Abusive electrical testing of batteries, modules and cells
Test your batteries under the most severe electrical conditions
The Emitech Group carries out stress tests on cells, modules and complete batteries to simulate extreme and accidental operating conditions: overcharging, over-discharging and intensive cycling.
These tests enable the safety, electrical stability and response of energy storage systems to be characterised in the face of voltage and current fluctuations — whether at the level of cell chemistry, the mechanical integration of the module or the system behaviour of the pack.
Why are electrical tests classified as abusive?
Batteries are sensitive to variations in voltage, current and charge/discharge time. Electrical drifts can lead to :
- Thermal runaway,
- Chemical or physical deterioration,
- Irreversible loss of capacity,
- An explosion or gas release.
These tests enable the validation of the battery system design, the sizing of the BMS and the robustness of the internal protection mechanisms at every level of the architecture: cell, module and pack.
What standards and benchmarks are covered?
UN 38.3 (T.7 and T.8 tests)
ECE R100 (electrical safety of traction batteries)
IEC 62660 / IEC 62660-1 (lithium-ion cell life cycle tests)
UL 2580, UL 1973, ISO 12405
The types of tests proposed for abusive electrical testing
Overload
Loading beyond the rated voltage or current capacity. Overloading occurs both at the individual cell level (chemical deviation, localised thermal runaway) and at the pack level (verification of the activation of passive or active protection mechanisms: BMS, fuses, pressure relief valves).
Overload
Excessive discharge below the critical voltage threshold. Simulation of a fault or prolonged misuse. Observation of chemical decomposition and internal short-circuit phenomena, with differentiated analysis depending on the level being tested (cell or system).
Specific severe cycles
Accelerated charge/discharge cycle testing (stress test). Application of non-linear or asymmetric profiles, which can be imported from real-world field data. Analysis of capacity drift, internal resistance (DCIR) and temperature rise.
DCIR characterisation and HPPC testing
Direct current internal resistance (DCIR) measurement and hybrid pulse power (HPPC) testing to assess a cell’s dynamic performance throughout its entire service life.
Talk to our battery abuse test experts
Our dedicated technical resources within the Emitech Group
Battery cell level — Battery cell cycling bench
- 32 independent channels, configurable in parallel up to 800 A
- Voltage / current per channel: up to 5 V / 120 A
- Test modes: CC, CV, CCCV, CP, CR, Pulse, DCIR, HPPC
- High accuracy: ±0.03% FSR (voltage and current)
- Current response time ≤ 3 ms — acquisition period up to 10 ms
- Compatible with cylindrical (18650, 21700…), prismatic and pouch cells
- Integrated protections: overvoltage, overcurrent, reverse polarity, temperature, BMS
Module and pack level — High-power test benches
- Up to 1000 V / 1000 A
- Precision control of voltage, current and duration
- Synchronised acquisition of electrical and thermal parameters
- Real-time monitoring of gases, temperature and deformation
What guarantees of safety and supervision does the Emitech Group offer?
- Secure test benches with warning and shutdown systems.
- Specific procedures for severe overloading or high-risk batteries.
- Automatic logging of critical events.
Why choose the Emitech Group for your abuse tests?
- Testing capabilities across all levels of the battery architecture: cell, module, pack
- In-depth expertise in electrical testing, cell characterisation and BMS validation
- Integration into comprehensive abuse test plans
- Customisable cycling equipment tailored to your test profiles
Needs
Discover a selection of additional resources that explore topics related to this page including regulatory contexts, technical articles, and specific areas of expertise. These materials provide further insight to help you better understand the key challenges and available solutions.
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