Extrusion Needle Battery Test Machine OEM ODM with Adjustable Frame

1. Product Name and Purpose

2. Product Features

• Robust and Adjustable Frame
  • The machine is constructed with a heavy-duty frame, typically made of high-strength steel, to ensure stability and durability during the testing process. The frame is designed to accommodate different battery sizes and shapes, with adjustable fixtures and clamps. This flexibility enables the testing of a wide range of battery chemistries and form factors, from small coin-cell batteries to large-format lithium-ion packs used in electric vehicles and energy storage systems. The adjustable components are precisely calibrated, allowing for quick and accurate setup, minimizing the time required between different test runs.
• Precision Extrusion Needle Mechanism
  • The extrusion needle is a critical component of the machine. It is made of a hardened and corrosion-resistant material, such as stainless steel or tungsten carbide, to ensure it can withstand the forces exerted during testing without deforming or breaking. The needle's diameter and length can be adjusted according to the specific requirements of the battery being tested. The machine is equipped with a highly accurate force control system that can apply a consistent and precisely measured extrusion force. This force can range from a few Newtons for small, delicate batteries to several hundred Newtons for larger, more robust ones. The control system allows for fine-tuning of the force application rate, enabling the simulation of different impact scenarios, from slow, gradual compression to rapid, sudden jolts.
• Advanced Sensing and Monitoring Capabilities
  • To comprehensively assess the battery's response to the extrusion test, the machine is outfitted with a suite of sensors. Voltage and current sensors are installed to monitor any electrical changes within the battery during the test. A sudden increase in current or a drop in voltage could indicate the onset of a short circuit or internal damage. Temperature sensors are strategically placed on the battery's surface and, in some cases, within the cell to measure any temperature fluctuations. An abnormal temperature rise might suggest a potential thermal runaway. Pressure sensors are also incorporated to measure the internal pressure of the battery, providing valuable insights into its structural integrity and the likelihood of leakage or rupture. These sensors are connected to a state-of-the-art data acquisition system that records and analyzes the data in real-time. The data acquisition system is highly configurable, allowing users to set custom sampling rates and trigger thresholds. It can also generate detailed reports and graphs, facilitating in-depth analysis and comparison of different test results.
• Enhanced Safety Features
  • Given the potential risks associated with battery testing, the Battery Extrusion Needle Test Machine is equipped with multiple safety features. It has an automatic emergency stop button that can be easily accessed by the operator in case of any abnormal behavior or imminent danger. The machine is enclosed in a safety shield made of transparent, impact-resistant material, protecting the operator from any potential flying debris or battery fragments in the event of a failure. Additionally, it is equipped with a fire suppression system, which can quickly extinguish any flames that might occur due to a battery malfunction. The ventilation system is designed to remove any potentially harmful gases or fumes that could be released during the test, ensuring a safe working environment.

3. Specific Parameters

• Battery Size Compatibility: The machine can handle batteries with dimensions ranging from a few millimeters (such as coin-cell batteries) to several tens of centimeters (for large industrial or automotive batteries). The adjustable fixtures can accommodate different battery geometries, including cylindrical, prismatic, and pouch cells.
• Extrusion Force Range: The force application range typically spans from 10 N to 500 N, with an accuracy of ± 2 N. This wide range allows for the testing of batteries with varying levels of robustness and intended applications. For example, a small consumer electronics battery might only require a relatively low extrusion force, while a heavy-duty automotive battery would need to withstand a much higher force.
• Needle Dimensions: The extrusion needle diameters can be adjusted from 1 mm to 10 mm, and the length can be customized based on the battery's thickness. The choice of needle dimensions depends on the specific test requirements and the battery's characteristics. A thinner needle might be used for more precise testing of a specific area of the battery, while a thicker needle could be employed for a more general assessment of the battery's overall strength.
• Data Acquisition Rate: The data acquisition system can sample sensor data at a frequency of 50 to 500 samples per second. This high sampling rate ensures that even the most rapid changes in the battery's parameters, such as a sudden spike in current or a rapid temperature increase, are accurately recorded and can be analyzed in detail.

4. Product Functions

• Accurate Detection of Battery Weaknesses
  • The primary function of the Battery Extrusion Needle Test Machine is to identify potential weaknesses in batteries. By subjecting the battery to a controlled extrusion force, it can detect if the battery's casing is prone to cracking, if the internal components are likely to shift and cause a short circuit, or if the battery's seals are likely to fail and lead to leakage. For example, if a battery's casing shows signs of deformation or cracking during the test, it indicates that the battery may not be able to withstand the mechanical stresses it could encounter in real-world applications. This information is invaluable for battery manufacturers, as it allows them to take corrective actions, such as improving the casing design or strengthening the internal structure, before the batteries are deployed in the market.
  • The machine also helps in evaluating the effectiveness of a battery's safety mechanisms. For instance, it can determine if the battery's overpressure protection system activates properly when subjected to an extrusion force. If the system fails to activate or activates too late, it could lead to a dangerous situation, such as a battery explosion. By testing different battery models and designs, manufacturers can optimize their safety features and ensure the highest level of protection for end-users.
• Enhanced Battery Quality and Reliability
  • Through comprehensive testing with the Battery Extrusion Needle Test Machine, battery manufacturers can significantly improve the quality and reliability of their products. By identifying and addressing potential issues early in the production process, they can reduce the number of defective batteries that reach the market. This not only enhances customer satisfaction but also helps in building a reputation for quality and safety. For example, a manufacturer that regularly tests its batteries and takes corrective actions based on the test results is more likely to produce batteries that meet or exceed industry safety standards. In the long run, this can lead to increased market share and a competitive advantage.
  • The machine also serves as a valuable tool for research and development. By studying the behavior of batteries under different extrusion conditions, researchers can develop new materials and designs that are more resistant to mechanical stress. For instance, they can explore new casing materials that have higher strength-to-weight ratios or develop internal structures that better distribute and absorb external forces. This continuous innovation in battery design and materials can lead to the development of more durable and reliable batteries, which is crucial for the advancement of various industries, including automotive, electronics, and renewable energy.
• Compliance with Industry Standards and Regulations
  • The battery industry is highly regulated, with numerous safety and performance standards that must be met. The Battery Extrusion Needle Test Machine is an essential tool for ensuring compliance. For example, in the automotive and consumer electronics industries, batteries must pass specific mechanical stress tests to prove their safety and reliability. By using this machine to conduct tests in accordance with relevant standards, such as those set by the International Electrotechnical Commission (IEC) or the Society of Automotive Engineers (SAE), manufacturers can prove that their batteries are safe and reliable, facilitating market access and enhancing consumer confidence. Regulatory bodies rely on accurate test results obtained from such machines to enforce safety and quality regulations, ensuring the safety of consumers and the proper functioning of battery-powered devices.

5. Production and Quality Assurance

• Stringent Manufacturing Process
  • The Battery Extrusion Needle Test Machine is manufactured under strict quality control procedures. Each component, from the high-strength frame to the precision sensors, is carefully sourced and inspected for quality and performance. The assembly process is carried out by highly trained technicians in a clean and controlled environment, ensuring the proper installation and functionality of all parts. The machine undergoes a series of calibration and validation tests during the manufacturing process to ensure that it meets the required accuracy and performance standards.
  • The calibration of the force control system, sensors, and other critical components is a regular and meticulous part of the manufacturing process. It is performed using traceable reference standards to guarantee the reproducibility of the test results. Rigorous quality audits and inspections are conducted at various stages of production to maintain the highest level of product quality.
• Quality Certification and Validation
  Our machine has obtained relevant quality certifications and has been validated by independent battery testing laboratories. It has been proven to provide accurate and reliable test results, conforming to the relevant international and national battery standards. We also continuously update and improve our product based on the latest technological advancements and customer feedback from the battery industry to ensure its long-term performance and compliance.

6. Application Areas and Success Stories

• Consumer Electronics Battery Testing
  • A leading smartphone manufacturer used the Battery Extrusion Needle Test Machine to test the batteries for their new models. The tests revealed a potential issue with the battery's casing design, which could lead to cracking and short circuits under moderate pressure. By redesigning the casing and conducting further tests, they were able to enhance the battery's safety and performance, reducing the risk of overheating and potential damage to the smartphone.
  • A laptop battery supplier used the machine to evaluate the durability of their batteries. The testing identified a weakness in the battery's internal structure, which could cause the electrodes to shift and short circuit when subjected to a certain level of extrusion. By improving the internal bracing and conducting additional tests, they were able to improve the battery's reliability and lifespan, ensuring the proper functioning of the laptops and enhancing customer satisfaction.
• Automotive Battery Testing
  • An electric vehicle battery manufacturer utilized the machine to conduct extensive tests on their high-capacity battery packs. The tests helped them optimize the battery's enclosure design and safety features. By detecting and addressing potential weak points, they were able to improve the overall safety and performance of the electric vehicles. For example, they were able to enhance the battery's resistance to impacts and vibrations, reducing the likelihood of a short circuit during driving and increasing the vehicle's safety and reliability.
  • A major automotive OEM used the Battery Extrusion Needle Test Machine to test batteries from different suppliers. The testing enabled them to select the most reliable and safe battery for their new vehicle models. By ensuring the batteries met their strict safety and performance requirements, they were able to provide customers with a high-quality and safe driving experience. The machine also helped them in setting up their own battery testing standards and procedures, which further enhanced their quality control and product development capabilities.
• Industrial Battery Testing
  • A manufacturer of industrial forklift batteries used the machine to evaluate the safety and durability of their batteries. The testing identified a potential issue with the battery's sealing, which could lead to electrolyte leakage under pressure. By improving the sealing technology and conducting further tests, they were able to increase the battery's lifespan and reliability, reducing downtime and maintenance costs for industrial customers.
  • A company producing backup power batteries for data centers used the equipment to test the batteries' resistance to mechanical stress. The testing ensured that the batteries could safely operate in a data center environment, providing reliable backup power in case of power outages and minimizing the risk of fire or other hazards. The machine's accurate detection and diagnosis capabilities allowed them to quickly identify and address any potential issues, ensuring the continuous and secure operation of the data centers.

7. Service and Support

• Pre-Sales Technical Consultation
  Our team of battery experts provides in-depth technical consultations to help customers understand the capabilities and suitability of the Battery Extrusion Needle Test Machine for their specific battery testing needs. We offer demonstrations and training to familiarize customers with the operation and functionality of the equipment before purchase. We also assist in selecting the appropriate test methods and accessories based on the battery types and applications to be tested.
• After-Sales Service and Maintenance
  We offer comprehensive after-sales service, including on-site installation and commissioning. Our technicians are available for regular maintenance, calibration, and emergency repairs. We provide spare parts and upgrades to keep the machine operating at peak performance. We also offer service contracts that include preventive maintenance and priority technical support, ensuring the long-term reliability and availability of the equipment.
• Training and Technical Support
  We conduct training programs for new users to ensure they can effectively operate the Battery Extrusion Needle Test Machine and interpret the test results. Our technical support team is available 24/7 to answer questions, provide troubleshooting assistance, and offer guidance on test method optimization and compliance with relevant battery standards. We also provide software updates and support for the data acquisition and analysis systems, enabling customers to take full advantage of the latest features and technologies in battery testing.