电芯和电池可靠性的测试和方法介绍.doc

WORKING INSTRUCTIONDOC. NO.:WI-284REV.:DDESCRIPTION:新产品设计验证测试指导书PAGE:14of14CHANGE HISTORYREVCHANGE DESCRIPTIONEFF. DATEPREPARED BYAPPROVED BYDEPT.ABCDNEW RELEASEAdd named rulesUpdate 5.1. Add For the series and parallelBattery capacity and cell balance check, when first make sample and first massproduction,update cycle life require, and add appearance check require12/11/201210/15/201310/31/201307/11/2014刘斌刘斌刘斌刘斌陈光辉陈光辉陈光辉陈光辉TETETETECONFIDENTIALITY( )TOP CONFIDENTIAL( )CONFIDENTIAL( )INTERNAL ONLYDISTRIBUTION( )MFG( )QA( )R&D( )FNC( )PMC( )PME( )SRC( )HR&A( )S&M( )PRJ( )IE( )TE( )BCU( )OTHERISSUE NO.: NO.: QF-003-01F1. Purpose (目的)规范本公司产品新产品设计验证测试项目、测试条件及判定标准Standardize the new product design verification test item、test condition and criteria.2. Scope (范围)适用于本公司新研发的所有型号电池产品Applicable to all the new battery products3. Definition (定义)设计验证：对产品的电池功能，可靠性，安全性进行验证,确保产品符合设计要求Design verification: verify the batteries protect function, reliability, safety whether meet the spec definition make sure the batteries meet design requirement.4. Responsibility (职责权限)4.1 R&D（研发部）:编制新产品设计计划，计划输入输出/输出, 完成客户产品的定义，输出产品规格书，新样品样板制作，设计转移，新零件/模具承认，编制产品规格书 Prepares the new product design planning, design input/output, Provide the product definition and specification basing on customers request. sample making, design transfer, the new Parts/molds verification, establishment product specification4.2 PRJ（项目工程部）:和客户沟通产品的需求，编制及执行品质控制计划，跟踪项目研发，负责安排样品试制，产品试产至量产全过程，对项目成不及项目过程中的风险进行控制,跟踪过程问题至解决。 Communicate with customer, understand customers requirement. Prepare and implement quality control flow chart (QCFC).Track the entire process of project from R&D, sample building, pilot production to volume production. Control the project costs and risks. Follow up all the issues until solved.4.3 S&M (市场营销部)：负责新项目立项，客户报价，售后服务，客户信息反馈。 In charge of the new project definition, customer quotation, after-sales service, customer feedback.4.4 QA（品质部）:负责新产品样品FAE与产品质量管理 Be responsible for new products quality management and FAE.4.5 TE（测试工程部）:负责产品测试设备，产品验证，可靠性验证测试，提供测试报告。 Be responsible for test equipment, product verification, reliability test, and summit test report.5. Instruction（作业指引）5.1 Test time：（测试时机）5.1.1 Proto type阶段，RD负责样品测试验证及报告At proto type step, RD is in charge of test verification and report5.1.2 对于多串并电池,第一次制样及第一次量产时，项目部需送3PCS到实验室进行容量及压差测试。For the series and parallel battery, when first made sample and first mass production, prj need send 3 pcs samplesTo lab do the capacity and cell balance check.5.1.3 产品进入EVT阶段，实验室负责完成设计验证At EVT step, laboratory. is in charge of complete design verification5.1.3项目部负责提供样品给实验室Project is in charge of provide the test samples to laboratory5.2 Design change（设计变更）如接下来设计有变更，R&D需针对变更项目及有影响项目重新测试，项目部需重新送样至实验室，实验室针对变更项目进行再次验证测试When the product design changed in next step, R&D must retest the affected items by the change retested, and PRJ need to apply for afresh test. According to the change lab will do the related test 5.3 Sample quantity：（测试数量） 根据测试标准，每一项测试需要测试验证3pcs，如有特殊要求，可以根据需要适当调整测试数量. For the test criteria, for each test item need 3pcs sample to verification. if there have special requests, it can adjust the test quantity by need5.4 Test item（测试项目） 5.4.1参考附件二 Reference the attachment two 5.4.2 当客户有特殊要求时，各项目的测试方法及判定条件按客户要求；The test method and criteria shall been in accord with the customer demand.5.4.3当实验室无法进行相关测试时，由项目部统一申请外送给有资质的供应商测试；When it cant be test by lab, prj shall apply for testing by the professional vendor.5.5样品测试完成后，测试人员须参照QSI-025-FM015A完成设计验证报告，再将测试报告交由实验室工程师及TE经理审批存档，并影印一份副本或者以邮件形式发给相关人员。After finished the test, tester should follow QSI-025-FM015A finished the report and submit to reliability engineer and TE Manager for approving, lastly make a copy of report or send report to the correlative persons.5.6可靠性测试的品质目标是零不合格。当测试不合格时，立即通知测试/项目/研发/品质部门等相关部门，组成FA分析小组一同对不合格进行原因分析，并制定纠正预防措施，且此批产品按照QEP-023不合格品控制程序处理；若该批次产品已出货给客户，须立即通知客户The target of reliability test is zero reject rate, if fail, immediately notify TE/PRJ/QA Related department, create FA Group to analyze the root cause then take corrective and preventive action, this product shall be handled according toQEP-023 Non-conforming Control Procedure, If this product had been shipped, we shall inform customer Immediately6 Named rules(测试报告命名规格)测试命名为测试类型+机种名称+发行日期+流水号，测试类型有设计验证（DT），可靠测试(RT)，抽样测试(OT)三种类型例如：8708可靠性振动测试报告，发行日期为2013-10-12，流水号为1 则命名为：RT-NNB8708-Vibration Test Report 2013101201Test type named + model name + issue date + serial number, test types for design verification (DT), reliable testing (RT), sampling test (OT) there tapesSuch as: 8708 reliable vibration test, release date for the 2013-10-12, serial number 1 is namedRT-NNB8708-Vibration Test Report 20131012017.ATTENTION（注意事项）： N/A8.REFERENCE DOCUMENT(参考文件):GB/T18287-2000UL-2054UL-1642UN38.3IEC-6100000-4-2UL-60950-19.RECORD(相关记录)：QSI-025-FM1510.ATTACHMENT(附件):Attachment one (附件一)设计验证测试流程图(Design verification test flow chart)Attachment two (附件二)No类别Type测试项目Item测试条件Test Condition判定标准Criteria 备注Remark1ReliabilityTest消耗电流测试Consume current check用DC电源代替CELL 设置不同电压读取不同状态的消耗电流Use DC replace the cell set different voltage ,use the meter measure the consume currentReference EE-Spec2过压保护功能检测（过充电/过放电）Over Voltage protection function test (over charge/over discharge)用DC电源代替CELL 设置慢慢调大或调小电压检查PCM板，过压保护功能检测是否正常。Use DC replace the cell, adjust the voltage to check PCM ,make sure the over voltage protection function is okReference EE-Spec3过流保护功能检测（过充电/过放电）Over Current protection function test (over charge/over discharge)放电过流保护。DC 电源输出接PCM板B+,B-,PCM P+,P-接电子负载，用电池负载OCP功能测试PCM 过流保护功能是否正常Over discharge protection powerconnecting with PCM B+ , B-and P+,P-with load, use OCP function, of load to check the over current protection function is normal or not充电过流保护DC 电源输出接PCM板P+,P-,，PCM B+,B-接电子负载，用电池负载OCP功能测试PCM 过流保护功能是否正常Over charge protectionDC power connecting with PCM P+,P- and B+ , B- with load, use OCP function, of load to check the over current protection function Reference EE-Spec4短路保护功能检测short protection function test用额定电流，满充电池,静置1小时，短路电池输出端，用示波器检查电池短路保护功能是否正常Charge full the battery with rate current, rest for 1 hour, short the output terminal, use oscilloscope to check the short protection functionReference EE-Spec5反充保护功能检测Reverse charge function test正负极反接后用DC充电，检测反充保护功能是否正常Connect P+,P- reversed with DC power to check the reverse charge function Reference EE-Spec6NTC 0/25/45不同温度阻值是否符合零件规格NTC Value measure in different temperatureNTC放入温箱，用安捷伦meter测量不同温度下的阻抗是否符合零件规格Put NTC into chamber, measure the impedance for NTC in different temperature, check it whether meet EE-SpecReference EE-Spec7电压精度检测（0/25/45）Temperature accuracy check（0/25/45）电池放入温箱，在不同温度下检测BQ显示电压和meter实际量测电压是否符合EE-SpecPut battery into chamber, check BQ voltage and the voltage measured by meter in different temperature, make sure it whether meet EE-SpecReference EE-Spec只适用于带 Gas gauge 电池8电流精度检测（0/25/45）Voltage accuracy check（0/25/45）电池放入温箱，在不同温度下对电池放电，检测BQ显示电流和实际测量电流是否符合EE-SpecPut the battery into chamber, discharge in different temperature and check the BQ current and the current measured by load, make sure it whether meet EE-Spec Reference EE-Spec只适用于带 Gas gauge 电池9温度精度检测（0/25/45）Temperature accuracy check（0/25/45）电池放入温箱，检测不同温度下BQ显示温度和实际测量温度是否符合EE-SpecPut battery into chamber, check BQ temperature and the real measured temperature, make sure it whether meet EE-SpecReference EE-Spec只适用于带 Gas gauge 电池10过温保护（充电&放电）Over Temperature protection(charge& discharge)根据EE-Spec，设置温度，检查BQ中过温保护功能在充放电过程中是否会起作用Refer to EE-Spec, set temperature to check the charge &discharge over temperature protection function whether okReference EE-Spec只适用于带 Gas gauge 电池110.2C5A放电性能0.2C discharge capacity标准充电后，休眠0.51h后，以0.2C放完电reset0.51 hour after standard charge full, use 0.2C discharge电池放电时间5hdischarge time5h121C5A放电性能1C discharge capacity标准充电，休眠0.51h后，以1C放完电reset0.51 hour after standard charge full, use 0.2C discharge电池放电时间51mindischarge time51 minutes13高温性能high temperature Capacity test标准充电后，电池放入552高温箱中，恒温2h,然后以0.2C放完电，然后取出在205环境下搁置2小时；standard charge, put the battery into 552,keep 2 hours ,then use 1C discharge to cutoff voltage, take out put it at 205 environment 2 hours电池放电时间5h，无变形，无爆裂。Discharge time 5h no distortion ,no crack14低温性能low temperature Capacity test标准充电后，电池放入102高温箱中，恒温4h,然后以0.2C放完电，然后取出在205环境下搁置2小时；standard charge, put battery into 102 environment ,keep 4 hours ,then use 0.2C discharge to cutoff voltage ,take out put it at 205 environment 2 hours电池放电时间3.h，无变形，无爆裂。Discharge time 3hno distortion ,no crack15恒定恒湿性能constant temperature & humidity test标准充电，电池放入452，相对湿度为9095的恒温恒湿箱中搁置72h，然后取出，在205搁置2h目测电外观，然后以0.2C放完电standard charge ,put the battery into 402/9095 environment 48 hours ,then take out put it at 205 environment 2 hours ,check appearance, use 1C discharge to cutoff voltage无明显变形、锈蚀、冒烟、爆炸；放电时间5hNo significant deformation, rust, smoke, explosion, discharge time 5h16ESDIEC-6100000-4-2Reference EE-Spec17内阻检测IR check用额定电流满充电池，静置1小时后用内阻测试仪量测内阻Use the rate current charge full the battery, rest 1 hour use the IR meter measure the IRReference EE-Spec18开路电压检测open circuit voltage check用额定电流满充电池，静置1小时后用万用表量测电池开路电压Use the rate current charge full the battery, rest 1 hour the use the meter measure battery open circuit voltageReference EE-Spec19循环寿命cycle life test按照产品规格进行充放电循环测试 Do the charge/discharge cycle test follow product criteria每100循环结束后满充电池检查内阻及厚度Each 100 cycle charge full battery check battery impedance and thicknessThe relative capacity 80%Thickness swell less than 10%Impedance in spec20Label 酒精耐摩擦测试Label alcohol test用棉布蘸上浓度最小为95%的酒精，用500g的压力摩擦15次Rub with a cotton cloth dampened in alcohol（95% min）Force: 500gTest cycles: 15 timesLabel 字迹能辨认，无划痕，无油墨脱落The label must be recognized. No scratches no ink off21Label 纸带剥离测试Label peel strength test用3M胶带完整的粘贴到label 上再以至少45度角拉扯胶带使之与label 分离，测试1次 Mack sure the tap(3M #610) totally sticks on the label. Remove the tap from label at 45 degree.Total is 1 timesLabel 字迹能辨认，无划痕，无油墨脱落The label must be recognized. No scratches no ink off22Label 纸带耐摩擦测试Label abrasion resistance test使用RAC压力为175g的测试设备摩擦label 3次175g, 3 timesUse RCA equipmentLabel 字迹能辨认，无划痕，无油墨脱落The label must be recognized. No scratches no ink off23Label 条码测试Label bar code identify酒精耐摩擦测试纸带剥离测试1. Alcohol resistance test2. Peel strength testBarcode 能扫描无划痕，无油墨脱落The bar code must can be scanned. No scratches no ink off24Label 存储测试Label Storage test把电池label面朝下放在材质为(Mitsubishi MB1700PC+ABS)的塑料板上，用100g砝码压在电池中心。Put battery with 100g loading on a plate(Mitsubishi MB1700PC+ABS)电池在以下温度条件下测试一次Temperature test condition for 1 cycle:Label 没有粘到塑胶板上没油墨脱落Without any label adhere to plateNo ink off25SafetyTest自由跌落drop test电池标准充电，将电池从1m的高度跌落到放置在水泥地面18mm20mm后的硬木板上，从X/Y/Z正负方向各跌落1次，跌落后，电池以1C放完电，然后以0.2C充电，放电时间不能低于51分钟standard charge ,drop the battery from 1m high to 18mm20mm hardwood platform ,X/Y/Y direction each 1 time ,total 6 times, after drop use 1C discharge ,then use 0.2 charge times ,the discharge time not less than 51min无明显变形、锈蚀、冒烟、爆炸，能放入设备中；放电时间51minNo significant deformation, rust, smoke, explosion, discharge time 51min可选项目26振动vibration test将电池稳固地有保护地固定在振动平台上，不要扭曲电芯，以便振动能很好的传送，振动频率按正弦波形在15分钟内按对数方式从7 Hz扫描到200 Hz 再回到7 Hz，振动沿电芯互相垂直地三个方向进行，每一个方向按上述循环重复12次，用时共3小时，振动方向中的一个必须垂直电芯和电池的最大面；对数扫描频率如下：维持1gn的峰值加速度，从7 Hz一直扫描到18 Hz，振幅维持在 0.8mm(整个行程1.6mm)，同时频率增长，直到峰值加速度达到8gn（约50 Hz），然后维持8gn的峰值加速度，直到频率增长到200Hzfix up the battery on the vibration plat, the frequency use sine wave from 7HZ to 200HZ in 15 minutes and down to 15 HZ ,the there vibration direction each other perpendicularity, each direction repeat 12 times, total 3 hours; logarithm scan frequency as below, keep 1gn peak acceleration, from 7HZ to 18HZ,the extent keep 0.8mm,and the frequency raise, until the acceleration to 8gn(about 50HZ),and then keep 8gn peak ,until frequency reach to 200HZ无明显变形、锈蚀、冒烟、爆炸；电压3.6VNo significant deformation, rust, smoke, explosion, Voltage 3.6V27热冲击heat shock safety将电池在温度为752的环境中存储至少6小时，接着在温度为-402的环境中存储至少6小时。极端温度变化的时间间隔最长为30分钟。重复上述过程10次，然后将样品在温度为205的环境中放置24小时；对于大电池，在极端温度中搁置的时间至少为12小时。Put the battery into 752 environment at least 6 hours, then change the temperature to -402 keep the battery in that environment at least 6 hours, the temperature charge rate is no exceed 30 minutes, repeat 10 times, put the battery into 205 environment 24 hours, for the big battery put it to the extreme temperature no less than 12 hours不起火，不爆炸no fire ,no burst可选项目28强制放电测试Force Discharge在环境温度下将测试电芯与一个12V的直流电源串联起来进行强制放电，直流电源初始电流等于制造商指定的最大放电电流；把一负载与直流电源串联，这个负载的阻抗与测试电芯阻抗相当，这样可以获得指定的放电电流；测试电芯的额定容量除以初始测试电流（安培）等于被迫放电的时间（小时）。In environment temperature ,series the DC and cell force discharge, the DC original Current is the max discharge current test time=cell rate capacity/original Current(A)1.不起火、不爆炸2.不起火、不爆炸、不漏液1. no fire ,no burst2. no fire ,no burst , no leakage可选项目29强制放温度循环测试Temperature cycle test1.样品在一自然对流或强制对流烘箱中加热，烘箱温度以52/min速度升温至130，并保持10min后停止。25热循环测试2.电池放于测试室内并承受以下循环：a)30min内升温至703，保温4h。b)30min内降温至203，保温2h。c)30min内升温至403，保温4h。d)30min内降温至203。e)重复上述循环9次。f)10次循环后，电池放置7天待检。1.Put the battery into temperature chamber the temperature rise rate is 52/min reach to 130 ,keep 10 minutes stop ,cycle 25 times2.put the batteries into the temperature chamber do below testa) rise temperature to 703 from room temperature keep 4 hoursb) down the temperature to 203 keep 2 hoursc) rise temperature to 403 keep 4 hoursd) down the temperature to 203e) repeat 9 cyclesf) after 10 cycles reset 7 days ,check the batteries不解体，不起火No rupture , no fire30过充电保护性能over charge protect电池标准充电后，用恒流恒压源持续给电池加载8小时，电压为标称电压的2倍，电流为2Cstandard charge, use constant current source charge 8 hours ,voltage is 2C standard voltage, current is 2C standard current不起火、不爆炸、不冒烟、不露液no fire, no burst, no smoke, no leakage31过放电保护性能over discharge protect在205温度下，0.2C放完电后，外接30 Ohm电阻放电24hat 205 environment 0.2C discharge to cutoff voltage ,then connect with 30ohm resistance discharge 24 hours不起火、不爆炸、不冒烟、不露液no fire, no burst, no smoke, no leakage32短路保护性能short protection test电池标准充电后，外接0.1 Ohm电阻，短路1h,将正负极断开，以1C电流充电5s后，测电池电压Reset 1 hour after charge full, check the OCV and impedance, use resistance 0.1ohm short the output terminal 1hour ,then use 1C current charge 5s check voltage不起火，不爆炸，电池表面温度不超过150 no fire ,no explosion ,battery surface temperature no more than 15033过充电over charge test最大充电电流的2倍,测试最低电压为制造商建议的最大充电电压的2倍；测试在环境温度下进行，时间为24小时use 2C voltage and 2C current ,continues charge 24 hours测试后的7天内可充电电池无解体，无起火after test 7 days ago the battery can charge and discharge ,no leakage, no fire34异常充电测试abnormal charge test以0.2C放完电，再以3倍电池最大充电电流，以电池最高充电电压为限制，充电至少7h或达到生产商规定的充电结束条件。After use 0.2C discharge ,then use 3C maximum current ,maximum voltage charge 7 hours不起火，不爆炸。No fire , no burst35强制放电测试Force discharge test 一个完全放电的电池被强制性串联同型号的满充电池，串联满充电池数目等于串联应用的最大数目减1个，当完全放电的电池与特定数目的满充电池串联好后，对形成的电池组进行短路测试。将电池组的正负极用电阻小于0.1欧姆的负载短接，并监控电池表面温度变化；当电池组着火，爆炸，或电压低于0.2V且表面温度回到环境温度10 时停止测试。Discharge the battery until cut off voltage ,the series battery must series the same cell, serine battery quantity is the series applies -1 ,when full discharge battery seriated, short the battery pack use 0.1ohm resister ,monitor the battery surface temperature ,when battery pack fire ,burst ,or the output voltage low than 0.2V and the battery pack surface temperature return to environment temperature 10 stop test不起火，不爆炸。No fire , no burst36 常温短路External short test满充后，搁置1h,测OCV和电池内阻，然后用电阻0.1ohm的负载短接电池正负极，并监控电池表面温度，当电池着火、爆炸或者当电池电压低于0.1V且电池表面温度降到高于环境温度10以下时停止测试Standard charge put it at 205 environment 1 hours ,blackout the PCM, use 100 mom resistance short the cell ,when the battery surface temperature low than tiptop temperature 10 stop test不起火，不爆炸，电池温度150no fire ,no burst ,battery temperature 15037挤压测试Crush test满充后，搁置1h,测OCV和电池内阻，电池将在两个平面之间被挤压，最大压力不小于13kN，一旦压力达到13kN应立即卸压，charge full the battery reset 1 hour, check OCV and impedance ,extrusion the battery between two plane, the stress no less than 13KN不起火，不爆炸no fire ,no burst可选项目38高加速冲击acceleration shock test面充电，将电池被有保护的固定在冲击台上，每个电池承受峰值加速度为150 gn，脉冲宽度为6毫秒的半正弦冲击，每个电池将沿着三个互相垂直轴的正负方向每个方向冲击3次，共18次charge full the battery ,put the battery on the shock platform, each battery endure acceleration peak value is 150gn,pulse width 6ms half sine shock, each battery shocks 3 times for X/Y/Z direction total 18 times电池无质量损失、无漏液、无排气、无解体、无开裂、无着火，测试后开路电压不低于测试前的90% battery no lose, no leak, no disjoint, no rupture ,no fire ,the OCV no less than 90% ,39撞击测试impinge against test满充后，搁置1h,测OCV和电池内阻，把电池放在一平面上，将一直径15.8mm的铁棒横放在电池的中心，让一重9.1Kg的铁块从61 2.5 cm的高度跌落到电池上charge full the battery ,reset 1 hour, check the OCV and impedance