INTRODUCTION

Rigorous testing and validation protocols ensure battery systems meet stringent automotive performance, safety, and durability requirements across their operational lifespan. Applus+ IDIADA's comprehensive validation services encompass functional evaluation, durability testing, performance characterization, and safety assessments using state-of-the-art testing equipment and methodologies.

 

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THE Applus+ SOLUTION

Our facilities support complete design validation plans from cell level to full battery system integration, including benchmarking analysis, failsafe testing, and battery teardown services that provide detailed insights into system architecture, component quality, and competitive positioning within the rapidly evolving electric mobility landscape.

Battery System Benchmarking

Functional evaluation - Battery system performance.

  • Characterization
  • Performance
  • Application fulfilment

Failsafe analysis - E/E Failure injection.

  • I/V sensor loss
  • Isolation failure
  • Power derating

Battery teardown - Complete analysis up to cell.

  • Architecture study
  • Concept analysis
  • Bill of materials (BOM)

Durability Testing

  • Aging to End-of-Life
  • Customized durability cycles
  • High Temperature Storage
  • Periodic check-up

Performance Testing

  • Functional capabilities
  • Real driving and charging performance
  • BMS functional validation
  • Characterization tests

Battery System Safety Testing

  • Electrical safety testing (shortcircuit, overcharge, over-discharge, over current,…)
  • Thermal propagation
  • Immersion
  • Fire resistance
  • Crush / Mechanical integrity
  • Mechanical shock
  • Drop
  • Vibration
  • Bottom impact
  • Altitude testing

Test Infrastructure:

  • 4 Test benches
    • High power cyclers: Up to 500 kW / 1000A / 1000V
    • Coolant conditioners: Up to 15kW with pressure, temperature and flow control
    • 500 Data channels: Voltage, Temperature, Deformation, Pressure for complete monitoring
    • Temperature range: -40ºC to +75ºC
  • Firehall for safety testing
    • Testing area > 250 m2
    • 45 cm of concrete bunker
    • Extraction system (50.000 m3/h)
    • Gas analysis
    • HQ video cameras & IR cameras
    • >100 DAQ channels (HV, LV, TCKs, CAN)

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