eDLP – World’s largest e-mobility & battery development and testing center
Efficient Battery Development and Testing
eDLP – The innovative battery development and testing center
Since 2008, FEV has been successfully conducting electric and thermal endurance tests on battery cells, modules, and packs for clients around the world at its Trappes Test Center in France. Furthermore, in Aachen (Germany) FEV has additional cell and pack testing benches for everything related to both predevelopment and innovation. In the field of battery cells, a broad range of cell test channels are available at EVA Fahrzeugtechnik in Munich as well as FEV UK in England. Aachen, England, and Munich mainly focus on development tests, while France primarily focuses on endurance tests.
Due to the steadily increasing demand for high-voltage battery tests in recent years, the FEV Group decided in 2019 to set up another test facility where all development and validation tests required by the industry could be carried out under one roof. That is how the company came to begin building the world's largest and most modern development and testing center for various types of battery modules and high-voltage batteries. Almost all types of electrical tests (both performance and endurance), environmental, mechanical, safety, and abuse tests will be offered in approximately 12,000 m² of building space.
eDLP – All types of battery testing in one place
Battery testing at eDLP
- Durability testing based on customer profiles
- Electrical, thermal and mechanical aging (cycling and calendric aging)
- Capacity, resistance and efficiency tests
- Cold start, self-discharge tests and OCV-measurement
- Swelling force tests
- Cooling performance and cooling system calidation incl. thermal-resistance housing profiles and dew testing
- ...
- Crush tests
- Thermal propagation tests (e.g. nail penetration)
- Overcharging, deep discharge, short circuit tests
- Fire restistance tests
- Cooling and electrolyte leakage tests
- Drop tests
- Underbody protection tests
- Hammer hit tests
- Overpressure tests
- ...
- Un 38.3 transportation tests
- Vibration and shock tests including thermal and electrical cycling
- Climate tests
- Corrosion tests
- IP-class tests (e.g. IPX6, IPX7, IPX9K)
- Vacuum chamber tests and high atitude simulation
- Dust chamber tests
- Immersion tests
- Thermo-shock tests
- Rock fall tests
- ...
- Tear down on intact and damaged batteries
- Disassembly and documentation
- Benchmarking
- Result reporting
- Improvement workshops
Testing of resistance against:
- Vacuum, temperature changes (-40 to 80 °C)
- Vibration and shock (also during temperature changes)
- Falling and starting
Test in the field “Usage”
- Cleaning with high-pressure washer
- Environmental conditions (immersion, water mist and salt water mist, dust and falling rock)
- Damaged cooling system (Overpressure in cooling system and loss of cooling fluid)
Shaker (IMV SA50HM) with temperature hood &
A 350 kN shaker is available for mechanical tests. It also has a climate hood by means of which test objects can be tested in ambient conditions from -40 to
- Max load 3,000 kg Oscillation 76.2 mm (pk-pk)
- Force: Sinus 350 kN, Noise 315 kN, Shock 900 kN, Max frequency 2,000 Hz
- Max acceleration: Sinus 1,000 m/s², Noise 700 m/s², Shock 2,000 m/s²
- Shock test: 1,700 kg: 30 g 6 ms, 100 kg: 50 g 11 ms
Your engineering partner in
battery development and testing
The key to the electrification of the automotive industry is the high voltage battery system. It supplies the high-voltage electrical system and the drive train of the vehicle with energy and is the single largest contributor to the value chain of an electric vehicle.
High-voltage batteries (HVB) must be comprehensively tested at the beginning of production to ensure they are ready for series production. Based on various criteria such as mechanical stability, life span, and intrinsic safety, a test program for the development object is created that is customized to the degree of maturity. The goal is to end up with complete, validated results that meet all the requirements of the high-voltage battery.
Here, FEV covers the following phases of series development in the automotive industry:
1. Prototype: Evaluation of sample batteries in the early concept phase
2. Design validation: Validation of initial design samples
There are usually errors identified in this step, as the product lacks the required robustness
3. Product validation: Creation of final product design, final anomalies are identified
4. Certification/homologation: Series status is confirmed, final homologation is carried out
