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UN 38.3 Shock Test Data Collection

UN 38.3 Shock Test Data Collection. Rich Byczek, Intertek Oct 2013. http://www.psessymposium.org/. T4: Shock. Small Cells/Batteries = 150g/6ms = consumer battery specs Large Cells/ Batteries= 50g/11ms = automotive OEM Specs Large Cells -> Small Batteries: Cells at 50G, Battery at 150G.

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UN 38.3 Shock Test Data Collection

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  1. UN 38.3 Shock Test Data Collection Rich Byczek, Intertek Oct2013 http://www.psessymposium.org/

  2. T4: Shock • Small Cells/Batteries = 150g/6ms = consumer battery specs • Large Cells/ Batteries= 50g/11ms = automotive OEM Specs • Large Cells -> Small Batteries: Cells at 50G, Battery at 150G

  3. Measurement Methods • Shipping of Representative shipments and packaging. • OEM selected Samples • OEM selected Methods • Small, Medium, Large sample shipments

  4. Measurement Methods • INTERTEK RECOMMENDATIONS • Pallet (LTL) and Small (UPS, FEDEX, etc) • Assume small parcels have the roughest handling. • Measure at package, not at device (do not assume dampening)

  5. Measurement Methods • Measurement Equipment • EDR-3C by IST • 3axis internal accelerometer • Use 2 to test both package and • battery. • - Set minimum G threshold, to collect primarily shock pulse data (i.e. 3G, 5G)

  6. Measurement Methods • May require multiple runs per shipment size and type. • Set realistic thresholds to maximize data collection • Potential variation from shipment to shipment • Variation based on sample and packages size and method.

  7. Measurement Methods • Measurement Analysis • Convert recorded data to time history • Cursory review of peaks and durations • Data “reduction” based on revised threshold • Statistical calculation of Peak G and Duration

  8. Measurement Methods • Resultant Shock Pulse ASSUMPTIONS • Half Sine Pulse • Small/ Large have separate parameters • Peak G level: based on max for each shipment size, regardless of method • Duration: based on average pulse width above threshold • Pulse Count: TBD, based on average pulses per shipment

  9. Measurement Methods • NOTE on PEAK and NUMBER of PULSES: • Increasing number of pulses may be a way to reduce test peak levels. • Typical 1-3 pulse per direction is an ACCELERATED TEST, and therefore peak G level may not be representative of actual accumulated stress. • Alternate is realistic G level, with representative test duration (number of pulses seen in a typical or multiple shipments)

  10. Vibration and Shock • “Test cells and batteries shall be secured to the testing machine by means of a rigid mount” • Fixturing: • Support the product • May simulate packaging • May simulate mounting in position • Not well defined currently. • Cannot assume package dampening

  11. Vibration and Shock • CONSIDER WHAT IS BEING SHIPPED! • CONSIDER HOW IT IS SHIPPED! • CONSIDER HOW IT IS TRANSPORTED AFTER INITIAL SHIPMENT

  12. THANKYOU Rich Byczek Intertek Global Technical Lead Electric Vehicle & Energy Storage 248-219-1099 rich.byczek@intertek.com Mike Wells Vibration Test Department Manager 734-582-2900 Michael.wells@intertek.com

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