Low-Pressure Test Chamber: Customized Thermal Runaway Risk Assessment for EV Battery Packs

Tailored to address the critical need of detecting thermal runaway risks in electric vehicle (EV) battery packs under specific environmental conditions, Danble's  low-pressure test chambers offer specialized features to simulate and evaluate battery performance in 85℃/30%RH environments combined with low-pressure scenarios.

|Technical Specification for Thermal Runaway Simulaiton:

• Precise Environmental Control: Strictly maintains the 85℃ temperature and 30% relative humidity (RH) setpoints within the test chamber, while enabling adjustable low-pressure settings (mimicking high-altitude or specific low-pressure operating conditions) to replicate real-world stress factors that may trigger thermal issues in battery packs.

• Battery-Specific Sensing Integration: Equipped with high-precision sensors to monitor key parameters of the battery pack during testing, including cell voltage, internal temperature, gas emission (such as CO, H₂, etc.), and pressure changes within the pack, providing comprehensive data for risk assessment.

• Controlled Pressure Transitions: Allows for programmed low-pressure transitions to simulate sudden altitude changes or pressure fluctuations that EVs may encounter, testing the battery pack’s response and stability under such dynamic conditions.

• Safety-Enhanced Design: Incorporates multiple safety mechanisms, including explosion-proof enclosures, fire suppression systems, and rapid gas exhaust channels, to handle potential thermal runaway incidents during testing and ensure operational safety.

• Large Capacity Accommodation: Customizable chamber sizes to fit various EV battery pack dimensions, enabling testing of full-size battery modules or packs without compromising the accuracy of environmental simulation.

|Key Detection Capabilities:

• Identifies thermal runaway initiation risks, such as abnormal temperature rises, gas leakage, or voltage drops, in battery packs when exposed to 85℃/30%RH and low-pressure environments.

• Evaluates the effectiveness of battery thermal management systems under combined high temperature, low humidity, and low-pressure stress, ensuring they can prevent or mitigate thermal runaway.

• Assesses the structural integrity of battery packs, including seals and casings, to determine if they can withstand pressure changes and contain potential hazards during thermal events.

|Typical Workflow

• Requirement Analysis: Define test parameters (temperature range, cycle duration, stress types).

• Chamber Design: Select materials (SUS304 stainless steel for corrosion resistance) and control systems (PID auto-tuning).

• Prototype Testing: Validate uniformity (±2°C) and stability (≤±0.5°C fluctuation).

• Certification Support: Provide compliance documentation for IEC/EN/UL standards.

|Solution Advantages:

• Provides accurate and repeatable test results that closely reflect real-world operating conditions, helping EV manufacturers optimize battery pack design and enhance safety performance.

• Supports compliance with relevant industry standards and regulations for EV battery safety testing, facilitating certification processes.

• Enables early detection of potential thermal risks, reducing the likelihood of on-road incidents and improving overall vehicle reliability.

|Case Study:
A leading EV manufacturer used DANBLE's solution to certify a new battery pack:

• Test Conditions:

• Temperature: 85°C ±0.5°C

• Humidity: 30% RH

• Pressure: 10 kPa → Rapid decompression to 1 kPa (10 cycles)

• Results:

• Identified thermal runaway initiation at 18h under combined stress.

• Reduced gas emission levels by 40% through venting design optimization.