Safety Testing of Lithium-Ion Batteries

The trend of ecology and everything green directly influenced the development of various commercial solutions, which were unimaginable until recently. The possibility of unlimited availability offered to customers and the development of new technologies and products, such as electric vehicles, have influenced the increasing popularization of batteries. Currently, lithium-ion batteries are among the best and most cost-effective technologies.

This type of battery can be found in products such as mobile phones, laptops, and the already-mentioned electric vehicles. Of the solutions mentioned, electric vehicles are the most interesting, not just because of their growing popularity but also because of the size of the battery built into the product.

The goal of this article is not to try to convince that the electrification of anything is “greener” or a better solution than other currently available solutions on the market, but to draw attention to the safety of using lithium-ion batteries that are installed in final products.

Although we live in a period when almost all information is instantly available to users through various digital platforms, including on this topic, it is necessary to emphasize that in case of problems during use, lithium-ion batteries can cause very unpleasant situations.

Several factors affect the safety of lithium-ion batteries. As the first of them, we can point out the consumerist lifestyle and efforts to make quick and big profits, which is why batteries are made according to the principle that they should be produced as cheap as possible, with as much capacity as possible, and as quickly as possible (because of the fast-growing auto industry, of course). Serial production of many products of reduced quality is not a new phenomenon on the market but in the case of complex solutions such as lithium-ion batteries, production guided by this approach results in an unsafe product for the consumer and the environment.

Another factor that affects safety is the distribution of batteries around the world, which is carried out by various means of transport under different conditions, for example, pressure changes, exposure to high or low temperatures, and vibrations.

The third important factor is human error, which can occur either during installation in an electric vehicle or during driving, for example, participation in a traffic accident.

In addition to manufacturing errors, inadequate transport and distribution conditions, and human factors, there are certainly other elements that can affect the safety of batteries. To increase product quality, prevent damage, and save human lives, lithium-ion batteries must pass a series of safety tests.

The Laboratory Center operating within the KONČAR – Electrical Engineering Institute, conducts safety tests of lithium-ion batteries following UN guidelines for safety in transport (also known as UN 38.3), tests following regulations, i.e., ECE R100 documents (for homologation of battery systems on EVs), and safety standards, such as EN 62133-2.

The most common laboratory tests simulate a situation that can arise from improper use or an accident. Here, short-circuit or over-charging tests stand out. Seemingly simple tests are also very interesting, such as dropping batteries onto a hard surface from a certain height. But we must not forget less destructive tests, such as climate tests, simulation of pressure changes, and vibration tests, which simulate possible events in the life cycle of such an important and complex device.

During the preparation for such interesting, but sometimes stressful tests, we paid special attention to the safety of our testing specialists. A test environment has been created in which, after the initial installation of the test object, the laboratory staff does not need to enter, and its environment and conditions are such that they allow the test to be performed in a completely safe manner.

Finally, whether you are a manufacturer, distributor, or user of lithium-ion batteries or the final products in which they are installed, do not forget – safety comes first!