Applus+ IDIADA, a global provider of automotive testing and engineering services, has announced the opening of its state-of-the-art Battery Safety Laboratory in Santa Oliva, Catalonia. This facility significantly expands the company’s capacity to deliver cutting-edge testing and validation services for battery systems in the automotive sector.
Spanning over 2,000 square meters, the lab is among the world’s largest and most advanced facilities for battery abuse testing. It offers comprehensive services, including thermal propagation, fire resistance, drop tests, crush tests, nail penetration, and water immersion. These rigorous evaluations ensure the safety and performance of battery systems under extreme conditions.
In addition to its safety-focused capabilities, the lab incorporates advanced environmental protection measures, such as gas scrubbing and water treatment systems, to minimize the impact of testing processes on the environment.
Integrated Testing and Engineering Services
The new laboratory complements IDIADA’s broader battery engineering services, which support the complete battery development cycle. This includes everything from cell selection and integration to system-level validation. By combining abuse testing with aging and performance evaluations, the facility ensures a holistic approach to battery system development.
Key offerings include:
- Aging and Performance Testing: Calendar and cycling aging, endurance tests with customized profiles, real driving cycles at various temperatures, electrochemical impedance spectroscopy (EIS), and validation of battery management system (BMS) functions.
- Abuse and Safety Testing: Electrical abuse tests such as short-circuit, overcharge, and over-discharge; thermal testing including overheating and thermal propagation; and mechanical abuse testing like drop tests, vibration, and nail penetration. These tests adhere to global standards, including ECE R100, UN 38.3, and FreedomCAR.
- Failsafe Testing: Simulating failure scenarios to evaluate system responses.
- Battery Teardown and Benchmarking: Functional evaluation and detailed analyses of battery component performance and costs.
Facility Highlights
IDIADA’s advanced facilities are designed to handle pre-damaged samples and battery failures safely. Key specifications include:
- Climatized test benches operating from -45°C to +75°C.
- High-power cyclers up to 500kW/1000V/1000A and low-power battery cyclers up to 50kW/800V/150A.
- Over 500 data channels for comprehensive performance monitoring.
- Testing tools such as voltage, current, and gas sensors, as well as thermocouples, strain gauges, and video cameras for detailed analysis.
A Commitment to Innovation and Sustainability
“This new Battery Safety Lab represents a major step forward in our commitment to innovation and safety in the rapidly evolving field of battery technology,” said Miquel Maureso, Head of e-Powertrain at Applus+ IDIADA. “As the automotive industry continues its shift toward electrification, our expanded capabilities will play a critical role in ensuring the safety and performance of the next generation of battery systems.”
With the opening of this facility, Applus+ IDIADA strengthens its position as a leader in supporting the global automotive industry’s transition to sustainable and electrified mobility solutions.
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Source/Photo Credit: Applus+ IDIADA
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