Environmental Testing IS 16893 (Part 2) : 2018/IEC 62660-2 : 2010

Reliability is the backbone of the electric vehicle ecosystem. IS 16893 (Part 2) is the critical Indian Standard designed to characterize the behavior of lithium-ion cells under extreme stress and abuse conditions. Unlike basic safety checks, this standard provides deep data on how cells degrade or fail when pushed to their limits, ensuring that the Battery Management System (BMS) is designed with accurate safety margins.

Key Objectives:

• Behavioral Analysis: Understanding failure modes (venting, fire, rupture) under abuse.
• Durability Verification: Assessing long-term reliability under mechanical and thermal stress.
• System Integration: Providing essential data for the design of safe battery packs.

This testing regimen operates under the dual-reference model, ensuring both national and international market acceptance.

• Indian Standard: IS 16893 (Part 2): 2018
• International Equivalent: IEC 62660-2: 2010
• Title: Secondary lithium-ion cells for the propulsion of electric road vehicles — Part 2: Reliability and abuse testing.

This standard is strictly applicable to Secondary Lithium-Ion Cells intended for the propulsion of electric road vehicles. It covers the two primary classes of EV applications:

• BEV (Battery Electric Vehicles): Cells designed for high energy density and long range.
• HEV (Hybrid Electric Vehicles): Cells designed for high power density and rapid charge/discharge cycles.

The testing scope is rigorous, divided into three distinct categories to simulate real-world catastrophic scenarios and operational stress.

Mechanical Abuse:

• Vibration Testing: Simulating road noise and chassis vibration.
• Mechanical Shock: Simulating impact loads (potholes/collisions).
• Crush Test: Simulating physical deformation during a crash.

Thermal Abuse:

• High-Temperature Endurance: Validating stability at elevated temperatures (typically 130°C).
• Temperature Cycling: Stress-testing material expansion/contraction.

Electrical Abuse:

• External Short Circuit: Testing current interruption capabilities.
• Overcharge: Testing resilience against BMS failure.
• Forced Discharge: Simulating deep discharge scenarios.

To ensure your test reports are accepted by regulatory bodies (such as for PLI schemes or AIS approvals), testing must be conducted at a facility with the following credentials:

• NABL Accredited: Conforming to ISO/IEC 17025 general requirements.
• BIS Recognized: Listed under the Bureau of Indian Standards LIMS scope.

Due to the destructive nature of the tests and the duration of thermal cycling, this standard requires a methodical approach.

• Standard Lead Time: 4 to 6 weeks from sample receipt.
• Expedited Services: Available upon request (subject to chamber availability).

Since most tests in Part 2 are destructive, a significant number of samples are required to run tests in parallel sequences.

• Quantity: Typically 30–40 cells (depending on the specific lab's batching process).
• Condition: Cells must be fresh (manufactured within 3 months) and shipped at 30%–50% SOC (State of Charge) unless specified otherwise.

Costs are calculated based on the specific cell chemistry and capacity (Ah), as higher capacity cells require specialized containment chambers for safety during abuse testing.

• Pricing Model: Per Project / Per Cell Model.
• Contact us for a tailored quotation based on your cell specifications.

To initiate the testing process smoothly, the following technical documentation is mandatory:

• Cell Datasheet: Detailed specifications including nominal voltage, capacity, and dimensions.
• ISO 9001 Certificate: Of the cell manufacturer.
• UN 38.3 Report: Prior transportation safety test report (if imported).
• CCL (Critical Components List): Details of the cathode, anode, separator, and electrolyte.