Accumulators and batteries must also prove their performance capacity under the most extreme conditions and prerequisites. Here our work focuses on characterising the accumulators under various operating conditions as well as determining their qualitative properties and investigating their behaviour during incorrect operation and in accident situations.

The electrical battery test is used to test the functionality of cells, modules and systems, to measure their performance and to determine their expected service life under defined loads and environmental conditions.

Using abuse tests, we can assess the reactions and potential risks of accumulators when there is extreme damage and also the resistance of accumulators relative to various abuse conditions and operating failures.


Dr. Olaf Böse
+49 731 95-30-551
Electrical tests

// Testing of large batteries, modules, and cells

Test facility for electrical batterym moduels, and cell testing. Bild: ZSW/M. Duckek
Test facility for electrical batterym moduels, and cell testing. Bild: ZSW/M. Duckek

"The electrical batterie test is used to test the functionality of cells, modules and systems for function, perforemance and lifetime under defined loads and defined environmental conditions."

To characterise electrical properties, performance and lifetime, the battery systems undergo performance and service life tests. The measuring tasks involve not only recording the physical variables of current, time, temperature and voltage, plus the mathematically derived variables, but also messages from the battery management system such as CAN or LIN bus.

Independent tests must prove that battery systems not only meet safety requirements but also satisfy a multitude of very demanding operating conditions in the automotive sector. Such requirements include:

  • Operating temperatures from -40 °C to +60 °C
  • Several thousand charge/discharge cycles and
  • More than ten years of calendar service life.

Batteries that are simultaneously used for the load management face additional challenges.

The combination of electrical tests in a temperature environment with mechanical stress is of increasing interest. The recording of mechanical variables, such as the development of power during charging, discharging and ageing (expansion or contraction), as well as the acceleration and resonances when stressed with vibration, is becoming more and more important.

Our services include tests on cells, modules and battery packs up to a power of 360 kilowatts. In addition, measurements on supercapacitors, as well as for peripheral devices and components of electrochemical energy storage systems can be provided.

Furthermore, we offer tests on the interaction of energy storage systems with automotive wiring systems according to LV123, LV124 and LV 148. Tests for battery systems are possible up to 500V/500A/100kW.


Dipl.-Ing. (FH) Harald Brazel
+49 162 2915631
Safety tests

// Abuse tests - from cells to complete battery systems up to 5 kWh

100 tons crush test. Source: ZSW/Bosa
100 tons crush test. Source: ZSW/Bosa

The safety of batteries and the analysis of their performance under all conceivable conditions, including extreme situations, have the highest priority for service in everyday life.

In our safety test centre we perform abuse tests on cells all the way up to complete battery systems up to 5 kWh. The tests on operational safety are performed according to specific customer requirements, or according to national and international test protocols.

Specially designed test bunkers with fire extinguishing systems, waste gas treatment, video monitoring and data recording are used for tests of this kind. Our services include mechanical, thermal and electrical safety assessments.


Michael Wörz
+49 731 9530-547

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