Design and Construction of an Automation System for Battery Drop Test Machine
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Abstract
This research presents the design and construction of an automated battery drop test machine developed to overcome the high costs of commercial equipment and the physical limitations of existing testers regarding large-scale battery research. The proposed system features an adjustable drop height ranging from 300 mm to 1500 mm and utilizes a stainless-steel hinge clamping mechanism for secure battery positioning. The control architecture is built upon a Siemens LOGO!8 PLC integrated with an HMI touchscreen, employing Finite State Machine (FSM) principles to ensure precise operation in both manual and automatic modes. To prioritize user safety, the machine is housed within a secure test chamber equipped with a CO2 fire suppression system and water cooling to mitigate thermal runaway risks.
Experimental validation was conducted following the testing protocols outlined in the IEC 62133 and MIL-STD-810H standards, utilizing battery samples weighing up to 80 kg. Results confirmed the machine’s ability to accurately release batteries in various orientations, including 6 surfaces, 12 edges, and 8 corners, with impacts consistently aligning with target positions. The system offers a flexible, cost-effective, and safe alternative for the continuous testing of diverse battery types, particularly those intended for electric vehicles and energy storage systems. Future work will focus on expanding compliance to include UN 38.3 and UL 2054 standards for international product certification.
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