Knowledge
Our business is built upon knowledge. Here is a peak into the areas we work with.
Thermal management
Thermal management in battery packs is the process of controlling the temperature of a battery pack to ensure its safe and efficient operation. This is important because battery packs can be damaged by overheating or overcooling.
There are many different ways to achieve thermal management in battery packs. Some common methods include:
PCM, active, passive, heat barriers
Phase-Change-Material (PCM) absorbs heat during charging and discharging, keeping the battery pack at a safe temperature.
Active thermal management are fans, pumps, or other devices that actively remove heat from the battery pack.
Passive thermal management are natural convection or conduction that removes heat from the battery pack
Heat barriers are materials that slow down the transfer of heat.
Mica
Mica is a mineral that can be used to improve the thermal management of battery packs. It is lightweight, durable, and cost-effective. Mica can be used to conduct heat away from the battery cells, insulate the cells from each other, and protect the cells from damage.
Thermal runaway detection
Thermal runaway detection is a safety measure that uses sensors to monitor the levels of flammable gases in the air around the battery pack.
Gas detection
Gas sensors are placed in strategic locations in the battery pack and regularly calibrated to ensure accurate readings. An alarm should sound if the levels of flammable gases rise too high.
DCIR
DCIR measures the resistance of a battery pack to direct current (DC) flow. The higher the DCIR, the more resistance the battery pack has, and the slower it will charge and discharge.
When the DCIR increases significantly, the battery pack should be replaced to aviod a potential thermal incident. DCIR monitoring can help prevent thermal runaway situations.
Fire extinguishing/suppression
Fire extinguishing and suppression in battery packs are a critical safety measures to prevent the spread of fire and explosion. There are a variety of fire extinguishing agents that can be used for battery packs, each with its own advantages and disadvantages.
Standards & Regulations
These ensure safety, quality, and consistency throughout the value chain. At WS Technicals we work with internationally accredited testing laboratories to ensure that we met customer and market requirements.
Battery standards
IEC standards ensure global consistency in electronics, fostering interoperability and safety. UN38.3 tests lithium battery safety for transportation, preventing hazards. Both standards bolster technological advancement while prioritizing user and environmental protection.
UN38.3
Transport testing standard
Needed for transporting batteries
- Altitude simulation
- Thermal test
- Vibration
- Shock
- External short-circuit
- Impact/crush
IEC-62619
Safety requirements for secondary lithium cells and batteries, for use in industrial applications
Widely used for many applications such as AGV’s and forklifts (Referenced by EN-1175) and considers functional safety as well.
- Pack level tests
- Drop test
- Propagation test
- Overcharge control of voltage
- Overcharge control of current
- Overheating control
IEC-62133
Safety requirements for secondary lithium cells and batteries, for use in portable applications
Combines some vibrational/mechanical testing with some control testing. Often used for smaller battery systems
- Pack level tests
- Case stress
- External short-circuit
- Drop test
- Overcharge control
- Vibration
- Mechanical shock
ECE R100.01
UN ECE Regulation 100, revision 2
Test standard for type approval of batteries for hybrids, plug-in vehicles and electric vehicles
- Vibration test
- Thermal shock cycling
- Mechanical shock
- Mechanical integrity (crush test)
- Fire resistance
- External short circuit
- Overcharge protection
- Over-discharge protection
- Over-temperature protection
- Mechanical shock
UL Standards
Underwriters Laboratories (UL) are most widely known for standards in electrical products. E.g., every light bulb, lamp, or outlet purchased in the U.S. usually has a UL symbol and says UL Listed. In point of fact, they issue a much wider range of standards – all related to product safety for consumers. UL Standards
UL 2054
Standard for Household and Commercial Batteries
Similar to IEC-62133/UL-62133
UL1642
Standard for Lithium Batteries (Cells)
Typically used for cell level testing and often viewed as the minimum requirement for a single cell
UL 2271
Batteries for Use in Light Electric Vehicles (LEV)
UL 2580
Batteries for Use in Electric Vehicles
UL 9540
Standard for Energy Storage Systems (ESS) and Equipment
UL 1973
Standard for Batteries for Use in Stationary Vehicle Auxiliary Power and Light Electric Rail Applications
BMS Development
Cloud platform (4G/5G)
Cloud platforms offer a number of advantages over traditional BMSs, including remote monitoring and control, data analytics, and over-the-air updates.
Functional safety (ISO26262, ISO-13849)
ISO 26262 and ISO 13849 are functional safety standards that ensure the safety of electrical and electronic systems.
ISO 26262 is more comprehensive and is specifically designed for road vehicles, while ISO 13849 is less comprehensive but can be used for a variety of applications.
