Testing & Validation Services

Our testing services provide comprehensive validation of automotive battery systems at cell, module, and pack level, ensuring readiness for market introduction and compliance with international, regulatory and OEM standards. 

Performance & Characterization Testing

• Functional capabilities 
• Real driving and charging performance at different temperatures
• Electrochemical impedance spectroscopy (EIS)
• BMS functional validation

Endurance & Durability Testing

• End-of-life testing
• Calendar and cycling aging
• Endurance tests with customized profiles
• Durability standard cycles 
• Testing on pre-damaged samples

Abuse & Safety Testing

• Electrical abuse: short-circuit, overcharge, over-discharge, insulation resistance, overcurrent
• Thermal abuse: over temperature, thermal shock, thermal propagation, fire resistance
• Mechanical abuse: drop test, nail penetration, vibration (up to 200 kN), mechanical shock, mechanical integrity
• Water immersion
• EMC testing of battery packs and modules, focusing on BMS and battery electronics. 

Regulatory Testing and Standards

We offer a full portfolio of development and compliance tests for automotive battery systems, including:

• Development Tests
• Compliance Tests for UNECE R100 & R136 regulations
• Compliance Tests for UNECE R10
• Compliance Tests for UN DOT 38.3 standard
• Compliance Tests for OEM standards based on ISO 19453-6:2020
• Compliance Testing for Regulation (EU) 2023/1542 on Batteries and Waste Batteries: This regulation introduces new requirements for battery safety, sustainability, and end-of-life management. Applus+ is fully prepared to support clients in meeting these obligations, ensuring that battery systems comply with the latest European regulatory framework.
• Facilities, Capabilities & Equipment
• Battery Safety Lab: Over 2,000 m² for battery abuse testing, including postmortem analysis area, with advanced safety, gas scrubbing, and water treatment systems
• Climatic Chambers: For temperature and humidity control, including EUCAR 6-rated safety for large packs (up to 15 m3). 
• High-power Battery Cyclers: Up to 500 kW/1000 V/1000 A; low-power up to 50 kW/800 V/150 A
• Advanced Data Acquisition: 500+ channels for voltage, current, temperature, strain, and video 
• Shakers and Mechanical Test Systems: Multiple test facilities, up to 200 kN vibration, 400 kN shock, with environmental integration.
   

Engineering Services

• Battery System Design & Development
• Cell selection and integration (cylindrical, pouch, prismatic) into modules and packs
• Battery architecture definition (housing, thermal management, BMS, power/junction box)
• Design validation plan: definition and execution
• Full engineering assessment in high-voltage and battery safety
• Virtual Development
• Structure deformation (CAE)
• Mechanical integrity/crush
• Drop
• Nail penetration
• Roll-over simulation
• Mechanical shock (shaker)
• Stone impact test
• Electro-Thermal Simulation (CFD)
• Electric performance: Energy & Power (1D-3D simulation)
• Cooling system optimization
• Cells temperature distribution
• Thermal propagation (CFD)
• Cell-to-cell propagation time calculation
• Venting channels study
• Insulation layers materials selection
• Cell characterization rig: Heat release, Venting gasses 
• Battery modelling and virtual validation to optimize system performance and reliability
• Replication of experimental validation processes through virtual models

Benchmarking & Teardown Analysis

• Functional evaluation and battery system performance 
• Failsafe analysis trough E/E failure injection 
• Battery teardown- complete analysis up to cell
• Battery pack dismantling and detailed bill of materials
• Module, HV circuit, and BMS analysis

Experiment Design

• Target-oriented experiment planning
• System characterization and test-to-failure approach