3MW Battery Thermal Release Test System

TESTech Instrument (Suzhou) Technologies is one of the leading manufacturers and suppliers of 3mw battery thermal release test system in China. Welcome to wholesale premium test equipment at competitive price from our factory. If you have any enquiry about quotation, please feel free to email us.

• This large heat release test system is designed with reference to ISO 9705, GB/T 20286-2006, GB/T 27904-2011, and GB/T 25207-2010 for large-scale heat release measurement.
• The theoretical basis follows oxygen-consumption calorimetry, where the generated heat is proportional to the consumed oxygen and each kilogram of oxygen corresponds to 13.1 MJ/kg of heat.
• Measured values include heat release, ignition time, oxygen consumption rate, CO generation rate, CO2 generation rate, gas flow, smoke density, and related combustion parameters.
• The duct and sampling arrangement are designed with reference to foreign large-scale heat release systems and airflow studies, in order to improve stability and accuracy of smoke sampling.
• Built-in temperature sensors, gas flowmeters, gas samplers, and multi-stage filtered sampling lines are provided to support long-term analyzer operation.
• The Windows-based Labview system performs automatic acquisition, calculation, storage, and report generation for heat release rate, total heat release, smoke density release, and other parameters.

• The complete system includes the exhaust system, specimen fixtures, ignition system, smoke sampling and pretreatment system, gas analysis system, integrated control cabinet, and computer analysis system.

• The exhaust system includes collection hood, guide duct, mixing duct, and test flue section.
• Collection hood and ducts are made of SUS304 stainless steel, with hood plate thickness not less than 2 mm.
• Conical stainless steel collection hood bottom opening size: 4000 mm x 4000 mm; hood height not less than 1000 mm.
• Exhaust duct diameter: not less than 600 mm.
• Straight exhaust duct length: not less than 4000 mm, fitted with a motorized air valve.
• A gas mixer of not less than 900 mm x 900 mm x 900 mm is installed, with double-layer baffles and temperature resistance not less than 1100 °C.
• A motorized fire-resistant fabric curtain is installed under the hood, size 4 m x 4 m.
• The test section includes flue gas sampler, smoke temperature measurement, airflow measurement, and photoelectric smoke density test system.
• An additional 1.2 m diameter three-way valve is provided at the duct connection for connection to the existing on-site flue.
• An operating platform is arranged at the flue sampling section for installation, maintenance, and servicing.

• The system consists of fan, frequency inverter, airflow probe, differential pressure gauge, and thermocouple.
• A three-phase variable-frequency fan controls airflow at 12000 m3/h and ensures collection of all combustion smoke, with adjustable airflow during testing.
• A Taiwan Delta inverter is used for accurate flue velocity control.
• A bidirectional airflow probe is used for airflow pressure measurement.
• Imported U.S. differential pressure transmitter: range 0 to 2000 Pa, accuracy ±1% FS, hysteresis ±0.1% FS, maximum linear pressure 69 kPa, and 90% response time within 1 s.
• Imported OMEGA thermocouples monitor smoke temperature in real time, with temperature accuracy 0.1 °C.
• Air velocity signals are automatically calculated and fed back to achieve closed-loop control with stable airflow and strong anti-interference capability.

• The system includes sampler, filters, cold trap, suction pump, drying tube, and flow controller.
• The stainless sampler is provided with sampling holes facing opposite to the gas flow direction.
• A three-stage filtration system with soot particle filter, intermediate filter, and fine filter is used, with filtration accuracy up to 0.2 um.
• The cold trap uses compressor refrigeration and is controlled at 0 to 5 °C, while sample gas is controlled at 4 ±1 °C.
• Imported suction pump: flow 33 L/min, vacuum degree 700 mmHg, pressure 2.5 bar.
• The drying tube removes water and impurities from the sampled gas.
• The imported flow controller supplies stable sample gas flow to the analyzers.

• Smoke density light source: imported 0.5 W helium-neon laser from the USA.
• Imported photoelectric receiver: wavelength range 350 to 1100 nm, peak response 0.65 A/W, maximum output current 100 mA, gain adjustment 70 dB, linearity not less than 99.8%, instability less than 0.1%, and receiving accuracy 0.1%.
• A one-touch five-level optical calibration system with imported Thorlabs filters is provided; deviation between calculated and theoretical values is controlled within 3%.
• A compensation photoelectric detection system is used to reduce fluctuation interference from the light source.
• The battery combustion heat flux module includes heat flux meters, water cooling module, and acquisition system.
• European Hukseflux heat flux meters are provided in 5 kW, 10 kW, and 20 kW ranges.
• The water cooling circulation system with built-in tank and pump can support up to 16 heat flux meters simultaneously.
• A 16-channel, 16-bit Advantech acquisition module records heat flux data in real time, with RS485 MODBUS RTU communication and 1 Hz acquisition frequency.

• The combustion control system consists of stainless steel gas piping, check valve, explosion-proof solenoid valve, mass flow controller, burner, and ignition controller.
• Gas use safety is ensured through the sampling check valve, explosion-proof solenoid valve, and burner controller with flame detection.
• A sandbox burner and mass flow controller are used for stepwise heat release calibration.
• The ignition device is installed above the test battery to remotely ignite combustible gas released at the early stage of thermal runaway.
• The heat release calibration system uses a heptane burner system including burner, support, heptane line, gas line, control system, booster pump, pressure gauge, and fittings.
• The heptane line is made of stainless steel fittings, and the burner support is mounted on casters for convenient movement.
• The booster pump has a flow range of 0 to 30 L/min and a pressure range of 0 to 1 MPa, with a stainless steel pump head.

• An Advantech temperature acquisition system provides 180 channels, 16-bit resolution, temperature range 0 to 1370 °C, and display resolution 0.1 °C.
• The battery heating system includes intelligent temperature control with programmable heating curve, maximum temperature 400 °C, and heating rate 4 to 7 °C/min.
• The DC heating control system provides heating power not less than 3 kW.
• The Omron intelligent temperature controller supports multi-step programming and MODBUS RTU data transmission with display precision 0.1 °C.
• The paramagnetic oxygen analyzer measures O2 from 0 to 25%, with linear deviation not greater than 0.5% of range and T90 below 3.5 s.
• The infrared CO and CO2 analyzer measures CO from 0 to 1% and CO2 from 0 to 10%, with T90 below 2.5 s.
• The total hydrocarbon analyzer uses flame ionization detection and measures THC from 0 to 10000 ppm, with T90 below 3 s.
• The palladium-nickel hydrogen analyzer measures H2 from 0.4 to 5%, with measurement accuracy 0.3% and real-time compensation for interfering gases according to the provided auxiliary hydrogen analysis scheme.

• The monitoring system includes two Hikvision cameras and one hard-disk recorder, with 8 MP, 4K resolution, 2.8 mm focal length, infrared distance up to 50 m, and white-light distance up to 30 m.
• Two movable fire walls are provided for each smoke system, using black fire-resistant surface material, 16 ±1 mm gypsum board, and 19.05 ±1 mm plywood.
• The control cabinet is a standard cabinet equipped with a Dell computer, 19-inch display, and 16-bit high-precision acquisition modules.
• System time recording accuracy is 0.1 s, and Modbus digital communication is used for real-time monitoring and accurate data recording.
• The Labview software supports parameter setting, analyzer calibration, optical calibration, heat release calibration, test information management, testing, data analysis, and report printing.
• All measured parameters, including O2, CO2, CO, H2, hydrocarbon concentration, ambient conditions, flow, pressure, transmittance, temperature, and heat flux, can be displayed, enlarged, reduced, and reviewed independently.
• The software performs real-time calculation of heat release rate, smoke production rate, oxygen consumption, CO2 generation, CO generation, mass loss, radiant heat, wind speed, and total heat release.
• Automatic five-level optical calibration is provided at 0%, 25%, 50%, 75%, and 100%, and the report can be generated automatically in Excel or PDF format.

• Recommended site area for the 3 MW system: 12 m x 10 m x 7 m, excluding the control room and outdoor exhaust pipe space.
• Recommended control room size: 3 m x 3 m x 3 m, adjustable, and more than 3 m away from the collection hood.
• The floor should be flat, and no external airflow is allowed to disturb the burning environment below the hood during testing.
• Electrical requirement: 380 V, 30 kW, 35 A, with incoming cable not less than 10 mm².
• The laboratory should be equipped with fire extinguishing measures such as portable CO2 extinguishers in addition to automatic smoke detection.
• Auxiliary gases to be provided by the customer include high-purity nitrogen, methane, 8.5% CO2, and 0.85% CO.
• Consumables such as anhydrous calcium sulfate should be prepared by the customer.
• Test gases listed in the source include calibration and purge gases, hydrogen, compressed air, propane calibration gas, and fuel propane 99% in 30 kg cylinder specification.

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