSA's standard accelerometer mounting procedure.
6. Take a picture of the test setup.
7. Run the vibration table using the vibration profile shown in Figure 3 for 60 seconds.
8. Once the profile has been run, visually inspect the vibration jig for damage.
9. Measure the open circuit voltage (OCV) of each battery using the procedure in the previous section.

Figure 2: UMS-0445 Battery Vibration Jig Mounting Locations for X, Y, and Z Axis Vibration Testing

Figure 3: Battery Vibration Profile

Post-Test Confirmation (To be Completed by UMSTARLab)

Once the batteries have been returned to UMSTARLab:

Measure the OCV of each cell
Check the change in OCV from before and after vibration testing.
Confirm if the changes in OCV and Capacity are acceptable, as per our maximum 0.1% OCV change and maximum 5% change in capacity pass/fail criteria

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