BATTERIES Testing for safe L


ithium batteries are a reliable and cost- effective power source, but there are still some safety concerns, especially when battery inventories are transported via aircraft. Testing is therefore required for all lithium batteries according to Section 38.3 of the United Nations Manual of Tests and Criteria: Lithium Battery Testing Requirements, commonly referred to as UN/DOT 38.3. This includes detailed information about the  batteries, the number of samples required for testing, and the minimum acceptable test results.


For transportation companies to accept lithium-ion batteries, tests must be conducted for each battery type for various  charge cycle, 50th


charge cycle). Five out


of eight tests are mandatory and apply to all cells and batteries, while the other three depend on what is being tested. To replicate a battery’s real lifetime usage tests must be  sequence of tests must be repeated if any of 


The following tests must be performed in this order:


Test 1 – Altitude simulation Simulates air transportation under low pressure conditions. During the test the battery is stored at 11.6 kPa or less for six hours at ambient temperature. Test 2 – Thermal test


Assesses the cell and battery seal integrity and internal electrical connections using thermal cycling to simulate rapid and extreme temperature changes. The test requires 10 cycles between +72o


C and -40o Test 4 – Shock


Imitates possible shock during transport- ation, with different test requirements according to the size of cells or batteries. The test includes a half-sine shock of peak acceleration of 150g and pulse duration of six milliseconds for small cells, and 11 milliseconds for large cells. Each cell or battery is also subjected to three shocks in the positive and three in the negative direction of the three perpendicular mounting positions - a total of 18 shocks. Test 5 – External short circuit Once stabilised at 55o


C, the battery is


subjected to an external short circuit with a resistance of less than 0.1 ohm for one hour. Test 6 – Impact


C,


six to 12 hours per cycle (depending on the battery size) with no more than 30 minutes between cycles, and is then observed for 24 hours at ambient temperature. Test 3 – Vibration


Simulates vibration that the product may be subjected to during transportation and uses a sinusoidal waveform with a logarithmic sweep from 7 to 200 Hz and back over 15 minutes. The cycle must be repeated 12 times for a total of three hours in each of three perpendicular mounting positions of the cell or battery.


Replicates the kind of impact that might be expected in transportation and is only applicable to cells and not batteries. The test involves a 9.1kg mass being dropped from a height of 61cm onto a bar across the cell. The cell is then observed for six hours. Test 7 – Overcharge


Evaluates how a rechargeable battery withstands overcharge . It is charged at twice the manufacturer’s recommended maximum continuous charge current for 24 hours and then observed for seven days. Test 8 – Forced discharge


12 SEPTEMBER 2025 | ELECTRONICS FOR ENGINEERS


The test evaluates cells’ ability to withstand a forced discharge at an initial current equal to  the manufacturer. Each cell shall be forced discharged for a time interval (hrs) equal to its rated capacity divided by the initial test current (A) and is then observed for seven days.


While tests 1 through to 5 must be conducted in sequence on the same cell sample, the overcharge test can be conducted using undamaged samples from earlier tests. However, the impact and forced discharge test must be conducted on cell samples not previously used for other tests.


Effective packaging


To ensure safety during transportation, the analysis of packaging integrity includes drop, stacking and topple tests.


Whether they are considered dangerous goods or not, all lithium-ion batteries also have strict labelling and documentation requirements. Those batteries listed as dangerous goods must also be accompanied by a Dangerous Goods Transport Document, which is a declaration from the manufacturer that what the transport company is conveying complies with the safety regulations.


transportation of batteries


Grant Gibbs, senior manager for energy storage atTÜV SÜD, 


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46