TESTING

Kais Testing center is equipped with a broad range of testing equipment to ensure the safety and reliability of our components and products. The equipment ranges from mechanical reliability testing to charge/discharge testing systems, as well as battery cell research lab equipment.

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Battery cell research lab

Our understanding of the battery goes beyond its chemistry and manufacturing process. We’ve also developed our own testing philosophy based on our profound knowledge of battery application and performance requirements. We understand the subtle changes and development occurring inside the battery in different conditions and stages of the life-cycle, and we incorporate that knowledge into the design of our battery management system to provide all-weather, total life cycle protection.

 

The battery cells are dissected inside a glovebox filled with argon to ensure safety and avoid contamination.

 

We take apart multiple sample battery cells from each batch to analyze and assess the cell quality.

 

All battery cell dissections are carried out strictly according to our cell dissection standard of practice.

 

Our battery cell research lab are capable of:

Electrical Safety Test

  • Over-charge
  • External short-circuit
  • Forced discharge
  • Abnormal charging
  • Internal short-circuit test
  • Over-discharge
  • Imbalanced charging
  • Limited power source test
  • Over-current protection

Environmental Test

  • Altitude simulation
  • Thermal test
  • High temperature stress
  • Projectile/External fire
  • High temperature working
  • Immersion test
  • Water exposure
  • Salt spray test
  • Dewing (temperature change)
  • Passive propagation resistance
  • Thermal stability
  • Separator shutdown integrity

Mechanical Safety Test

  • Vibration
  • Shock
  • Impact
  • Free fall
  • Crush
  • Arcuate crush
  • Nail penetration
  • Tumble test

tworkplace of kais finest

Electrical engineering corp

Kais Electrical Engineering Laboratory is a highly advanced tech hub for efficiency and innovations. Driven by an ambition for perfection, this is where the Kais finest work and reflect on new designs or improving existing products. The lab is complemented with a wide range of best-in-class precision measuring equipment and monitoring devices, enabling Kais engineers to develop robust and dependable products for our clients.

 

simulation for perfection

Battery Testing Systems

We operate a legion of multi-channel battery pack charge/discharge cycle test systems designed for comprehensive voltage platforms from consumer electronics to electric passenger vehicles, where maximum test configuration flexibility is needed to cover a broad range of voltage, current and power requirements.

 

150v
UP TO
600Amp
MAX.
ZERO Volt
OPTION
90kW
MAX.
232
TOTAL
CHANNELS
0.1%
MEASUREMENT
ACCURACY

 

 

Our multi channel battery test systems are capable:

  • Zero Volt option
  • Support CAN Bus, RS485 and other communication protocols
  • Simulation of actual operating condition base on road test profile
  • Up to 150 Volt
  • Max. 600 Amp
  • Measurement accuracy of 0.1%
  • Regenerate over 90% of energy back to the grid
  • Over 30 channels operate by the prototype team
  • Over 200 channels operate by the manufacturing team
  • 32 cell test channels

 

Fully automatic testing; Capable of handling multiple charging/discharging tests.

 

The battery proceeds to the next step of charging/discharging tests.

 

Cabinet BTS350 in operation.

 

After the testing has been completed, the output log data are carefully cross-examined.

 

reliability is our first priority

Reliability Testing Lab

It is our belief that reliability cannot be achieved only through design, but it also needs to be repeatedly tested against various conditions and abuse scenarios. The importance of testing and validation cannot be overstated, that’s why our reliability lab is filled with versatile types of equipment to simulate mechanical and electrical challenges, so our engineers can test and adjust in real time, significantly reducing design flaws and project development time.

 

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structural safety and vibration durability

MULTI-AXIS SHAKER

Our software-controlled 10 kN multi-axis shaker can be loaded with a weight of 300 kg and test sliding sine, superimposed sinus and shock pulses...

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simulation of upper atmosphere conditions

Thermal Vacuum Chamber

Our 255L inside capacity thermal vacuum chamber can be used to perform low-pressure (high-altitude) testing on battery packs in accordance with the EN, IEC...

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tensile force simulation

Twin-column Tensile Tester

Our advanced software-controlled higher-capacity tensile tester is an ideal bench-top device for medium to large battery pack tensile force simulation according...

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ability to cope with the different climatic zones

rapid-rate Climate Chamber

Our fast ramp rate climate chambers are able to carry out two types of temperature testing that while similar in name, are very different in their actual procedures...

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measure the corrosion resistance

Salt Spray Chamber

Our salt spray test chambers are used to perform corrosion testing, and use high-saline environments to measure the corrosion resistance of our battery pack designs...

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safety performance and failure mechanisms

battery Abuse TEST Bunker

Safety is always a critical concern when it comes to lithium-ion batteries. Our 4 channel battery abuse test bunker helps us to safely perform rigorous safety evaluations...

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Multi-axis Shaker

Our software-controlled 10 kN multi-axis shaker can be loaded with a weight of 300 kg and test sliding sine, superimposed sinus and shock pulses. It enables us to identify the structural safety and vibration durability of our battery pack designs to withstand various scenarios encountered in the manufacturing, assembly, transportation and use phases execution.

  • Payload up to 300 kg
  • Rated sine excitation force up to 10 kN
  • Shooting table for patterns up to 0.5 x 0.5 m
  • Frequency range from 5 to 3,000 Hz

Thermal Vacuum Chamber

Our 255L inside capacity thermal vacuum chamber can be used to perform low-pressure (high-altitude) testing on battery packs in accordance with the EN, IEC and UN Manual of Test and Criteria for air transport. It allows for the simulation of space and upper atmosphere conditions including temperature and altitude to make sure our battery packs excel even in high altitude environments.

  • Temperature range 10 to 200 °C
  • Pressure range -100 kPa
  • Tolerance of ±1.0 °C after stabilization
  • Vacuum Bake Out systems available

Twin-column Tensile Tester

Our advanced software-controlled higher-capacity tensile tester is an ideal bench-top device for medium to large battery pack tensile force simulation according to the most demanding industry standards and real-world conditions.

A wide range of tensile grips, bend jigs enables the tester to conduct challenging customized tests, such as verifying the durability of our in-house developed power connectors through more than 10,000 insertions.

  • Measuring forces up to 50 kN (11,000 lbf)
  • Speed range 5 to 500 mm/min
  • Crosshead travel 1000 mm
  • Load accuracy ±0.5% of full scale depending on load cell selected

rapid-rate Climate Chamber

Our fast ramp rate climate chambers are able to carry out two types of temperature testing that while similar in name, are very different in their actual procedures. Both thermal cycling testing and thermal shock testing require bringing a product to two different temperature extremes but where they deviate is the time it takes to reach those extremes. By rapidly exposing the battery pack to two drastically different temperatures we can test to find potential failures and as well as testing the battery pack ability to cope with the different climatic zones.

  • Fast temperature ramp rate 5°C/min (Linear Control)
  • Temperature range from -40 to 150°C
  • Humidity range 20% to 98% RH
  • Temperature Uniformity ≤2°C
  • Temperature Accuracy ±0.3°C

Salt Spray Chamber

Our salt spray test chambers are used to perform corrosion testing, and use high-saline environments to measure the corrosion resistance of our battery pack designs. By simulating a highly corrosive atmosphere with a predetermined amount of time, temperature and humidity, we can see the impact of years of corrosive exposure (specific climates or working conditions) within 96 hours.

  • Inside capacity 270 L
  • pH Value NSS ACSS 6.5~7.5 / CASS 3.0~3.2
  • Air pressure gauge accurate to 1±0.01kgf/cm
  • Following ATSM, JIS, CNS and GB

Battery Abuse TEST Bunker

Safety is always a critical concern when it comes to lithium-ion batteries. Our 4 channel battery abuse test bunker helps us to safely perform rigorous safety evaluations on our own battery pack and third party battery cells.

In these tests, we would push the battery packs and battery cells to their limits in order to assess their safety performance and failure mechanisms, which help us to develop strategies and techniques to mitigate battery pack performance and system failures.

  • CO₂ fire suppression equipment
  • Stainless-steel pressure relief flap installed
  • Enhanced door-locking mechanism with reinforced brackets
  • Temperature-monitored and history log
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