Case study: VISPIRON SYSTEMS GmbH

Customized battery test chambers for efficient and safe battery tests. VISPIRON SYSTEMS relies on solutions from BINDER.

Battery testing with climate chambers from BINDER

VISPIRON SYSTEMS from Munich, Germany, offers development and testing solutions for electromobility, smart charging, and connected energy systems. The company works with OEMS, suppliers, and system developers to validate complex components. Its portfolio of services includes systems engineering, test automation, and data-based analyses. Its aim is to shorten innovation cycles in the mobility and energy sectors on a measurable scale.

When it comes to aging and performance tests on battery cells, the company relies on battery test chambers from BINDER, specifically the MK 720 and MK 1020 models. All units are custom-produced and tailored precisely to the requirements of VISPIRON SYSTEMS.

Aging and performance tests on battery cells

Battery cells of various formats (prismatic, cylindrical, and pouch cells) are tested as part of electrochemical aging and performance tests. The tests involve continuously charging and discharging the cells to simulate realistic long-term exposure and characterize their aging and performance behavior. Depending on the test concept, the trials run for periods lasting from several weeks up to nine months.

Safety and risk management

Lithium-ion cells contain a huge amount of energy and are regarded as hazardous goods, which is why safety is at the forefront during the tests. The electrochemical aging processes can, in rare cases, lead to electrolyte escaping in the test chamber. The gases that arise as a result are harmful to health and should not be inhaled. VISPIRON SYSTEMS uses battery test chambers from BINDER featuring the safety package P with EUCAR Hazard Level 4. These have relevant safety precautions such as special seals, an enhanced mechanical door-locking mechanism, and a pressure relief flap. The latter is essential in diverting the large volumes of gas that arise in the event of an accident in a rapid and controlled manner.

Battery test chambers from BINDER in a battery test laboratory.

Battery test chamber from BINDER in a battery test laboratory with connected exhaust system and orange-colored cabling on the top of the unit.

Individual solution for cable feed-throughs

Charging and discharging the battery cells requires cables to be routed into the test chamber from outside. The cable feed-throughs needed for this create open points on the test chamber that are not gastight. In an emergency situation, these openings can allow harmful gases to enter the laboratory, putting the health of personnel at risk.

Together with BINDER Customized Solutions, VISPIRON SYSTEMS searched for a solution and designed a gastight cable feed-through. It is a metal plate construction sealed with a special plastic through which the cables can be routed into the chamber. On the top of the battery test chamber, there is a stainless steel plate with numerous cut-outs that can be sealed with elastic rubber plugs. These rubber plugs seal the openings so they are airtight and the cables can be routed into the chamber without the gas entering the laboratory environment.

The tailored solutions from BINDER provide us with maximum flexibility for the future. Specific adaptations allow our test environments to cater to new requirements at any time, enabling us to respond quickly and reliably even in a dynamic market environment.

Benedikt Soballa, Battery Analytics Team Leader

VISPIRON SYSTEMS

Cost-benefit ratio plays decisive role

When it comes to selecting test units, the cost-benefit ratio plays a decisive role for VISPIRON SYSTEMS. Above all, it is the reliability of the units that counts. Possible failures during long test cycles are a serious factor, as, in addition to incurring costs, they can also mean important test data gets lost. Battery test chambers from BINDER reduce the risk of failure to a minimum. The high-performance and flexible models of the MK series balance out high heat losses at low temperatures and ensure reliable continuous operation over long periods of time.