Dongguan Yizhan Electronics Technology Co., Ltd. conducts vibration testing on its lithium battery packs to evaluate their mechanical stability under simulated real-world road conditions.
As part of the company’s battery quality-control process, each battery pack undergoes 10,000 vibration cycles designed to simulate the repeated vibration and bumps that a battery may experience during actual vehicle operation.
Simulating Real-World Road Conditions
Lithium batteries installed on e-bikes, electric scooters, electric motorcycles, and other mobile equipment can experience repeated mechanical vibration during daily use.
Uneven roads, speed changes, bumps, acceleration, braking, and vehicle movement can all create mechanical stress on the battery PACK.
For this reason, Yizhan conducts vibration testing to evaluate the structural condition of the battery under repeated vibration.
During the test, each battery PACK is securely fixed to the vibration testing equipment. The test equipment generates repeated vibration according to the defined testing parameters.
Each battery is subjected to 10,000 vibration cycles.
The purpose is to simulate repeated mechanical stress that can occur during actual road operation and to evaluate the battery PACK’s structural condition after the test.
What Does the Vibration Test Check?
A lithium battery PACK contains multiple components, including:
- Lithium battery cells
- Busbars
- BMS
- Wiring
- Connecteurs
- Capteurs de température
- Protection components
- Boîtier de batterie
- Internal fixing structures
Repeated vibration can place mechanical stress on these components.
During the testing process, attention can be given to the condition of:
- Boîtier de batterie
- Cell fixation
- Internal structures
- Welding points
- Busbar connections
- Connecteurs
- Wiring
- Installation du système de gestion de batterie (BMS)
- External appearance
After completing the specified vibration cycles, the battery can be inspected and evaluated according to the product’s testing requirements.
10,000 Vibration Cycles for Each Battery
Rather than testing only one sample and applying the result to an entire production batch, Yizhan’s specified testing process requires each tested battery PACK to complete 10,000 vibration cycles.
This means the vibration test is performed on the individual battery being evaluated.
The 10,000-cycle test provides a defined mechanical test workload for the battery PACK and allows the condition of the battery to be checked after repeated vibration.
The actual vibration frequency, acceleration, displacement, direction, and other parameters are determined according to the product design and applicable testing requirements.
The purpose of the test is not to reproduce every possible road condition, but to provide a controlled and repeatable vibration environment for battery evaluation.
Why Is Vibration Testing Important for Battery PACKs?
Battery performance is not determined only by electrical parameters.
A battery PACK installed on a moving vehicle also needs appropriate mechanical design.
If internal components are not adequately secured, repeated vibration may place stress on:
- Cell connections
- Welding points
- Busbars
- Wiring
- Connecteurs
- BMS components
- Battery housing
Vibration testing can help identify potential mechanical issues during battery development and quality control.
For OEM and ODM battery projects, the testing process can also provide engineering information for improving battery structure and component fixation.
From Battery Design to Testing
Yizhan’s battery development process considers the battery as a complete PACK rather than only a collection of cells.
Depending on the application, the development process can include:
Cell Selection → PACK Design → BMS Integration → Prototype → Aging Test → Vibration Test → Functional Test → Production
The vibration test is one part of the overall battery validation process.
Other tests may include:
- Essais de capacité
- Tests de charge et de décharge
- BMS protection testing
- Essais de température
- Tests de vieillissement
- Tests de communication
- Contrôle de l'isolation
- Waterproof testing where applicable
The specific test program is determined according to the battery application, customer requirements, product specifications, and applicable standards.
Designed for Different Mobile Applications
Different battery applications can have different vibration environments.
For example, batteries used in e-bikes and electric scooters may experience continuous vibration from road surfaces, while batteries installed in industrial vehicles may experience vibration from different operating conditions.
Yizhan provides customized lithium battery PACK solutions for applications including:
- E-bike batteries
- Electric scooter batteries
- Electric motorcycle batteries
- Golf cart batteries
- Batteries AGV
- AMR batteries
- Forklift batteries
- Logistics equipment batteries
- Industrial equipment batteries
Battery structure and testing requirements can be adjusted according to the equipment and application environment.
Testing Every Battery With a Defined Process
For a lithium battery manufacturer, quality control involves more than checking voltage and capacity.
Mechanical testing is also an important part of battery PACK evaluation for applications exposed to movement and vibration.
By conducting 10,000 vibration cycles on each battery under the specified testing process, Yizhan establishes a defined mechanical test procedure for the battery PACKs being evaluated.
The test results can then be used together with electrical, thermal, BMS, and aging test data to assess the overall condition of the battery.
À propos de Dongguan Yizhan Electronics Technology Co.
Dongguan Yizhan Electronics Technology Co., Ltd. specializes in customized lithium battery PACK development and manufacturing.
The company provides OEM and ODM battery solutions for e-mobility, industrial equipment, logistics equipment, robotics, medical equipment, marine applications, and energy storage.
Its services include:
- Lithium cell selection
- Battery PACK design
- Intégration du système de gestion de batterie (BMS)
- Développement de prototypes
- Test des batteries
- Soutien à la certification
- Production de masse
Vibration testing is part of the company’s battery quality-control and validation process.
For its specified vibration test procedure, each battery PACK undergoes 10,000 vibration cycles designed to simulate repeated vibration under real-world road conditions.
Through structured testing and application-specific battery design, Yizhan works with equipment manufacturers to develop lithium battery PACKs according to their electrical, mechanical, and operating requirements.
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