Test Chamber Made to Protect EV Batteries

April 11, 2023 - Author: David Suehs - Engineering Manger, Machine Design

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EV battery test chamber for dust protection

ISO 20653 Certified EV Battery Test Chamber for Dust Protection

As described in detail in the SAE Automotive Engineering article titled “Chamber Designed for EV Battery Protection,” ACS was chosen by a prominent automaker to create a self-contained testing station featuring a dust chamber, aligned with ISO and client-specific criteria. ACS designed and constructed an environmental test chamber, adhering to standards that ensure the suspension of 2kg of dust per cubic meter of volume.

The complete testing station is sealed against dust, preventing any potential mess in the facility. It occupies a floor space of 8 x 8 ft (2.4 x 2.4 m), stands at a height of 7 ft (2.1 m), and has a weight of under 4000 lb (1814 kg). The unit is easily portable and has a low power consumption, operating efficiently with just 480V at 60A.

The dimensions of the test chamber were precisely tailored to accommodate the specific devices being tested. The chamber’s volume was fine-tuned to ensure sufficient airflow around the largest test item while minimizing unnecessary space for a test article with a smaller volumetric footprint.

By understanding the constraints of the test article, the team effectively optimized the fan size and minimized the amount of ISO dust present. The unit is equipped with an Allen-Bradley PLC, allowing the operator to precisely control both the duration and speed of the suspended air-dust mixture.

The automotive manufacturer can now assess the level of protection against foreign objects, establishing whether its batteries meet the criteria for 5K ingress protection (dust-protected) or 6K ingress protection (dust-tight).

“One of the technical challenges with this project was to design the chamber and size the test stand for multiple battery sizes. The ISO standard requires a 2kg mass of dust per cubic meter. As the unoccupied volume interior to the chamber changes with the test article, the fan velocity and volume of raw dust product needed to be varied,” said David Suehs, Engineering Manager, Machine Design Group at ACS.

Read the full article starting on page 35 here.

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