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ELECTRIC VEHICLE BATTERY TEST PROCEDURES MANUAL

ELECTRIC VEHICLE . BATTERY TEST PROCEDURES . MANUAL . Revision 2. Published January 1996. Summary of Changes for USABC MANUAL Revision 2. (Not including minor editorial and typographical corrections). PAGE DESCRIPTION OF CHANGE. 2, A-5 The list of Core Performance tests is clarified in Figure 1, and the test plan outline is clarified to note that written direction from the USABC Program Manager is needed to bypass these tests . The number and type of core tests required is NOT changed. 6, E-2, F-3, F-5 A single Rated Capacity' value is clearly defined as the basis for measuring depth- of- discharge (and hence capacity) for all USABC performance tests .

test plans. 9, E-3, F-5, I-3 The Discharge Voltage Limit (DVL) for the Peak Power Test is clarified to be a fixed value established at beginning of life. An alternate equation for calculating Peak Power Capability is added to account for decreases in open circuit voltage beyond

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Transcription of ELECTRIC VEHICLE BATTERY TEST PROCEDURES MANUAL

1 ELECTRIC VEHICLE . BATTERY TEST PROCEDURES . MANUAL . Revision 2. Published January 1996. Summary of Changes for USABC MANUAL Revision 2. (Not including minor editorial and typographical corrections). PAGE DESCRIPTION OF CHANGE. 2, A-5 The list of Core Performance tests is clarified in Figure 1, and the test plan outline is clarified to note that written direction from the USABC Program Manager is needed to bypass these tests . The number and type of core tests required is NOT changed. 6, E-2, F-3, F-5 A single Rated Capacity' value is clearly defined as the basis for measuring depth- of- discharge (and hence capacity) for all USABC performance tests .

2 The Rated Capacity is established by the manufacturer based on whatever tradeoffs he chooses to make for the best balance of power, capacity and life. 6, A-1 Both USABC Test Manager and Program Manager approval are required for all test plans. 9, E-3, F-5, I-3 The discharge Voltage Limit (DVL) for the Peak Power Test is clarified to be a fixed value established at beginning of life. An alternate equation for calculating Peak Power Capability is added to account for decreases in open circuit voltage beyond 80% DOD or later in life. Conduct of the Peak Power test itself is NOT changed except for requiring voltage to stay above the DVL.

3 13, 15, 40 discharge Voltage Limit is a default termination condition for FUDS, DST and Life Cycle Testing. 15 The DST procedure is modified to eliminate the reduced power criterion for Step 15. All steps are now treated the same (as in the FUDS test); and the test terminates when the programmed power cannot be achieved for any step without exceeding a BATTERY limit. 15, F-6 The terminology DSTn is established to indicate the peak power scaling for a DST. test, DST120 is a test scaled to 120 W/kg. 22ff, J-34ff A vibration test using random vibration is added to Procedure 10. The existing swept sine wave vibration test is retained unchanged as an alternative.

4 31, 35, 37, 39, 40 The interval for conducting Reference Performance tests during life cycle test regimes is generalized to an appropriate interval rather than fixed at 28 days. 35 The method for counting the number of cycles achieved during life testing of a BATTERY is formalized. 37, 38 The Actual Use Simulation test is extended to include the effects of ambient temperature variation, and temperature test regimes are established based on historical data from specific hot and cold weather locations. 40 The Baseline Life Cycle Test is defined based on DST cycling to 80% DOD at nominal environmental conditions. (This test is already being widely used.)

5 F-7 End-of-life is clarified to occur when either the net DST delivered capacity or peak power capability at 80% DOD is less than 80% of rated. Appendix F A detailed glossary of terminology is included. Appendix I An explanation of the method and rationale for calculating Peak Power Capability is provided. Appendix J Detailed PROCEDURES (previously issued separately) are included to supplement some procedure summaries, and the special procedure previously proposed for resistance determination is deleted. ii ELECTRIC VEHICLE BATTERY TEST PROCEDURES MANUAL . TABLE OF CONTENTS. Foreword .. iv Introduction .. 1. Outline and Flow Diagram of USABC Testing Process.

6 2. BATTERY Test Procedure Summaries .. 4. Organization Chart of USABC BATTERY Test PROCEDURES .. 5. 1A. BATTERY Pre-Test Preparation .. 6. 1B. Readiness Review .. 7. * 2. Constant Current discharge Test Series .. 8. ?* 3. Peak Power Test .. 9. * 4. Constant Power discharge Test .. 11. * 5. Variable Power discharge Testing [Overview] .. 12. ? 5A. FUDS Regime (Variable Power discharge ) .. 13. ? 5B. DST Regime (Variable Power Testing) .. 15. 6 - 12. Special Performance tests [Overview] .. 17. ? 6. Partial discharge Test .. 18. ? 7. Stand Test .. 19. 8. Sustained Hill-Climbing Power Test .. 20. ? 9. Thermal Performance Test .. 21. ? 10.

7 BATTERY Vibration Test .. 22. 11. Charge Optimization Testing .. 27. 12. Fast Charge Test .. 28. 13. Safety and Abuse Testing .. 29. 14. Life Cycle Testing [General] .. 31. 14A. Accelerated Aging Testing .. 33. 14B. Actual-Use Simulation Test including Ambient Temperature Influence .. 37. 14C. Reference Performance tests .. 39. 14D. Baseline Life Cycle Test .. 40. (? indicates that detailed PROCEDURES are available in Appendix J). (* indicates core performance tests - see Appendix A Section for details). Appendices A. Generic Test Plan Outline for USABC BATTERY Testing .. A-1. B. Definition of Data Acquisition and Reporting Requirements.

8 B-1. C. DOE National Laboratory Test Facilities Listing .. C-1. D. Methodology for Assigning USABC Identification Numbers .. D-1. E. Worksheet for Manufacturer-Supplied Testing Information .. E-1. F. Glossary of BATTERY and BATTERY Testing Terminology .. F-1. G. USABC Advanced BATTERY Criteria .. G-1. H. Procedure to Measure Actual Peak Power .. H-1. I. Derivation of USABC BATTERY Peak Power Calculations .. I-1. J. Detailed PROCEDURES .. J-1. iii FOREWORD. This USABC BATTERY Test PROCEDURES MANUAL was prepared by a team composed of USABC and DOE National Laboratories personnel. It is based on the experience and methods developed at Argonne National Laboratory (ANL), Idaho National Engineering Laboratory (INEL) and Sandia National Laboratories (SNL).

9 The specific PROCEDURES were developed primarily to characterize the performance of a particular BATTERY relative to the USABC mid term and long term BATTERY requirements. The principal contributor and author of this document is Gary Hunt of INEL. Although it is used as a "standard" for USABC BATTERY testing, a continuing need to improve these PROCEDURES is expected. Suggestions should be directed to Gary Hunt, INEL, telephone number 208-526-1095. BATTERY Test Procedure (BTP) Working Group Contributors USABC National Laboratories Helen Cost Jeffrey Braithwaite Pat Davis (DOE) Paul Butler Edward Dowgiallo (DOE) William De Luca Matthew Dzieciuch Narayan Doddapaneni Michael Eskra James Freese Harold Haskins Jasper Hardin Bernie Heinrich Gary Hunt Russell Moy John Smaga Jim Pass Naum Pinsky Bruce Rauhe Bill Schank Ray Sutula (DOE).

10 Robert Swaroop Tom Tartamella John Williams iv INTRODUCTION. This MANUAL summarizes the procedural information needed to perform the BATTERY testing being sponsored by the United States Advanced BATTERY Consortium (USABC). In this MANUAL , the general term BATTERY refers to full-voltage BATTERY packs, modules, and cells. This information provides the structure and standards to be used by all testing organizations, including the USABC. developers, national laboratories, or other relevant test facilities. The structure of the USABC testing process is shown in Figures 1 and 2. These figures represent two methods for describing the same process: Figure 1 is an outline and Figure 2 is a flow diagram.


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