Yuelian YL-FZ-1500 Battery Pack Tumble Test Machine

Overview

The Yuelian YL-FZ-1500 Battery Pack Tumble Test Machine is an engineered mechanical reliability testing system designed specifically for evaluating the structural integrity and safety performance of electric vehicle (EV) battery packs and high-voltage energy storage systems under controlled multi-axis rotational stress. It implements standardized tumble protocols aligned with UN GTR 20, GB/T 31467.3–2015, and ISO 12405–4, simulating real-world mechanical disturbances—including transport vibration, rollover scenarios, and installation-induced angular displacement—without subjecting samples to impact or shock loading. The machine executes sequential, programmable rotations about orthogonal X- and Y-axes, each comprising a continuous 360° sweep at 6°/s followed by discrete 90° incremental steps with user-defined dwell periods (up to 99 hours per step). This methodology subjects enclosures, mounting interfaces, cooling channels, and high-voltage interconnects to sustained gravitational and inertial loading, enabling detection of latent weaknesses in sealing, fastener retention, cell module alignment, and insulation integrity.

Key Features

• Independent dual-axis (X/Y) servo-driven rotation system with zero-backlash precision gearmotors and absolute rotary encoders for repeatable angular positioning (±1° accuracy, 0.01° display resolution)
• Motorized vertical lift platform with adjustable travel range (80 mm to maximum height), facilitating safe loading/unloading of heavy battery assemblies up to 1000 kg
• Modular, welded steel chassis fabricated from high-tensile industrial-grade structural steel; surface-treated with corrosion-resistant gray/blue epoxy powder coating
• Integrated PLC-based control architecture with 10.1″ resistive touchscreen HMI and optional PC-based supervisory software for script-based test sequencing, parameter logging, and remote monitoring
• Comprehensive safety subsystem including Class I earth leakage protection, thermal cutoff sensors on motor windings and drive electronics, overload current monitoring, and emergency stop circuitry compliant with IEC 60204-1
• Optional light-curtain guarded access zone and HD IP67-rated internal camera system with time-stamped video recording for post-test forensic analysis

Sample Compatibility & Compliance

The YL-FZ-1500 accommodates battery modules and complete packs with maximum external dimensions of 1500 mm (W) × 1000 mm (D) × 800 mm (H), mounted via standardized multi-hole base plate and high-strength polyester webbing restraints rated to ≥5000 N tensile load. Its test profile satisfies functional requirements defined in multiple international standards: UN Regulation No. 100 Annex 8 (tumble test for REESS), GB/T 31467.3 Clause 7.1 (mechanical abuse testing), and ISO 12405–4 Section 6.3.2 (tumble durability). Post-test evaluation criteria include absence of electrolyte leakage, housing fracture, fire, explosion, or electrical short circuits; maintenance of terminal torque specifications; and verification that insulation resistance remains ≥100 Ω/V (measured per ISO 6469–1 using 500 V DC megohmmeter after 2-hour stabilization period).

Software & Data Management

Test execution is governed by embedded firmware supporting programmable multi-step sequences with independent angle, speed, dwell time, and axis selection per step. All operational parameters—including actual rotational position, motor current, temperature readings, and alarm events—are timestamped and logged internally (SD card) and optionally streamed to a Windows-based host PC via Ethernet (TCP/IP) or USB-C. Data export is supported in CSV and XML formats compatible with LIMS integration. Audit-trail functionality records operator ID, test start/stop timestamps, parameter modifications, and fault events—supporting GLP/GMP-aligned documentation practices. Firmware updates are performed via secure OTA protocol with digital signature validation.

Applications

• Pre-certification mechanical validation of traction battery systems prior to UN 38.3, IEC 62660, or GB/T 31467 series testing
• Design verification of enclosure gasketing, vent cap retention, busbar anchoring, and BMS housing mounting under prolonged off-axis loading
• Manufacturing process qualification for adhesive bonding strength, weld integrity, and bracket deformation limits
• Root-cause analysis of field failures attributed to transport-related mechanical fatigue or misalignment-induced thermal runaway propagation
• Supporting Failure Modes and Effects Analysis (FMEA) for high-voltage battery subsystems in accordance with AIAG-VDA standards

FAQ

What standards does the YL-FZ-1500 comply with for battery tumble testing?
It supports test profiles referenced in UN GTR 20 Annex 4, GB/T 31467.3–2015 Clause 7.1, ISO 12405–4 Section 6.3.2, and internal OEM specifications requiring programmable multi-axis dwell-and-rotate sequences.
Can the machine perform continuous rotation without discrete stops?
Yes—the system supports both continuous 360° sweeps at user-defined angular velocities (0–18°/s) and stepped rotation modes with configurable dwell durations.
Is insulation resistance measurement integrated into the system?
No—insulation resistance must be measured externally using a calibrated megohmmeter per ISO 6469–1 after test completion and 2-hour stabilization; the YL-FZ-1500 provides the mechanical conditioning only.
What safety certifications apply to the electrical architecture?
The control cabinet conforms to IEC 60204-1 (Safety of Machinery – Electrical Equipment), and all power distribution components carry CE marking per Low Voltage Directive 2014/35/EU and EMC Directive 2014/30/EU.
Is remote diagnostics or predictive maintenance supported?
Basic remote status monitoring (motor temperature, encoder feedback, alarm flags) is available via Ethernet; advanced predictive analytics require integration with third-party CMMS platforms using exported CSV logs.