Electromagnetic vibration test for power lithium battery pack

Electromagnetic vibration test for power lithium battery packTesting standard process

Phase 1: Test Preparation and Installation (Pre test)

Equipment and tooling preparation

Check if the electromagnetic vibration table is level and confirm that there are no foreign objects on the table.

According to the size of the lithium battery pack, customized or selected specialized fixing fixtures (fixture plates) are required, with a fixture firmness greater than three times the weight of the sample to ensure that it does not loosen during the testing process.

Sample pretreatment

Confirm the status of the test sample: Record the initial voltage, internal resistance, insulation resistance, and appearance structure of the battery pack (without deformation or leakage).

Place the power lithium battery pack steadily in the center of the vibration table, ensuring that the center of gravity coincides with the center of the table.

Use high-strength bolts to lock the battery pack with fixtures to the specified torque (usually recommended torque for M8 bolts is 25-35N · m, depending on the material).

Wiring and monitoring

Connect the vibration controller to the battery tester/data acquisition card.

Set vibration parameters (frequency range, acceleration, time) and battery monitoring parameters (voltage, current acquisition frequency).

Arrange testing personnel to be present for supervision, equipped with fire extinguishers and emergency power-off devices.

Phase 2: Parameter Setup

Enter the following test parameters in the vibration control software (general standard reference):

Vibration direction: Vertical direction (X-axis) is the main direction, and horizontal direction (Y/Z-axis) may be added if necessary.

Frequency range: 10 Hz~50 Hz (simulating low-frequency bumps in road conditions) or 50 Hz~2000 Hz (simulating high-frequency resonance).

Frequency sweep method: logarithmic sweep (1 oct/min or 2 oct/min).

Acceleration: 1g~5g for simulating normal road conditions; The rigorous testing of vehicle specifications can reach 10g~20g.

Test duration: 30 minutes to 2 hours per cycle, or a total cumulative duration (such as 1 hour/3 hours/24 hours of cumulative testing).

Phase 3: Test Execution

Start no-load operation

Start the no-load operation first, check if the tabletop is running smoothly, and confirm that there are no abnormal vibrations or noises.

Start formal testing

Start the vibration program, and the device begins to generate sine/random vibrations.

Full process monitoring: Real time observation of battery status during testing, and touching live parts is strictly prohibited.

Automatic recording: The system automatically records the amplitude and frequency response of the vibration table, as well as the real-time variation curves of the voltage and internal resistance of the battery pack.

Multi axis switching (if required)

If a comprehensive evaluation of mechanical reliability is required, after completing the vertical direction test, switch to the horizontal direction (X/Y axis) and repeat the above steps.

Stage 4: Conclusion and Post test

Shutdown and Cooling

After the testing program is completed, the equipment will automatically shut down. After the amplitude wan of the table is completely zero, cut off the main power supply.

Wait for the device to cool down (usually 5-10 minutes).

Sample disassembly and retesting

Be careful when disassembling the fixture and battery pack, and wear an anti-static wristband before operation.

Appearance re inspection: visually inspect the battery pack casing for deformation, cracking, solder joint detachment, and bent terminal ears.

Electrical re inspection: Measure the voltage, internal resistance, and insulation resistance again, compare them with the data before the test, and determine whether there is drift.

data archiving

Export vibration test report (including vibration curve) and battery performance test report, and organize and archive them.

Stage 5: Judgment of Results

Based on the test data, it can be concluded that:

Pass: The battery did not disconnect or generate abnormal heat during the vibration process; After testing, there is no structural damage to the appearance, and the rate of change in electrical parameters (voltage, internal resistance) is within the allowable range (such as<5%).

Fail: If there is structural looseness, solder joint detachment, voltage drop to zero, shell deformation or slight leakage, it is judged as unqualified and the assembly process needs to be optimized.

💡 Explanation of professional testing terminology (suitable for making PPT or technical documents)

Sine vibration: Simulating vibrations of a single frequency, commonly used to detect resonance risks in specific components such as engines and motors.

Random vibration: Simulating complex and varied road bumps is currently the most mainstream testing method for power batteries, which is closer to real driving conditions.

G-Force: Multiple of gravitational acceleration. 1g is the Earth's gravity, and the higher the value, the more severe the simulated road conditions (such as off-road vehicle driving vs. high-speed car driving).

Sweep: Allow the device to automatically scan back and forth within a set frequency range, test the product's tolerance at different frequencies, and prevent structural damage caused by resonance.

Electromagnetic vibration test for power lithium battery pack