Battery Puncture Tester YL-PW-2T
| Brand | Yuelian |
|---|---|
| Origin | Guangdong, China |
| Manufacturer Type | Authorized Distributor |
| Country of Origin | China |
| Model | YL-PW-2T |
| Max. Puncture Force | 20 kN (2 metric tons) |
| Max. Sample Dimensions | W300 × D300 mm |
| Stroke Range | 0–300 mm (adjustable) |
| Penetration Speed | 1–50 mm/s (continuously adjustable) |
| Force Accuracy | ±0.5% of reading |
| Force Resolution | 1/500,000 full scale |
| Displacement Accuracy | ±0.5% of reading |
| Displacement Resolution | 0.01 mm |
| Voltage Measurement Range | 0–36 V (±0.5% FS) |
| Temperature Measurement Range | 0–300 °C (±1 °C) |
| Data Acquisition Rate | ≥30 Hz |
| Test Parameters Recorded | Force, Displacement, Voltage, Temperature, Time |
| Control System | Servo motor + PC-based software with real-time 5-channel curve overlay |
| Chamber Construction | Integrated explosion-resistant enclosure with dual-layer tempered safety glass viewport (350 × 400 mm), forced exhaust, and automatic pressure relief port |
| External Finish | Powder-coated heavy-gauge cold-rolled steel (gray/blue) |
| Internal Liner | Heavy-duty stainless steel |
| Power Supply | AC 220 V / 50 Hz or AC 380 V / 50 Hz |
Overview
The Yuelian YL-PW-2T Battery Puncture Tester is an engineered safety validation instrument designed for controlled mechanical abuse testing of lithium-ion and other rechargeable battery cells in accordance with international safety standards—including UN Manual of Tests and Criteria Part III, Section 38.3.5; IEC 62133-2:2017 Clause 7.3.2; GB/T 31485-2015 Annex C; and UL 1642 Section 9. The system applies a precisely controlled, quasi-static penetration force using a calibrated tungsten carbide needle to simulate internal short-circuit conditions induced by foreign object intrusion. Unlike impact-based abuse testers, the YL-PW-2T operates under displacement- and velocity-controlled servo actuation, enabling reproducible force–displacement profiling, synchronized multi-parameter acquisition (voltage, surface temperature, force, displacement, time), and strict compliance with GLP-aligned test documentation requirements.
Key Features
- High-fidelity servo-driven actuation delivering stable, programmable penetration speeds from 1 to 50 mm/s—fully compliant with the (25 ± 5) mm/s requirement specified in GB/T 31485 and equivalent regulatory protocols.
- Integrated explosion-resistant test chamber featuring dual-layer laminated tempered glass viewport (350 × 400 mm), automatic pressure-relief venting, and forced-air exhaust ducting rated for thermal runaway gas evacuation.
- Five-channel real-time data acquisition system capturing force (kN/N), displacement (mm), cell voltage (V), surface temperature (°C), and elapsed time (s) at ≥30 Hz sampling rate—enabling high-resolution event-triggered analysis of thermal runaway onset, voltage collapse, and mechanical failure progression.
- Modular fixture system including height-adjustable V-groove clamps (0–200 mm vertical range), dedicated puncture support plate, and fixed base mounts—ensuring repeatable alignment of needle trajectory perpendicular to the electrode plane per ISO 12405-3:2018 Annex E recommendations.
- Calibration-traceable load cell with ±0.5% accuracy and 1/500,000 internal resolution, coupled with sub-0.01 mm displacement feedback—supporting ASTM E4-compliant force verification and ISO 17025-compatible uncertainty reporting.
Sample Compatibility & Compliance
The YL-PW-2T accommodates prismatic, cylindrical, and pouch-type cells up to 300 mm in width and depth. Its open-top chamber design and vertically adjustable fixtures allow rapid reconfiguration between cell formats without tooling changes. All test sequences adhere to standardized positioning criteria: needle insertion centered on the largest geometric face, with tip geometry conforming to ISO 12405-3 (45°–60° conical angle, Ra ≤ 0.8 µm surface finish, Ø3/Ø5/Ø8 mm tungsten carbide needles supplied). The system supports audit-ready execution of tests required for CE marking (EN 62133-2), UL recognition, and China CCC certification. Full test logs—including raw time-series data, annotated event markers, and operator metadata—are exportable in CSV and PDF formats for FDA 21 CFR Part 11-compliant archival.
Software & Data Management
The proprietary YL-ControlSuite software provides intuitive test method configuration, real-time 5-parameter curve overlay (force vs. displacement, voltage decay vs. time, temperature ramp vs. force), and automated pass/fail evaluation against user-defined thresholds (e.g., voltage drop >1 V within 10 s, surface temperature >150 °C). All data files include embedded digital signatures, timestamped audit trails, and version-controlled method templates. Export options include IEEE C37.118-compliant time-series binaries, Excel-compatible CSV, and encrypted PDF reports with embedded calibration certificates. Optional integration with LIMS platforms via OPC UA or RESTful API enables centralized QA database synchronization.
Applications
- Cell-level safety qualification for automotive traction batteries (SAE J2464, GB/T 31467.3)
- R&D validation of separator integrity, thermal shutdown layers, and jelly-roll mechanical stability
- Comparative assessment of nail material effects (stainless steel vs. tungsten carbide) on short-circuit resistance
- Failure mode analysis for root cause investigation in field return investigations
- Pre-certification testing for UN 38.3 transport compliance submissions
- Process validation of cell assembly line robustness against handling-induced damage
FAQ
What needle diameters are included with the standard configuration?
Five tungsten carbide needles each of Ø3 mm, Ø5 mm, and Ø8 mm are supplied—certified for hardness ≥89 HRA and thermal stability up to 600 °C.
Does the system meet ISO/IEC 17025 calibration traceability requirements?
Yes—load cell and thermocouple channels are factory-calibrated against NIST-traceable standards; calibration certificates include measurement uncertainty budgets and are valid for 12 months.
Can test methods be password-protected and version-controlled?
Yes—software supports role-based access control (admin/operator), method locking, revision history logging, and electronic signature capture per 21 CFR Part 11 Subpart B.
Is remote monitoring supported during thermal runaway events?
The system includes Ethernet-connected IP camera integration (optional), live telemetry streaming via MQTT, and configurable SMS/email alerts triggered by voltage collapse or temperature excursion thresholds.
What maintenance intervals are recommended for long-term reliability?
Monthly visual inspection of guide rails and needle alignment; biannual recalibration of force and temperature channels; annual replacement of exhaust filter media and safety glass gaskets per OEM service schedule.
