Meeting Global Safety Standards: UN38.3 Certification
Transporting lithium batteries safely requires compliance with the UN38.3 certification, which is mandatory for ensuring secure logistics. One of the key tests in this certification process is the T4 – Shock Test, which evaluates whether batteries can withstand mechanical shocks likely to occur during transportation. By simulating real-world transport conditions, this test ensures that batteries remain intact and operational throughout shipping and handling processes.
UN38.3 T4 – Shock Test Parameters:
- Pulse Type: Half-sine wave shock pulse
- G-Value & Duration:
- 150g for 6ms – Small cells/batteries
- 50g for 11ms – Large cells/batteries
- Number of Shocks: 3 shocks per direction (Total 18 shocks)
- Directions: ±X, ±Y, ±Z (Total 18 shocks)
- Objective:
- Verify that the battery remains intact and safe with no leakage, rupture, fire, or explosion.
- Ensure voltage remains stable post-test.
In addition the RRC Company standard required that the battery has to be fully functional after this test - not even save!
Customized Tests Beyond the Standard
Our batteries are tested according to globally recognized DIN standards. These standards define the requirements for shock and vibration tests to ensure the mechanical stability and functionality of batteries. However, not all use cases are the same, and sometimes our customers require specialized tests that go far beyond the standard regulations. One such test requested by our customers is the RTCA DO-160G crash safety test. This test is specifically designed for electronics in airborne equipments.
RTCA DO-160G – Crash Safety (20g) Test
RTCA Do-160G Section 7 – Operational Shock and Crash Safety, ensures that electronic equipment, including batteries, can withstand the high-impact forces experienced during crashes or emergency landings. This test simulates extreme scenarios that may occur in aerospace applications or highly vibrating vehicles such as helicopters.
Test Parameters:
- Force Applied: 20 times the force of gravity (20g)
- Directions: All six directions (±X, ±Y, ±Z)
- Number of Shocks: 6 shock per direction (Total 36 shocks)
- Mounting: Equipment is mounted as it would be in real-world operation
- Objective: Ensure structural integrity, no detachment, and safe failure (no fire, explosion, or hazardous leakage).
At RRC, we go beyond the standard requirements to ensure exceptional reliability and safety. While the test mandates applying one shock per direction, we take it a step further by applying 100 shocks in all six spatial directions. This rigorous approach ensures the battery endures not only vertical and horizontal forces but also rotational impacts and unpredictable jolts, replicating real-world conditions more accurately. Thanks to our state-of-the-art test facilities, we can accurately replicate these real-world conditions and determine the limits of our batteries.
Going Beyond Standard Requirements
For shock and vibration testing, we push the boundaries even further. Instead of applying just one shock per direction, as required by standard testing, we go beyond and apply 100 shocks per direction. This approach allows us to gain deeper insights into battery performance under prolonged mechanical stress, ensuring maximum reliability in real-world applications.
Why Are These Tests Crucial?
Our customers rely on their batteries to be operational at all times, regardless of the environmental conditions. Insufficient resistance to vibrations and shocks can lead to serious problems, including performance loss, internal cell damage, or complete failure. This is particularly critical in safety-sensitive areas such as medical technology, where our batteries power life-sustaining devices.
A real-world example: In a rescue helicopter, a stable power supply is essential. Strong vibrations from rotor blades, air turbulence, and sudden directional changes put technical components under extreme stress. Our tests ensure that the battery maintains its full performance even under these conditions.
Superior Service for Our Customers
We understand that every customer has unique requirements. Our testing procedures are designed to meet these specific needs. We go far beyond minimum requirements and tailor our testing methods accordingly. Thanks to our extensive testing facilities, we can not only comply with existing standards but also implement customized tests and develop innovative solutions. This gives our customers the assurance that their batteries will perform reliably even in the most demanding applications.
Our experts continuously work on advancing testing procedures to tackle new challenges in battery technology. With cutting-edge measurement technology and years of experience, we can precisely determine stress limits and find ways to make batteries even more resilient.
A Look Behind the Scenes
In our latest "Behind the Battery" episode, we provide an exclusive look at how this advanced shake test was conducted. Join us as we subject our battery to extreme stress and analyze how it performs under these conditions.
Stay tuned for more exciting insights behind the scenes of our test labs. In the next episode of "Behind the Battery," we’ll take you further into the world of battery technology!
