Battery Immersion Test System for EV Battery Packs – Yuelian YL-JP-02

Overview

The Yuelian YL-JP-02 Battery Immersion Test System is an engineered environmental test platform designed specifically for evaluating the safety integrity of electric vehicle (EV) traction battery packs under simulated seawater immersion conditions. It implements standardized immersion protocols aligned with UN GTR 20, ISO 16750-4, and GB/T 31467.3—particularly Section 7.11 (Immersion Test), which mandates exposure to a 3.5% NaCl (mass fraction) aqueous solution at ambient temperature to assess thermal runaway resistance, electrical isolation degradation, and mechanical seal integrity following submersion. The system replicates real-world post-accident or marine transport scenarios where high-voltage battery enclosures may be exposed to conductive saline environments. Its core architecture integrates a corrosion-resistant immersion tank, programmable vertical sample positioning, real-time environmental monitoring, and multi-layered electrical safety interlocks—ensuring repeatable, auditable, and GLP-compliant test execution in R&D labs and third-party certification facilities.

Key Features

• Corrosion-inert immersion chamber constructed from thickened, optically transparent acrylic panels bonded with CPVC structural supports—enabling full visual observation while resisting chloride-induced stress cracking and hydrolytic degradation.
• Modular stainless-steel support frame with reinforced square tubing (SUS304, ≥3.0 mm wall thickness) providing static load capacity up to 1000 kg and long-term dimensional stability in humid, saline atmospheres.
• Precision electric lifting mechanism with servo-controlled linear actuation, offering 0–1600 mm vertical travel range, ±2 mm positional repeatability, and 0.1 mm resolution feedback via integrated optical encoder.
• PLC-based control system with 7-inch industrial HMI touchscreen interface supporting parameter logging, stepwise test sequencing (pre-soak, immersion, dwell, retrieval), and configurable alarm thresholds for temperature, leakage current, and voltage drift.
• Dual-mode water replenishment: manual fill port with level sensor feedback and automated solenoid-valve-driven top-up system synchronized with ultrasonic liquid level monitoring.
• Integrated safety architecture including Class I insulation monitoring, dual-channel thermal cutoffs (cut-off at 85 °C), redundant overcurrent relays, and simultaneous audible (85 dB) and visual (red strobe) fault indication per IEC 61508 SIL 2 requirements.

Sample Compatibility & Compliance

The YL-JP-02 accommodates battery modules and complete packs up to 1500 mm (W) × 800 mm (H) × 1200 mm (D) and 1000 kg gross weight—covering common NMC, LFP, and solid-state pack geometries used in BEV and PHEV platforms. The stainless-steel immersion basket features adjustable T-slot rails and standardized M8/M10 threaded inserts compatible with OEM-recommended mounting patterns per SAE J2929 Annex C. All wetted materials comply with ASTM D543 (resistance to chemical reagents) and ISO 10993-5 (cytotoxicity screening). Test reports generated by the system meet traceability requirements for ISO/IEC 17025 accreditation, with timestamped event logs, operator ID tagging, and digital signature capability for audit-ready documentation.

Software & Data Management

The embedded PLC firmware supports CSV export of time-stamped operational data—including lift position, elapsed immersion time, chamber temperature (±0.5 °C), and leakage current (0.1–100 mA range, ±2% FS). Optional Ethernet/IP or Modbus TCP connectivity enables integration into centralized lab management systems (e.g., LabWare LIMS or Siemens Desigo CC). All configuration changes and emergency stops are recorded with immutable timestamps and user authentication (role-based access: Operator, Engineer, Administrator), satisfying FDA 21 CFR Part 11 electronic record and signature requirements when paired with validated network infrastructure.

Applications

• Pre-certification validation of battery pack IPX7/IPX8 ingress protection ratings per IEC 60529.
• Failure mode analysis of gasket compression set, connector housing delamination, and busbar corrosion kinetics under prolonged saline exposure.
• Correlation testing between immersion duration and DC insulation resistance decay (measured via onboard 1000 Vdc megohmmeter interface).
• Supporting functional safety assessments per ISO 26262 ASIL-C, particularly for hazard analysis of HV system short-circuit propagation post-immersion.
• Accelerated aging studies combining immersion cycles with thermal cycling (when integrated with external climate chambers).

FAQ

What standards does the YL-JP-02 explicitly support?
It is configured to execute test sequences compliant with GB/T 31467.3–2015 Clause 7.11, ISO 16750-4:2010 Section 4.2, and UN GTR No. 20 Annex 5, including pre-conditioning, immersion depth verification, and post-test functional checks.
Can the system be upgraded for automated conductivity monitoring of the NaCl solution?
Yes—optional DIN-rail-mounted conductivity transmitters (0–200 mS/cm, ±1% accuracy) with 4–20 mA output can be integrated into the PLC I/O rack and displayed on the HMI.
Is remote operation possible without on-site personnel?
Remote supervision is supported via secure VPN-enabled web HMI (HTTPS), but safety-critical actions (e.g., emergency stop reset, basket release) require local physical confirmation per IEC 62061.
Does the acrylic tank meet UV stability requirements for extended use?
The cast acrylic panels are UV-stabilized (ISO 4892-3, 1000 h xenon arc exposure) and retain >90% light transmission after 2 years of continuous indoor operation.
How is calibration traceability maintained for the lift position sensor?
The optical encoder is factory-calibrated against NIST-traceable laser interferometry standards; calibration certificates and uncertainty budgets are supplied with each unit.