Pre-Production Testing (Raw Material & Cell Inspection)
Cell Sorting
Cells are classified using laser or X-ray scanning to ensure uniformity in performance (e.g., capacity, voltage, internal resistance). Only qualified cells proceed to assembly.
Material Compliance Check
Verify raw materials (electrolytes, separators, casings) meet ISO 9001 and environmental standards like RoHS.
Automated laser/ultrasonic welding ensures secure electrical connections between cells and the Battery Management System (BMS). Post-weld electrical tests check for short circuits or voltage irregularities.
Module Assembly
Cells are grouped into modules, tested for consistency in voltage and capacity. Automated systems validate insulation and thermal management components.
Overcharge/Overdischarge Protection: Validates BMS functionality under extreme conditions
Short-Circuit Test: Ensures no thermal runaway or fire occurs
Cycle Life Test: Measures capacity retention after hundreds of charge-discharge cycles (per IEC 61960)
Mechanical Stress Tests
Vibration & Impact Testing: Simulates transportation hazards (per UN 38.3)
Crush Test: Evaluates structural integrity under heavy pressure
Environmental & Durability Testing
Temperature Extremes
Batteries undergo high/low temperature storage (-30°C to 130°C) and thermal cycling to assess performance stability.
Humidity & Salt Spray Tests
Validates corrosion resistance and sealing integrity in harsh environments
Certification & Final Inspection
Third-Party Certification
Accredited labs (e.g., UL Solutions, CTIA-authorized facilities) conduct independent validation for standards like IEC 62133-2 (lithium systems) and UL 2054.
Batch Sampling
Random samples from production batches undergo OQC (Outgoing Quality Control) to ensure consistency. Tests include capacity verification and leakage checks
Documentation & Labeling
Prepare compliance files (test reports, MSDS, UN 38.3 transport certificates) and label packs with required markings (e.g., capacity, voltage, recycling symbols).
Pre-Shipment Verification
Final Functional Test
Full charge-discharge cycle to confirm performance metrics (capacity, efficiency) align with specifications.
Packaging & Transport Readiness
Validate packaging materials (e.g., fire-resistant casings) and perform 1.2-meter drop tests for UN transportation compliance.
