Battery Performance Evaluation & Testing

International Electrotechnical Commission (IEC), the Institute of Electrical and Electronics Engineers (IEEE), and the American Society for Testing and Materials (ASTM) define Battery testing as the process of assessing the performance, health, and reliability of a battery.

According to a report by MarketsandMarkets, the global battery testing market is projected to grow from USD 2.4 billion in 2020 to USD 4.7 billion by 2030, at a compound annual growth rate (CAGR) of 14.5%. The Asia Pacific region is expected to be the fastest-growing market for battery testing.

The Bangladesh government has set a target of generating 10% of the country's total electricity from renewable sources by 2028, which has led to a growing demand for energy storage systems such as batteries, and for this Battery Testing is a must.

ICONIC Engineering is the only accredited Lab in Bangladesh who have the ability to test battery and to provide battery testing lab service as they have also the only authorization in Bangladesh.

I. Introduction

What is battery testing and why it's important?
As per guidelines and procedures developed by the International Electrotechnical Commission (IEC), the Institute of Electrical and Electronics Engineers (IEEE), and the American Society for Testing and Materials (ASTM), Battery testing is the process of assessing the performance, health, and reliability of a battery, which involves evaluating its capacity, resistance, and other characteristics under different conditions. It is done to determine the battery's ability to supply electrical energy over time and to detect any issues that may affect its performance.

Figure: Battery Performance Evaluation and Testing

Battery testing is important for several reasons. Firstly, it helps to ensure the safe and reliable operation of the battery, especially in critical applications such as medical equipment, aerospace, and military applications. Accurate testing can identify any potential defects or issues that could cause a battery to fail, leak or explode, which could have serious consequences.

Secondly, battery testing can help to optimize the performance of the battery and extend its lifespan. By monitoring the battery's health and performance over time, it is possible to detect any degradation or loss of capacity and to take corrective action to prevent further deterioration.

Lastly, battery testing is essential for the development and improvement of battery technology. By analyzing the data collected during testing, engineers can identify areas for improvement, develop new materials, and optimize the design of batteries to make them more efficient, longer-lasting, and safer.

Types of batteries that are Tested by ICONIC Engineering:
There are many different types of batteries, each with its own unique characteristics and applications. Here is an overview of some of the most common types of Batteries which are Tested in ICONIC Engineering.

Alkaline batteries:
These are the most common type of disposable batteries, often used in consumer electronics like flashlights, remote controls, and toys. They are relatively cheap and have a long shelf life.

Lithium-ion batteries:
These are rechargeable batteries commonly used in portable electronics like smartphones, laptops, and electric vehicles. They have a high energy density and are relatively lightweight, making them popular for use in portable devices.

Figure: Lithium-ion batteries

Lead-acid batteries:
These are a type of rechargeable batteries commonly used in automotive and marine applications. They are heavy and have a relatively low energy density but are relatively cheap and reliable.

Nickel-cadmium (NiCad) batteries:
These are a type of rechargeable batteries commonly used in cordless power tools and medical equipment. They are durable and can withstand high discharge rates, but have a relatively low energy density and are toxic.

Nickel-metal hydride (NiMH) batteries:
These are a type of rechargeable batteries commonly used in hybrid cars, digital cameras, and other electronic devices. They have a higher energy density than NiCad batteries and are less toxic, but are more expensive.

Zinc-carbon batteries:
These are a type of disposable battery commonly used in low-drain applications like clocks and remote controls. They are relatively cheap but have a short shelf life and low energy density.

There are many other types of batteries, including silver-oxide, mercury, and lithium-polymer batteries, each with its own unique characteristics and applications.

II. Types of Battery Tests provided by ICONIC Engineering:

As per the Standards of IEC 61960, IEC 62133, UL 2054, and UN 38.3, the following tests are must to be done for the Battery Testing & ICONIC Engineering is Successfully Doing the tests for their clients:

Capacity Testing:
Capacity testing is a type of battery testing that measures the amount of electrical energy a battery can store and deliver under specific conditions, expressed in ampere-hours or milliampere-hours. ICONIC Engineering maintains the standards of IEC 61951-1, IEEE 1188, IEC 61427, and SAE J537 in terms of Capacity testing. This helps to ensure the battery can deliver the required energy for a specific application, monitor the health and remaining life of the battery, and compare the performance of different batteries.

Internal Resistance Testing:
Internal resistance testing is a type of battery testing that measures the resistance of a battery to the flow of electrical current within the battery itself. ICONIC Engineering follows the standards of IEC 60896-11, IEEE 450, IEC 61960, and SAE J537 in terms of Internal Resistance testing. This measurement can help determine the health and condition of the battery, as well as identify any defects or issues that could affect its performance.

Open Circuit Voltage Testing:
Open Circuit Voltage testing is a type of battery testing that measures the voltage of a battery when there is no current flowing through it. ICONIC Engineering maintains the standards of IEEE 450, IEC 60095-1, IEC 62620, and SAE J537 in terms of Open Circuit Voltage testing. This measurement can help determine the state of charge of the battery, as well as identify any defects or issues that could affect its performance.

Load Testing:
Load testing is a type of battery testing that measures the performance of a battery under a specific load or power demand. ICONIC Engineering follows the standards of IEC 60896-11, IEEE 450, IEC 61960, and SAE J537 in terms of Load testing. This measurement can help determine the ability of the battery to supply electrical energy under real-world operating conditions and identify any issues that could affect its performance.

Life Cycle Testing:
Life cycle testing is a type of battery testing that measures the number of charges and discharge cycles a battery can undergo before its capacity and performance significantly degrade. ICONIC Engineering maintains the standards of IEC 62660-1, IEC 61427-1, IEEE 1188, and SAE J2464 in terms of Life Cycle testing. This measurement can help determine the expected lifespan of the battery and its overall durability under typical usage conditions.

Impedance Spectroscopy Testing:
Impedance spectroscopy is a method that involves applying a small AC signal to the battery and measuring its response to determine the battery's internal resistance and other parameters. ICONIC Engineering maintains the standards of IEC 62660, IEEE 1188, SAE J2464, and ASTM EIS Standard Test Method in terms of Impedance Spectroscopy testing.

III. Importance of Battery Testing

Figure: Importance of Battery Testing

IV. Methods for Battery Testing ICONIC Engineering offers to Customers:

Manual Testing:
Manual testing is a battery testing method where a technician manually measures and records the voltage, current, and temperature of a battery during specific operating conditions offered by ICONIC Engineering. It is often time-consuming and labor-intensive and may not provide the level of detail needed for complex analyses.

Automated Testing:
Automated testing is a battery testing method that uses specialized software and equipment to automatically measure and record various battery parameters such as voltage, current, temperature, and impedance offered by ICONIC Engineering. This is more efficient and accurate testing of batteries, reducing the potential for human error and increasing the amount of data that can be collected. 

Non-destructive Testing:
Non-destructive testing is a battery testing method offered by ICONIC Engineering that evaluates the condition and performance of a battery without causing any damage or alteration to the battery itself. Examples of non-destructive testing methods for batteries include visual inspection, thermal imaging, and electrical impedance spectroscopy.

V. Common Battery Testing Standards

1. IEC 61960
2. IEC 62133
3. UL 2054
4. UN 38.3

VI. Conclusion

Battery testing is a critical process that ensures the safe and reliable operation of batteries in various applications. ICONIC Engineering evaluates the performance and condition of batteries using various testing methods such as capacity testing, internal resistance testing, open circuit voltage testing, load testing, life cycle testing, etc.

Battery testing by ICONIC Engineering helps identify defects or issues that may affect battery performance, determines the remaining life and health of batteries, optimizes battery performance, saves costs, and supports innovation. Overall, battery testing plays an essential role in ensuring the optimal performance and safety of batteries.

VII. FAQ (Frequently Asked Questions)

Q: What is battery testing?

A: Battery testing is the process of evaluating the performance, capacity, and longevity of a battery.

Q: Why is battery testing important?

A: Battery testing is important to ensure that batteries meet performance specifications, are safe to use, and identify potential problems before they occur.

Q: What are the common battery testing methods?

A: The common battery testing methods include open-circuit voltage testing, load testing, and impedance spectroscopy.

Q: What is open-circuit voltage testing?

A: Open-circuit voltage testing involves measuring the voltage of a battery while it is not connected to any load or charger.

Q: What is load testing?

A: Load testing involves applying a load to a battery and measuring its voltage and current to determine its capacity and performance under load.

Q: What is impedance spectroscopy?

A: Impedance spectroscopy is a method that involves applying a small AC signal to the battery and measuring its response to determine the battery's internal resistance and other parameters.

Q: What factors affect battery testing results?

A: Factors that affect battery testing results include temperature, age, history of use, and the type of battery.

Q: How often should batteries be tested?

A: The frequency of battery testing depends on the application and the manufacturer's recommendations. In general, batteries should be tested at least once a year.