Servo-Controlled Battery Mechanical Abuse Testing System for EV & Lithium Safety Validation
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The RS-8000A2-50KN Battery Puncture and Extrusion Tester is a high-performance servo-controlled mechanical abuse testing system designed for the safety validation of lithium-ion cells, battery modules, and small packs.
It simulates real-world extreme failure scenarios such as vehicle crash compression, localized puncture, and structural collapse, enabling EV manufacturers, battery OEMs, and certification laboratories to evaluate catastrophic failure behavior before product deployment.
This system is widely used in battery safety compliance testing, EV validation programs, and third-party certification labs.
What This System Is Designed For
The RS-8000A2-50KN is engineered for lithium battery mechanical abuse testing, including:
- Battery puncture / nail penetration testing
- Battery extrusion / crush testing
- Structural deformation analysis
- Thermal runaway trigger evaluation (mechanical induction)
- Cell-to-module failure propagation studies
It is suitable for R&D validation, pre-certification testing, and quality assurance workflows.
Advanced Safety & Explosion-Proof Engineering
Because battery abuse testing involves risks such as thermal runaway, gas release, and fire events, the RS-8000A2-50KN is built with a multi-layer protection architecture:
🔹 Reinforced Explosion-Proof Chamber
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Heavy-duty structural enclosure
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Internal lining with 304 stainless steel anti-corrosion plate
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Designed to withstand high-energy rupture events and electrolyte vapor exposure
🔹 Automatic Pressure Relief System
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Rear-mounted 200 × 200 mm mechanical pressure relief port
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Automatically opens under abnormal internal pressure spikes
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Directs blast energy away from operator area
🔹 Integrated Gas & Smoke Exhaust Interface
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Ø100 mm industrial exhaust duct
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Compatible with external scrubber / ventilation systems
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Enables rapid removal of toxic gases and smoke
🔹 Isolated Operator Control Station
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Fully separated industrial PC control console
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Physical isolation between operator and test chamber
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Ensures compliance with laboratory safety SOPs
Precision Servo-Controlled Drive System
The RS-8000A2-50KN is powered by a Panasonic AC servo control system, delivering stable and repeatable mechanical motion.
Key Performance Features:
- Smooth, non-impact force loading throughout full test cycle
- No mechanical vibration or force fluctuation
- High repeatability across long-duration testing sequences
Precision Control Capabilities:
- Force resolution: up to 1/500,000
- Displacement accuracy: ≤ ±0.1 mm
- Fully programmable speed profiles
This ensures reliable data consistency across hundreds of standardized test cycles.
Real-Time Data Acquisition System
The integrated software platform supports multi-channel synchronized data recording, including:
- Force (N)
- Displacement (mm)
- Time (s)
- Optional voltage drop monitoring (V)
- Optional temperature mapping (°C) via thermocouples or infrared sensors
This allows engineers to precisely capture the exact failure moment of battery internal short circuits or structural collapse events.
Compliance with International Testing Standards
The RS-8000A2-50KN supports major global lithium battery safety standards, including:
- UL 2580 – EV Battery Safety Standard
- UL 1642 – Lithium Cell Safety
- IEC 62660-3 – Mechanical Abuse Testing
- IEC 62133 – Battery Safety Requirements
- UN 38.3 – Transport Safety Certification
- GB/T 31485 / GB 38031 – China EV Battery Standards
- SAE J2464 – Electric Vehicle Abuse Testing
This makes it suitable for global certification and regulatory approval workflows.
Technical Specifications
| Parameter |
Specification |
| Model |
RS-8000A2-50KN (Servo-Controlled Type) |
| Force Range |
1 kN – 50 kN (optional up to 100–200 kN) |
| Force Accuracy |
Class 0.5 |
| Force Resolution |
1/500,000 |
| Displacement Accuracy |
≤ ±0.1 mm |
| Stroke Range |
0 – 400 mm (optional up to 800 mm) |
| Speed Range |
1 – 100 mm/s (programmable) |
| Chamber Material |
304 Stainless Steel Reinforced Structure |
| Work Area |
300 × 300 × 500 mm (customizable) |
| Safety Exhaust |
Ø100 mm gas vent + 200 × 200 mm relief port |
| Power Supply |
AC 220V / 50Hz (customizable 110V / 380V) |
Application Scenarios
The RS-8000A2-50KN is widely used across:
Battery Cell Testing
- 18650 / 21700 / 4680 cylindrical cells
- Pouch cells
- Prismatic cells
Module & Pack Testing
- Structural crush resistance
- Mechanical failure propagation
- Module-level safety validation
Industry Applications
- EV battery manufacturers
- Energy storage system developers
- Certification laboratories
- Automotive R&D centers
- Third-party testing institutions
Custom Engineering Options
Every laboratory has different testing standards and safety requirements. We provide full customization options including:
- Custom force capacity (up to 200 kN)
- Chamber size modifications
- Multi-point temperature sensing systems
- Gas scrubber integration
- Voltage monitoring modules
- Automated test sequencing software
Request a Technical Proposal
To provide a precise configuration and quotation, please share:
- Battery type (cylindrical / pouch / prismatic)
- Target test standards (UL / IEC / UN / GB)
- Required force range
- Chamber size requirements
- Data acquisition needs (voltage / temperature / none)
Our engineering team will respond with a tailored technical solution and quotation within 24 hours.
