Drop test simulation base on UN R136 : Swappable Battery Pack

Since there were concerns about fracture when the case was molded with resin, we conducted drop and flow analysis while changing the shape to confirm that there were no performance or moldability problems before conducting the test.

One method of verifying the safety and evaluating the durability of lithium-ion batteries is through a drop test. This test involves dropping the battery from a specified height in a predetermined manner (designating the angle and parts), onto a pre-determined type of floor material to measure its impact resistance.

Here, we present a case study of a drop test simulation that adopted the standards of UN R136, specifically for XYRON, which is used in actual battery cases and cell holders.

The durability of the battery pack against drop impacts and the verification of changes under the condition of being subjected to shock.

Detailed impact analysis simulation using Asahi Kasei internal know how to achieve as close requirements from battery safety standard (UN R136).

The drop test complies with AIS-156 Annex8C "Mechanical drop test for removable REESS."
In addition, the protection rating of the body (enclosure) is specified as IPXXB, and if cracks occur, the crack diameter must be less than 12 mm.

Below we show the actual simulation results.

The drop analysis predicted that cracks would only occur when dropped in the X and Y directions. However, the crack size was less than 10mm in either direction, which confirmed that there were no problems and XYRON™ battery case was successfully certified.

Drop test simulation results

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