Testing

Chemistry Analysis

• Raw Materials
• In Production Testing
• Cell Benchmarking
• Ageing
• Failure Mode
• Pack Materials

Cell Testing

• Performance Data: electrical performance under controlled conditions including capacity, OCV, impedance, self-discharge, formation, and charge characterisation
• Ageing: calendar and cycle life; the basis for lifetime estimation and SOH modelling
• Diagnostics: non-destructive techniques to detect internal faults and track degradation
• BMS Data: the complete measured dataset required to design and calibrate a battery management system
• Mechanical Tests: structural integrity, swelling, pressure behaviour, vibration, and shock
• Thermal Tests: heat generation, thermal properties, calorimetry, and thermal runaway characterisation
• Abuse Tests: behaviour at and beyond operational limits across electrical, thermal, and mechanical domains
• Legislative / Certification Testing: standards required for transport, sale, and use in global markets
• Fast Charge Current Limits
• Accelerated Testing
• End-of-Line Testing

Module Testing

• Performance Data: module-level capacity, energy, internal resistance, and power capability, including current sharing within parallel groups
• Electrical / Interconnect Testing: busbar resistance, joint and weld quality, insulation resistance, and HVIL continuity
• BMS Sensing & Data Validation: voltage sensing accuracy, temperature sensor placement, balancing function, and communications
• Thermal Tests: thermal imaging, cooling system validation, gradient mapping, and cell-to-cell thermal coupling
• Mechanical Tests: vibration, shock, crush, and structural integrity of the assembled stack
• Ageing & Parallel Group Divergence: module-level cycle and calendar ageing, and how cells within a group drift apart over life
• Abuse & Thermal Runaway Propagation: single-cell trigger methods and how a fault propagates through a populated module
• Legislative / Certification Testing: standards that test directly at module level, or that are commonly scaled down to it during development

HV Distribution

Placeholder — full write-up pending. HV distribution covers the pack’s high-voltage power path itself: contactor and interlock sequencing, HV interconnect and busbar integrity, and the isolation coordination between them, alongside the electrical, thermal and mechanical elements listed below. Power-up/down sequencing is already covered under Pack Testing‘s Control System section, and isolation resistance / dielectric strength under its Electrical section.

• Power on / Power off logic
• Electrical
• Thermal
• Mechanical

EV and Hybrid Qualifications

• Level 1 is basic hazard awareness
• Level 4 is where we do live HV work

BMS Testing

• Startup / Shutdown logic / Initialisation checks
• HV system control
• SoX algorithm performance
• Fault injection
• Handshake to system
• Error codes and reporting

Pack Testing

• Control System
• Performance
• Mechanical
• Thermal
• Electrical
• Abuse Testing
• Legislative Testing
• BESS Testing

Electrical Testing

Placeholder — full write-up pending. Pack-level capacity, internal resistance, and voltage-limit testing already has a fuller treatment under Pack Testing‘s Performance and Electrical sections (Pack Capacity, Pack Power Map, Isolation Resistance, Dielectric Strength); this section will expand to summarise and cross-reference that detail directly.

• Capacity Tests
• Internal Resistance
• Voltage Limits

Thermal Testing

• Cooling Curve

Mechanical Testing

• Leak Detection is a key test for systems and components within the battery pack from cells, contactors, cooling system and the enclosure.
• Mechanical Shock
• Drop Test
• Crush Testing
• Shock Test

Control System Tests

Placeholder — full write-up pending. The SOC-estimation robustness question below — proving the algorithm holds at cell and cell-group level, not only at pack level — sits alongside the wake-up/power-down sequencing, thermal management control, charger handshake, and cell-balancing tests already covered under Pack Testing‘s Control System section.

• State of Charge estimation is done at pack level, but algorithms need to be proven at cell and then cell group level to ensure robustness.

Safety Testing

• Abuse Testing