电芯和电池可靠性的测试和方法介绍

1、CHANGE HISTORYCHANGE DESCRIPTIONEFF. DATEPREPARED BYAPPROVED BYDEPT.REVANEW RELEASE Add named rulesUpdate 5.1. AddFor the series and parallel Battery capacity and cell balance check, when first make sample and first mass production, update cycle life require, and add appearance check require12/11/10

2、/15/10/31/07/11/刘斌刘斌刘斌刘斌陈光辉陈光辉陈光辉陈光辉TETETETE04CONFIDENTIALITYTOP CONFIDENTIAL ()CONFIDENTIAL ( ) INTERNAL ONLYDISTRIBUTION()MFG()QA()R&D()FNC()PMC()PME()SRC()HR&A()S&M()PRJ()IE()TE()BCU ( ) OTHERISSUENO.:Purpose （目的）规范本公司产品新产品设计验证测试项目、测试条件及判定标准Standardize the new product design verification test ite

3、m、test condition and criteria.Scope （范围）适用于本公司新研发的所有型号电池产品Applicable to all the new battery productsDefinition （定义）设计验证：对产品的电池功能，可靠性，安全性进行验证，确保产品符合设计要求 Design verification: verify the batteries protect function, reliability, safety whether meet the spec definition make sure thebatteries meet design

4、requirement.Responsibility （职责权限）R&D （研发部）：编制新产品设计计划，计划输入输出/输出，完成客户产品的定义，输出产品 规格书，新样品样板制作，设计转移，新零件/模具承认，编制产品规格书Prepares the new product design planning, design input/output, Provide the product definition and specification basing on customers request. sample making, design transfer, the new Parts/mo

5、lds verification, establishment product specificationPRJ （项目工程部）：和客户沟通产品的需求，编制及执行品质控制计划，跟踪项目研发，负责安 排样品试制，产品试产至量产全过程，对项目成不及项目过程中的风险进行 控制，跟踪过程问题至解决。Communicate with customer, understand customers requirement. Prepare and implement quality control flow chart （QCFC）.Track the entire process of project f

6、rom R&D, sample building, pilot production to volume production. Control the project costs and risks. Follow up all the issues until solved.S&M （市场营销部）：负责新项目立项，客户报价，售后服务，客户信息反馈。In charge of the new project definition, customer quotation, aftersales service, customer feedback.QA （品质部）：负责新产品样品FAE与产品质量

7、管理Be responsible for new producfs quali ty management and FAE.TE （测试工程部）：负责产品测试设备，产品验证，可靠性验证测试，提供测试报告。Be responsible for test equipment, product verification, reliability test, and summit test report.Instruction （作业指引）5.1 Test time：（测试时机）5.1.1 Proto type阶段，RD负责样品测试验证及报告At proto type step, RD is in c

8、harge of test verification and report5.1.2对于多串并电池,第一次制样及第一次量产时，项目部需送3PCS到实验 室进行容量及压差测试。For the series and parallel battery, when first made sample and first mass production, prj need send 3pcs samplesTo lab do the capacity and cell balancecheck.5.1.3产品进入EVT阶段，实验室负责完成设计验证At EVT step, laboratory. is i

9、n charge of complete design verification5.1.3项目部负责提供样品给实验室Project is in charge of provide the test samples to laboratory5.2Design change （设计变更）如接下来设计有变更，R&D需针对变更项目及有影响项目重新测试，项目部 需重新送样至实验室，实验室针对变更项目进行再次验证测试When the product design changed in next step, R&D must retest the affected items by the change

10、retested, and PRJ need to apply for afresh test. According to the change lab will do the related test5.3 Sample quantity ：（测试数量）根据测试标准，每一项测试需要测试验证3pcs，如有特殊要求，可以根据需要适当 调整测试数量. For the test criteria, for each test item need 3pcs sample to verification. if there have special requests, it canadjust the

11、test quantity by need5.4Test item （测试项目）5.4.1参考附件二Reference the attachment two5.4.2当客户有特殊要求时，各项目的测试方法及判定条件按客户要求；The test method and criteria shall been in accord with the customer demand.5.4.3当实验室无法进行相关测试时，由项目部统一申请外送给有资质的供应商测试；When it cant be test by lab, prj shall apply for testing by the professio

12、nal vendor.5.5样品测试完成后，测试人员须参照QSI025FM015A完成设计验证报告，再将 测试报告交由实验室工程师及TE经理审批存档，并影印一份副本或者以邮件 形式发给相关人员。After finished the test, tester should follow QSI025FM015A finished the report and submit to reliability engineerand TE Manager for approving, lastly make a copy of report or send report to the correlati

13、ve persons.5.6可靠性测试的品质目标是零不合格。当测试不合格时，立即通知测试/项目/研 发/品质部门等相关部门，组成FA分析小组一同对不合格进行原因分析，并 制定纠正预防措施，且此批产品按照QEP023M不合格品控制程序 处理；若 该批次产品已出货给客户，须立即通知客户The target of reliability test is zero reject rate, if fail, immediately notify TE/PRJ/QA Related department, createFA Group to analyze the root cause then tak

14、e corrective and preventive action, this product shall be handled according toQEP023 , If this product had been shipped, we shall inform customer Immediately6 Named rules （测试报告命名规格）测试命名为测试类型+机种名称+发行日期+流水号，测试类型有设计验证（DT），可靠测试（RT），抽样测试（OT ）三种类型例如：8708可靠性振动测试报告，发行日期为1012，流水号为1则命名为：RTNNB8708Vibration Tes

15、t Report 101201Test type named + model name + issue date + serial number, test types for design verification （DT）, reliabletesting （RT）, sampling test （OT） there tapesSuch as: 8708 reliable vibration test, release date for the 1012, serial number 1 is namedRTNNB8708Vibration Test Report 101201ATTENT

16、ION （注意事项）：N/AREFERENCE DOCUMENT（参考文件）：GB/T182872000UL2054UL1642UN38.3IEC610000042UL609501RECORD （相关记录）：QSI025FM15ATTACHMENT（附件）：Attachment one （附件一）设计验证测试流程图（Design verification test flow chart）NOAttachment two （附件二）No类别Type测试项目Item测试条件Test Condition判定标准Criteria备注Remark1Reliability Test消耗电流测试Consum

17、e current check用DC电源代替CELL设置不同电压读 取不同状态的消耗电流Use DC replace the cell set different voltage ,use the meter measure the consume currentReference EESpec2过压保护功能检测(过充电/过放 电)Over Voltage protection function test (over charge/over discharge)用DC电源代替CELL设置慢慢调大或 调小电压检查PCM板，过压保护功能检 测是否正常。Use DC replace the cell

18、, adjust the voltage to check PCM ,make sure the over voltage protection function is okReference EESpec3过流保护功能检测 (过充电/过放电)Over Current protection function test (over charge/over discharge)放电过流保护。DC电源输出接PCM板B+,B,PCM P+,P 接电子负载，用电池负载OCP功能测试 PCM过流保护功能是否正常Over discharge protection power connecting with

19、PCM B+ , Band P+,Pwith load, use OCP function, of load to check the over current protection function is normal or not 充电过流保护DC电源输出接PCM板P+,P, PCMB+,B接电子负载，用电池负载OCP功能 测试PCM过流保护功能是否正常Over charge protectionDC power connecting with PCM P+,P and B+ , B with load, use OCP function, of load to check the ove

20、r current protection functionReference EESpec4短路保护功能检测 short protection function test用额定电流，满充电池，静置1小时，短 路电池输出端，用示波器检查电池短路 保护功能是否正常Charge full the battery with rate current, rest for 1 hour, short the output terminal, use oscilloscope to check the short protection functionReference EESpec5反充保护功能检测Rev

21、erse charge function test正负极反接后用DC充电，检测反充保 护功能是否正常Connect P+,P reversed with DC power to check the reverse charge functionReference EESpec6NTC0C/25C/45C 不同 温度阻值是否符合 零件规格NTC Value measure in different temperatureNTC放入温箱，用安捷伦meter测量不 同温度下的阻抗是否符合零件规格 Put NTC into chamber, measure the impedance for NTC

22、in different temperature, check it whether meet EESpecReference EESpec7电压精度检测 (0C/25C/45C)Temperature accuracy check (0C/25C/45C)电池放入温箱，在不同温度下检测BQ 显示电压和meter实际量测电压是否符合EESpecPut battery into chamber, check BQ voltage and the voltage measured by meter in different temperature, make sure it whether mee

23、t EESpecReference EESpec只适用 于带Gasgauge 电池8电流精度检测 (0C/25C/45C) Voltage accuracy check (0C/25C/45C)电池放入温箱，在不同温度下对电池放 电，检测BQ显示电流和实际测量电流 是否符合EESpecPut the battery into chamber, discharge in different temperature and check the BQ current and the current measured by load, make sure it whether meet EESpecR

24、eference EESpec只适用 于带 Gasgauge 电池9温度精度检测 (0C/25C/45C)Temperature accuracy check (0C/25C/45C)电池放入温箱，检测不同温度下BQ显 示温度和实际测量温度是否符合EESpecPut battery into chamber, check BQ temperature and the real measured temperature, make sure it whether meet EESpecReference EESpec只适用 于带Gasgauge 电池10过温保护(充电& 放电)Over Temp

25、erature protection(charge& discharge)根据EESpec，设置温度，检查BQ中过 温保护功能在充放电过程中是否会起作 用Refer to EESpec, set temperature to check the charge &discharge over temperature protection function whether okReference EESpec只适用 于带 Gasgauge 电池110.2C5A放电性能0.2C discharge capacity标准充电后，休眠0.51h后，以0.2C 放完电reset0.51 hour afte

26、r standard charge full, use 0.2C discharge电池放电时间5h discharge time5h121C5A放电性能 1C discharge capacity标准充电，休眠0.51h后，以1C放完 电reset0.51 hour after standard charge full, use 0.2C discharge电池放电时间 51min discharge time 51 minutes13高温性能 high temperature Capacity test标准充电后，电池放入55C2C高温箱 中，恒温2h,然后以0.2C放完电，然后 取出在2

27、0C5C环境下搁置2小时； standard charge, put the battery into 55C2C,keep 2 hours ,then use 1C discharge to cutoff voltage, take out put it at 20 C 5 C environment 2 hours电池放电时间5h，无变形，无爆 裂。Discharge time 5h no distortion , no crack14低温性能 low temperature Capacity test标准充电后，电池放入一10C2C高温 箱中，恒温4h，然后以0.2C放完电，然 后取出在

28、20C5C环境下搁置2小时； standard charge, put battery into 一 10C2C environment ,keep 4 hours ,then use 0.2C discharge to cutoff voltage ,take out put it at 20 C 5 C environment 2 hours电池放电时间3.h，无变形，无爆裂。Discharge time 3hno distortion ,no crack15恒定恒湿性能constant temperature & humidity test标准充电，电池放入45C2C，相对湿 度为909

29、5%的恒温恒湿箱中搁置 72h，然后取出，在20C5C搁置2h目 测电外观，然后以0.2C放完电 standard charge ,put the battery into 40 C 2 C/90 95 % environment 48 hours ,then take out put it at 20 C 5 C environment 2 hours ,check appearance, use 1C discharge to cutoff voltage无明显变形、锈 蚀、冒烟、爆 炸；放电时间 5hNo significant deformation, rust, smoke, exp

30、losion, discharge time 5h16ESDIEC610000042ReferenceEESpec17内阻检测IR check用额定电流满充电池，静置1小时后用 内阻测试仪量测内阻Use the rate current charge full the battery, rest 1 hour use the IR meter measure the IRReferenceEESpec18开路电压检测 open circuit voltage check用额定电流满充电池，静置1小时后用 万用表量测电池开路电压Use the rate current charge full t

31、he battery, rest 1 hour the use the meter measure battery open circuit voltageReferenceEESpec19循环寿命cycle life test按照产品规格进行充放电循环测试Do the charge/discharge cycle test follow product criteria每100循环结束后满充电池检查内阻及 厚度Each 100 cycle charge full battery check battery impedance and thicknessThe relative capacit

32、y 80% Thickness swell less than 10% Impedance in spec20Label酒精耐摩擦 测试Label alcohol test用棉布蘸上浓度最小为95%的酒精，用 500g的压力摩擦15次Rub with a cotton cloth dampened inalcohol (95% min)Force: 500gTest cycles: 15 timesLabel字迹能辨 认，无划痕，无 油墨脱落The label must be recognized.No scratches no ink off21Label纸带剥离测 试Label peel

33、strength test用3M胶带完整的粘 少45度角拉扯胶带彳 测试1次 Mack sure the tap sticks on the labe from label at 45 c Total is 1 times贴到label上再以至 吏之与label分离，(3M #610) totally .Remove the tap egree.Label字迹能辨 认，无划痕，无 油墨脱落The label must be recognized.No scratches no ink off22Label纸带耐摩擦 测试Label abrasion resistance test使用RAC压力

34、为17 label 3 次175g, 3 timesUse RCA equipmer5g的测试设备摩擦ItLabel字迹能辨 认，无划痕，无 油墨脱落The label must be recognized.No scratches no ink off23Label条码测试 Label bar code identify酒精耐摩擦测试 纸带剥离测试Alcohol resistancePeel strength test:estBarcode能扫描 无划痕，无油墨 脱落The bar code must can be scanned.No scratches no ink off24Label

35、存储测试Label Storage test把电池label面朝下方 (Mitsubishi MB1700F 上，用100g砝码压 Put battery with 10( plate(Mitsubishi 文 寸性帷:a gr t ,攵在材质为C+ABS)的塑料板生电池中心。0g loading on aMB1700PC+ABS)a kll ip|!Label没有粘到 塑胶板上没油墨 脱落Without any label adhere to plate No ink off/ , N4：电池在以下温度条件 - 1Temperature test co! !好下测试一次indition fo

36、r 1 cycle:s；to GwcimI* =-|Tkia ikli：-25Safety Test自由跌落drop test电池标准充电，将电 到放置在水泥地面1 木板上，从X/Y/Z 正 次，跌落后，电池以 0.2C充电，放电时1日 standard charge ,drop high to 18mm20mm platform ,X/Y/Y direc 6 times, after drop use use 0.2 charge times ,t less than 51min，池从1m的高度跌落 8mm20mm后的硬 i负方向各跌落11C放完电，然后以不能彳氐于51分钟the batte

37、ry from 1m hardwoodtion each 1 time ,total 1C discharge ,then:he discharge time not无明显变形、锈 蚀、冒烟、爆 炸，能放入设备 中；放电时间 51minNo significant deformation, rust, smoke, explosion, discharge time 51min可选项 目26振动vibration test将电池稳固地有保护地固定在振动平台 上，不要扭曲电芯，以便振动能很好的 传送，振动频率按正弦波形在15分钟内 按对数方式从7 Hz扫描到200 Hz再回到 7 Hz，振动沿电

38、芯互相垂直地二个方向 进行，每一个方向按上述循环重复12 次，用时共3小时，振动方向中的一个 必须垂直电芯和电池的最大面；对数扫 描频率如下：维持1gn的峰值加速度， 从7 Hz 一直扫描到18 Hz，振幅维持在 0.8mm （整个行程1.6mm），同时频率增 长，直到峰值加速度达到8gn （约50 Hz），然后维持8gn的峰值加速度，直 到频率增长到200Hzfix up the battery on the vibration plat, the frequency use sine wave from 7HZ to 200HZ in 15 minutes and down to 15HZ

39、 ,the there vibration direction each other perpendicularity, each direction repeat 12 times, total 3 hours; logarithm scan frequency as below, keep 1gn peak acceleration, from 7HZ to 18HZ,the extent keep 0.8mm,and the frequency raise, until the acceleration to 8gn（about 50HZ）,and then keep 8gn peak

40、,until frequency reach to 200HZ无明显变形、锈 蚀、冒烟、爆 炸；电压3.6VNo significant deformation, rust, smoke, explosion, Voltage 3.6V27热冲击heat shock safety将电池在温度为752C的环境中存储至 少6小时，接着在温度为402C的环境 中存储至少6小时。极端温度变化的时 间间隔最长为30分钟。重复上述过程10 次，然后将样品在温度为205C的环境 中放置24小时；对于大电池，在极端温 度中搁置的时间至少为12小时。Put the battery into 752C envir

41、onment at least 6 hours, then change the temperature to 402C keep the battery in that environment at least 6 hours, the temperature charge rate is no exceed 30 minutes, repeat 10 times, put the battery into 205 C environment 24 hours, for the big battery put it to the extreme temperature no less tha

42、n 12 hours不起火，不爆炸no fire ,no burst可选项 目28强制放电测试Force Discharge在环境温度下将测试电芯与一个12V的 直流电源串联起来进行强制放电，直流 电源初始电流等于制造商指定的最大放 电电流；把一负载与直流电源串联，这 个负载的阻抗与测试电芯阻抗相当，这 样可以获得指定的放电电流；测试电芯不起火、不爆 炸不起火、不爆 炸、不漏液1. no fire ,no burst可选项 目的额定容量除以初始测试电流(安培) 等于被迫放电的时间(小时)。In environment temperature ,series the DC and cell fo

43、rce discharge, the DC original Current is the max discharge current test time=cell rate capacity/original Current(A)2. no fire ,no burst , no leakage29强制放温度循环测 试Temperature cycle test样品在一自然对流或强制对流烘箱中加 热，烘箱温度以52C/min速度升温至 130C，并保持10min后停止。25热循环 测试电池放于测试室内并承受以下循环：30min内升温至703C，保温4h。30min内降温至203C，保温2h。

44、30min内升温至403C，保温4h。30min 内降温至 203C。重复上述循环9次。10次循环后，电池放置7天待检。Put the battery into temperature chamber the temperature rise rate is 52C/min reach to 130 C ,keep 10 minutes stop ,cycle 25 timesput the batteries into the temperature chamber do below testrise temperature to 703 C from room temperature ke

45、ep 4 hoursdown the temperature to 203C keep 2 hoursrise temperature to 403 C keep 4 hoursdown the temperature to 203Crepeat 9 cyclesafter 10 cycles reset 7 days ,check the batteries不解体，不起火No rupture , no fire30过充电保护性能 over charge protect电池标准充电后，用恒流恒压源持续给 电池加载8小时，电压为标称电压的2 倍，电流为2Cstandard charge, use

46、 constant current source charge 8 hours ,voltage is 2C standard voltage, current is 2C standard current不起火、不爆 炸、不冒烟、不 露液no fire, no burst, no smoke, no leakage31过放电保护性能 over discharge protect在20C5C温度下，0.2C放完电后，外 接30 Ohm电阻放电24hat 20 C 5 C environment 0.2C discharge to cutoff voltage ,then connect wit

47、h 30ohm resistance discharge 24 hours不起火、不爆 炸、不冒烟、不 露液no fire, no burst, no smoke, no leakage32短路保护性能 short protection test电池标准充电后，外接0.1 Ohm电阻， 短路1h,将正负极断开，以1C电流充电 5s后，测电池电压Reset 1 hour after charge full, check the不起火，不爆 炸，电池表面温 度不超过150 C no fire ,noOCV and impedance, use resistance 0.1ohm short the

48、 output terminal 1hour ,then use 1C current charge 5s check voltageexplosion ,battery surfacetemperature no more than 150 C33过充电 over charge test最大充电电流的2倍，测试最低电压为制 造商建议的最大充电电压的2倍；测试 在环境温度下进行，时间为24小时 use 2C voltage and 2C current ,continues charge 24 hours测试后的7天内 可充电电池无解 体，无起火 after test 7 days ago t

49、he battery can charge and discharge ,no leakage, no fire34异常充电测试 abnormal charge test以0.2C放完电，再以3倍电池最大充电 电流，以电池最高充电电压为限制，充 电至少7h或达到生产商规定的充电结束 条件。After use 0.2C discharge ,then use 3C maximum current ,maximum voltage charge 7 hours不起火，不爆 炸。No fire , no burst35强制放电测试Force discharge test一个完全放电的电池被强制性串联

50、同型 号的满充电池，串联满充电池数目等于 串联应用的最大数目减1个，当完全放 电的电池与特定数目的满充电池串联好 后，对形成的电池组进行短路测试。将 电池组的正负极用电阻小于0.1欧姆的负 载短接，并监控电池表面温度变化；当 电池组着火，爆炸，或电压低于0.2V且 表面温度回到环境温度10 C时停止测 试。Discharge the battery until cut off voltage ,the series battery must series the same cell, serine battery quantity is the series applies 1 ,when f

51、ull discharge battery seriated, short the battery pack use 0.1ohm resister ,monitor the battery surface temperature ,when battery pack fire ,burst ,or the output voltage low than 0.2V and the battery pack surface temperature return to environment temperature 10C stop test不起火，不爆 炸。No fire , no burst3

52、6常温短路External short test满充后，搁置1h,测OCV和电池内阻， 然后用电阻0.1ohm的负载短接电池正负 极，并监控电池表面温度，当电池着 火、爆炸或者当电池电压低于0.1V且电 池表面温度降到高于环境温度10C以下 时停止测试Standard charge put it at 20 C 5 C不起火，不爆 炸，电池温度 150 Cno fire ,no burst ,battery temperature 150 Cenvironment 1 hours ,blackout the PCM, use 100 mom resistance short the cell

53、,when the battery surface temperature low than tiptop temperature 10 C stop test37挤压测试Crush test满充后，搁置1h,测OCV和电池内阻， 电池将在两个平面之间被挤压，最大压 力不小于13kN, 一旦压力达到13kN应 立即卸压，charge full the battery reset 1 hour, check OCV and impedance ,extrusion the battery between two plane, the stress no less than 13KN不起火，不爆炸

54、no fire ,no burst可选项 目38高加速冲击acceleration shocktest面充电，将电池被有保护的固定在冲击 台上，每个电池承受峰值加速度为150 gn，脉冲宽度为6毫秒的半正弦冲击， 每个电池将沿着三个互相垂直轴的正负 方向每个方向冲击3次，共18次charge full the battery ,put the battery on the shock platform, each battery endure acceleration peak value is 150gn,pulse width 6ms half sine shock, each batte

55、ry shocks 3 times for X/Y/Z direction total 18 times电池无质量损 失、无漏液、无 排气、无解体、 无开裂、无着 火，测试后开路 电压不低于测试 前的90% battery no lose, no leak, no disjoint, no rupture ,no fire ,the OCV no less than 90% ,39撞击测试impinge against test满充后，搁置1h,测OCV和电池内阻， 把电池放在一平面上，将一直径15.8mm 的铁棒横放在电池的中心，让一重9.1Kg 的铁块从61 2.5 cm的高度跌落到电池 上charge full the battery ,reset 1 hour, check the OCV and impedance, put the battery on a platform ,tak