Hybrid and Electric Vehicle Battery Testing

Millbrook conducts hybrid and electric vehicle (EV) battery testing to: assess the life of battery cells, modules and packs; determine battery safety in a wide range of situations including crash events; and validate the performance of automotive batteries under a range of environmental conditions.

Battery endurance test facility for battery life testing at Millbrook

EV Battery Testing Overview

Millbrook offers a wide range of battery safety and abuse tests including for UN 38.3 and ECE Reg 100 and operates a state-of-the-art battery life and performance test facility in the UK. It tests all major Lithium-ion chemistries and a range of other chemistries by simulating normal and extreme operating conditions.

Electric vehicle (EV) battery endurance testing laboratory for battery simulation and life cycling at Millbrook

Hybrid and Electric Battery Tests

Millbrook provides a wide range of test methods to assess the life, safety and performance of vehicle batteries. These include:

Millbrook also offers a range of electric machine and inverter tests and provides full vehicle test facilities including the ability to crash EVs and FCVs.

Strip and inspection for EV batteries in Millbrook's Battery Test Facility

Battery Strip and Inspection

After completing a battery test, Millbrook’s skilled team safely strips them down to component parts, while measuring key parameters, such as distances, torques, voltages, and resistances. A detailed photographic record can also be provided.

A high-resolution video link allows real-time interaction. This can be especially useful in situations where the battery pack is damaged, making it difficult to specify in advance what is of interest.

Millbrook conducts abuse testing of lithium ion batteries for applications including rail, aircraft, grid storage and electric vehicles, all of which can be followed up with battery strip and inspection.

Other capabilities include:

  • Battery repairs, such as fuse replacement, module replacement and software reflashing
  • Return shipping of batteries after testing
  • Secure battery disposal after testing
Battery turnover facility for testing rollover crash scenarios on an electric vehicle battery pack

Battery Coolant Testing

Millbrook conducts a range of tests to assess the performance of battery coolants from development samples to production. Coolant tests are performed on battery cells, modules and packs. These include:

  • Performance tests i.e. can the battery function as required in the vehicle over the expected range of ambient and use conditions?
  • Life tests i.e. does the battery meet its warranty targets, and customers’ expectations for life?
  • Safety tests i.e. is the battery safe enough in normal use and in other likely situations, such as a crash?

Find out more about the impact of the battery coolant in Dr. Peter Miller’s white paper – ‘The Impact of Battery Coolant Choice on Lithium-ion Batteries.