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Battery Testing for Rail Applications

Battery testing for rail applications ensures that lithium-ion (Li-ion) batteries comply with IEC 62928 standards for passenger and freight rail systems. At Clark Testing, we offer a comprehensive range of battery testing services tailored to meet the certification requirements of IEC 62928, IEC 61373, UL 1973, EN 50155, and UN 38.3 standards.

Advancing Rail Technology

Modern rail systems, including electrified and diesel trains, are now integrating battery hybrid systems. Battery technology enables the operation of battery-powered trains on partially electrified branch lines. In many cases, these batteries can be recharged during travel via a pantograph, offering a sustainable and efficient solution.

Compliance with IEC 62928 Standards

The design, operation, and safety parameters for lithium-ion batteries used in trains are typically governed by the IEC 62928 standard. This standard applies to energy storage systems (ESS) for the traction power of railway vehicles, including hybrid vehicles. Given the varied conditions such as vibration and temperature fluctuations that onboard train batteries are exposed to, IEC 62928 provides specific standards for design, operation, and load requirements for rail applications.

Enhancing Safety and Reliability

Battery testing for railway equipment is crucial for reducing potential failures and minimizing the risk of hazards associated with batteries used in rolling stock. Ensuring the safety and reliability of passenger rail systems through rigorous battery testing upholds the highest standards of IEC 62928, applicable to both city transit systems and long-distance metro trains.

Growing Utilization of Battery Systems

There is a continuous increase in the use of battery packs and systems in the rail sector, for both hybrid and all-electric traction. While lithium-ion batteries can be hazardous if not properly designed and utilized, validation testing is essential for identifying potential issues and enhancing the design of train batteries.

Comprehensive Testing Services

From the initial test plan preparation to the final certification, Clark Testing provides a thorough and reliable testing process for rail battery systems. Our services include:

  • Developing a Qualified Test Plan:  Clark’s engineering team work with our customers to coordinate the test plan with the design criteria while accommodating the IEC standards.
  • Validating Battery Design: Ensuring the battery meets design specifications.
  • Safety & Reliability Testing: Conducting tests to guarantee safe and reliable battery performance.
  • Compliance Testing: Ensuring lithium-ion batteries comply with standards such as IEC 62928, UL 1973, and EN 50155.
  • Issue Certified Test Report:  Upon conclusion of the test, Clark provides our customers with a comprehensive test report detailing all aspects of the validation program.

Specialized Testing Facilities

Our team of test engineers at Clark Testing will develop a rigorous test program in accordance with EN 50155 for railway applications, rolling stock, propulsion systems, and electronic rail equipment. Our laboratories provide the ideal environment for testing train battery designs and performance.

Testing Standards and Procedures

Clark Testing offers a wide range of railway battery testing and certification services for lithium-ion traction batteries used in rail applications:

  • Load Testing: Simulates a full load to measure the battery’s performance under actual operating conditions.
  • Voltage Testing: Measures the voltage levels to identify weak or failing cells.
  • Impedance Testing: Assesses internal resistance to predict battery life and potential failures.
  • Charge-Discharge Testing: Batteries undergo repeated charge-discharge cycle test to determine the number of cycles the battery can endure while maintaining specified performance levels.
  • Capacity Testing: Batteries are tested to determine their actual capacity compared to their rated capacity ensuring that the batteries meet the required energy storage specifications.
  • Short Circuit Testing: Batteries are subjected to short circuit conditions to evaluate their safety features and the ability to withstand internal faults without prompting failures.
  • Dielectric Testing:  Dielectric testing known as high potential test, hipot test, or insulation test applies a high level of voltage to the insulation barrier and measure the reaction.
  • Isolation Testing:  Isolation testing ensures batteries are free from unwanted electrical connections that could lead to short circuits particularly in high-voltage applications.
  • Overcharge Testing:  Overcharge testing is vital, particularly for Lithium-Ion batteries, for ensuring the safe use in consumer electronics, electric vehicles, eMobility, industrial, military and other applications.
  • Seismic Testing: Simulates the operating environment ensuring the battery generator, battery back-up or UPS system will operate despite the effects of an earthquake.
  • Vibration Testing: Batteries are subjected to a vibration profile emulating the vibration cycle in the field of operation.
  • Mechanical Shock Testing: Batteries are subjected to mechanical shocks to verify the structural integrity of the battery housing and its components.
  • Destructive/Abuse Testing:  Batteries are subjected to thermal runaway, drop test, penetration test and crush test to assess how batteries react to harsh conditions
  • Electromagnetic Compatibility (EMC/EMI) Testing: Batteries are tested for electromagnetic emissions and interference to ensure they do not interfere with other electrical and electronic systems.
  • Thermal Cycling: Batteries undergo heating and cooling cycles simulating the thermal stress determining the reaction to standard and critical operating conditions.
  • Material & Chemical Analysis:  Clark provides a complete profile of the elemental analysis and chemical properties of the base raw materials and battery cell.

Additional Testing Services

Clark Testing also provides:

  • EN 50155:2017 Tests: Including environmental tests, battery vibration testing as per EN 61373, and EMC tests according to EN 50212-3-2.
  • UL 1973 Tests: For batteries used in Light Electric Rail (LER) applications and stationary applications.

With Clark Testing, you can trust that your rail battery systems are tested to meet the highest safety and reliability standards.

“For over 30 years, the team at Clark Testing has partnered with our customers to guide them through the product validation and qualification process. We are a quality driven company, functioning as an extension of our customers’ engineering, product development and R&D staff to meet the technical challenges and schedule demands of the product development process. ”

Paul Heffernan