YL-PW-2T Battery Nail Penetration Tester

Overview

The YL-PW-2T Battery Nail Penetration Tester is an engineered safety evaluation system designed for controlled mechanical abuse testing of lithium-ion and other rechargeable battery cells and modules in accordance with international safety standards including UN Manual of Tests and Criteria Part III, Section 38.3; GB/T 31485–2015; IEC 62133–2; and UL 1642. It implements a precisely regulated needle penetration protocol to simulate internal short-circuit conditions caused by foreign object intrusion—such as manufacturing defects, mechanical impact, or thermal expansion-induced deformation—thereby enabling quantitative assessment of thermal runaway initiation, voltage collapse, gas evolution, and structural integrity under worst-case fault scenarios.

Key Features

• High-fidelity servo-controlled actuation system delivering consistent penetration velocity (25 ± 5 mm/s) and force application up to 20 kN, fully compliant with standardized test protocols for single-cell and module-level evaluation.
• Modular needle fixture assembly supporting interchangeable tungsten carbide needles (Φ5 mm to Φ8 mm) with certified tip geometry (45°–60° conical angle), surface roughness ≤ Ra 0.4 µm, and oxidation-resistant finish to ensure repeatable contact mechanics and minimal friction-induced artifacts.
• Integrated multi-parameter acquisition architecture synchronizing force, displacement, terminal voltage, surface temperature (via K-type thermocouple), and elapsed time at ≥30 samples per second—enabling millisecond-scale event correlation during thermal runaway onset.
• Robust safety enclosure featuring dual-layer laminated tempered glass viewing window (350 × 400 mm), Class II forced exhaust ventilation with flow rate monitoring, and fail-safe automatic pressure relief valve calibrated to activate below 100 kPa gauge overpressure.
• PC-based control software with GLP-compliant audit trail functionality, user-access-level management, electronic signature support, and 21 CFR Part 11–ready data export (CSV, PDF, XML) for regulatory submission and traceability.

Sample Compatibility & Compliance

The YL-PW-2T accommodates prismatic, cylindrical, and pouch-type cells up to 300 mm × 300 mm footprint and 300 mm maximum height. Its vertical penetration configuration ensures orthogonal alignment relative to electrode stacking direction—a critical requirement specified in GB/T 31485 Clause 7.1.3 and ISO 12405–4 Annex C. All hardware components meet RoHS Directive 2011/65/EU material restrictions. The system supports validation documentation packages aligned with ISO/IEC 17025 calibration traceability and can be configured with optional third-party witnessed verification per ASTM E2917 or IEC 61000-4-30 for EMC compliance.

Software & Data Management

The proprietary Yuelian TestSuite v4.2 software provides real-time visualization of five synchronized measurement channels on a single time-axis plot, with configurable trigger thresholds (e.g., voltage drop >10% within 100 ms) for automated event marking. Raw datasets are stored in encrypted binary format with embedded metadata (operator ID, sample ID, ambient conditions, calibration certificate ID). Export modules generate audit-ready reports containing statistical summaries (peak force, time-to-voltage-drop, max temperature rise), annotated waveform images, and digital signatures compliant with FDA 21 CFR Part 11 Subpart B requirements. Optional cloud synchronization enables centralized lab-wide data governance via secure TLS 1.3–encrypted API endpoints.

Applications

• Pre-release safety qualification of EV traction batteries according to UNECE R100 Rev.3 and China’s CATARC TB 001–2021 guidelines.
• Root-cause analysis of field failures involving dendrite-induced internal shorts or separator breach under mechanical stress.
• Material screening of next-generation separators, solid electrolytes, and flame-retardant additives under standardized nail penetration load profiles.
• Supporting Failure Modes and Effects Analysis (FMEA) for battery pack mechanical design validation, particularly in crash-safety simulation correlation studies.
• Academic research into thermal propagation dynamics across multi-cell arrays using synchronized multi-point temperature mapping (when integrated with optional external thermocouple grids).

FAQ

What standards does the YL-PW-2T comply with for battery safety testing?
It meets core requirements of GB/T 31485–2015, UN 38.3 Section 38.3.2.2, IEC 62133–2:2017 Clause 8.3.2, and UL 1642 Section 9 — specifically addressing needle diameter tolerance, penetration speed accuracy, dwell duration, and environmental observation criteria.
Can the system perform both single-cell and module-level penetration tests?
Yes. With appropriate fixture reconfiguration and needle selection (Φ5–Φ8 mm for cells; Φ6–Φ10 mm for modules), the YL-PW-2T supports sequential multi-cell penetration per GB/T 31485 Clause 7.1.4, including programmable pause intervals between punctures.
Is temperature measurement integrated or optional?
A calibrated K-type thermocouple input channel is standard, supporting up to two simultaneous surface temperature probes with ±1 °C accuracy across 0–600 °C range. Contactless IR sensor integration is available as a factory-configured option.
How is data integrity ensured during long-duration (1-hour) post-penetration observation?
Continuous acquisition runs uninterrupted for ≥3600 seconds; all channels maintain timestamp synchronization via onboard high-stability RTC. Power-loss recovery mode preserves last 60 seconds of pre-interruption data in non-volatile memory.
Does the system support remote operation and monitoring?
Yes. Web-enabled remote access (HTTPS/TLS) allows real-time dashboard viewing, parameter adjustment, and emergency stop activation from authorized network endpoints—subject to enterprise-grade firewall and role-based access control policies.