Batteries play a fundamental role in our world. From powering an everyday laptop to energizing an electric vehicle (EV) to supplying energy to a pacemaker, people rely on batteries to keep them moving.
With this heightened demand for reliability, it’s all the more important that batteries are built to last and be safe. At Associated Environmental Systems (AES), we understand this need, which is why we prioritize safety features and embed them into the design of each battery testing chamber. So, whether you’re conducting EV battery testing or testing consumer electronics, you can rely on our chambers. Learn more about our approach to safety and how our chambers are built to protect you and your lab.
Battery Test Chamber Safety Features
While batteries are extremely valuable, complex electrochemical reactions can potentially lead to a battery thermal event (BTE). Before bringing a product to market, rely on a test chamber to avoid future fires or explosions caused by overheating, a short circuit, or over-discharge. At AES, our AES SAFE chamber series is designed with secure features to first prevent and then mitigate a BTE.
Preventative Safety Features
To prevent battery safety hazards and keep a BTE from occurring, each AES chamber includes preventative safety features that closely monitor testing and product performance:
- Set Point Temperature Limit: This temperature control feature prevents a user from unintentionally setting temperatures beyond the established testing limits.
- High Low Temperature Limit: Operating independently of the set point temperature limit, this control temperature limit (FM approved) doesn’t exceed what is safe for cells. For example, AES’s ATP chambers do not exceed -20°C and 80°C.
- Product Sensors: These sensors are installed on the rear of the chamber. They measure the cell temperature, and if the temperature gets too high, testing will be stopped.
- Rapid Rise: This feature measures cell and air temperature. If the chamber heats or cools too fast, it shuts down testing before a BTE.
- Temperature-Limited Sheath Heaters: These stainless steel, finned tubular heaters with a temperature sensor help keep the heater's surface temperature far below the auto-ignition temperature of any gas.
- Alarm Input/Output: This hardwired input/output is designed to communicate alarm status between the chamber and cycler.
- Gas Sensor/s (Optional): These sensors monitor gas levels inside the chamber for abnormal conditions. If they detect unusual levels, the chamber is put in an alarm state.
Mitigation Safety Features
If a BTE occurs, our chambers are designed to reduce its effect quickly. Our mitigation safety features include the following:
- Emergency Stop Button: This button enables you to stop all temperature conditioning immediately and put the chamber in an alarm state.
- Reinforcement: A reinforced stainless steel interior and enhanced door structure designed to handle pressure increase during a BTE.
- Safety Purge: When the test chamber is in an alarm state, it removes oxygen from the chamber and replaces it with inert gas (fire suppression).
- Audible and Visual Alarm: Designed to communicate alarm status between chamber and cycler, a loud sound is emitted during an emergency. Visual cues additionally reveal the chamber's current status. A three-color system guides safe use: green indicates a chamber is ready for use and the door is unlocked, blue signals the chamber is in use, and the door is locked, and red announces the chamber is in alarm condition with the door locked.
Additionally, if your chamber is in an alarm state, you can view which specific alarm is triggered by clicking the Alarms tab on the controller screen or the chamber’s AESONE CONNECT® dashboard. Learn more about potential alarm messages, their indications, and how they can be resolved.
- Burst Disk/Low Flow Vent: Made from graphite, this burst disk contains rupture sensors that relieve pressure in case of BTE. Before the chamber leaves our floor, it’s designed and verified to withstand 1.5 PSI to keep the burst disk from breaking and avoid door vulnerability. For each chamber, large or small, our team makes exact calculations. We examine the cells’ quantity, size, and chemistry to determine the flow requirements and size of the disk.
- Door Lock: This lock prevents access to the chamber when running or in alarm condition. A cam position sensor indicates whether the door is locked. Most chambers will not function with an open or unlocked door.
- Alarm Input/Output: This hardwired input/output communicates alarm status between the chamber and cycler and triggers audible and visual alarms. It halts temperature conditioning and charging/discharging.
AES SAFE & EUCAR Battery Hazard Levels
Our AES SAFE line of battery test chambers has protective measures in place to support each EUCAR battery hazard level. Depending on the Severity Level you are testing, you’ll want to make sure you have the correct safety features in place:
- Severity Level 1 (reversible loss of function) and Severity Level 2 (irreversible defect/damage): High/low temperature limit and set point temperature limit features.
- Severity Level 3 (leakage with mass change less than 50%) and Severity Level 4 (venting with mass change greater than 50%): Emergency stop, chamber alarm input/output, product sensors, reinforcement, safety purge, low flow burst disk, temperature limited sheath heaters, audible and visual alarms, and door lock.
- Severity Level 5 (fire or flame), Severity Level 6 (Rupture), and Severity Level 7 (explosion): All the previously mentioned features, along with optional gas sensing features.
Let’s Design Your Ideal Chamber
How can we help? Contact a sales engineer today to learn more about our various chambers and safety features. We’ll even discuss best practices for preventative maintenance, such as test chamber calibration or cleaning, so you can avoid downtime and keep your chamber running for years to come. We understand your needs and look forward to designing a chamber that meets your challenges.
