We provide causation findings and solutions to product failures both in the lab and in the field. Unknown cause events often cause production to stop ship, recalls, and we are honored to provide clear answers and risk analysis in these tough times.
Fire investigators are rarely trained subject matter experts in battery pack failures. This often results in the battery being blamed, even if it were only involved by not causality. We approach forensic analysis with the expertise needed to prove your product's innocence, or explain root causality. Our presence helps identify and protect against common battery forensics mistakes or overlooked details during analysis.
Many batteries in the wild will face condensing humidity cycles, corrosive road salt droplet spray, dilute acid gas exposure, and more. Standards like IP67 or IP69 lead to false positives of environmental integrity. We have developed proprietary testing solutions to produce accelerated and repeatable quantification of environmental risks to performance and safety.
We offer test plan creation, audits, and guidance. We have a library of proven effective internal tests and custom test fixtures to encompass every type of electrical test, thermal behavior, environmental ruggedness, and cell or pack safe and unsafe operating conditions.
We validate each power component's operating parameters under ideal bench-testing conditions to find the safe temperature current-carrying ampacity, as well as the excessive current-induced failure bounds. After a component level understanding, the bare components are assembled into the application representative power bus, and ampacity and component operating temperatures and excessive current-induced failures are compared with the individual component test data to characterize reliable safe operating margins.
Our calorimeter is the largest and most capable ARC used for battery thermal runaway energy release, temperature, and pressure is quantified. This enables iterative cell development for safety improvements, or battery pack level safety system energy mitigation design effectiveness.
We perform verification of specifications to confirm solutions for battery components and materials. Our R+D continuously feeds materials and processes into the industry to improve readily available products.
Adhesives and encapsulation potting material properties require specific preparation methods. Through iterative adhesive joint refinement and development, we create optimum processes for challenging bonded joints.
We provide testing and guidance of long-term material behavior properties, including dielectric breakdown and ionic migration degradation.
We provide system and design overviews to enhance life expectancy, reliability, and flag any potential risks issues early. Our team has niche skills with ionic migration risks, electro-magnetic interference, material compatibility, state of charge algorithms, thermal analysis and more.
We share our real world experience in power component reliability and performance. If a custom part is needed to meet your applications needs, we create design specifications and assist with sourcing custom manufacturing and quality validation.
We provide technical design guidance and testing to pass the feasibility and risk assessment gates presented by cell providers before negotiating commercial contracts.
We have quantified various interconnect methods in a decision matrix based around more than 16 years of real application experience. Safe and reliable cell interconnect process without causing cell damage is mission critical for all battery systems.
We provide guidance on tool specifications and user techniques and skills needed to achieve success in analysis, testing, processes, and equipment for battery, motor, and related component validation manufacturing.
Our team has been instrumental in establishing successful battery manufacturing lines globally for our clients. Our team serves as an asset for new lines or during existing established lines looking to streamline and reduce manufacturing fall-out.
We provide various testing for cell development. Specialities include cycling under forced thermal gradients across cells, heat capacity and thermal conductivity across each axis, destructive and non-destructive performance qualification and abuse testing.
Our custom vacuum test chambers provide aircraft and space applications with electrical, thermal, and safety validation under application representative atmospheric conditions.
Leveraging thermal runaway cell data along with endothermic and ablative material test data enables lowest number of iterative development steps to meet safety and performance objectives.