The wide application of battery technology, especially in the field of electric vehicles, energy storage systems and portable electronic devices, the safety and reliability of battery Pack become the key link of product development. In order to ensure the safety of battery Pack in the process of design, manufacture and transportation, a series of strict testing standards have been formulated internationally, among which ISO 12405 series standards and UN proposal on transportation of dangerous goods 38. Clause 3 (UN38.3) is an important norm widely adopted in the industry. This article focuses on the development and verification of battery Pack, and introduces in detail the main contents and application requirements of ISO 12405 and UN38.3 to help developers understand and implement the standard requirements and ensure product compliance and safety.

I. Overview of ISO 12405 series standards

ISO 12405 is a set of international standards for performance and safety testing of lithium ion batteries and their systems (including battery Pack). This series of standards is divided into several parts, covering the design verification, electrical performance, safety characteristics and environmental adaptability of battery Pack.

1. ISO 12405-1: Performance Test

this part mainly stipulates lithium ion battery pack's charging and discharging performance test method, including capacity test, cycle life test, energy efficiency, etc. Through strict performance tests, the development team can evaluate the performance of the battery Pack under actual working conditions to ensure that it meets the design indicators.

2. ISO 12405-2: safety test

security testing is one of the most critical links in battery Pack development. This section defines in detail the safety performance evaluation methods of battery Pack in various extreme environments and fault states, including overcharge, overdischarge, short circuit, collision, extrusion, thermal shock and other tests. Through these tests, potential security risks can be found and design improvements can be guided.

3. ISO 12405-3: environmental adaptability test

this section focuses on the performance stability and safety of battery Pack under high and low temperature, vibration, humidity, salt spray and other environmental conditions. Environmental adaptability test ensures that the battery Pack can work normally in complex and changeable practical application environments without performance degradation or safety accidents.

4. ISO 12405-4: electrical performance and life evaluation

this section further refines the electrical safety performance of the battery Pack, including insulation test, electric strength test and electrical durability evaluation. Through life assessment, developers can master the long-term reliability of battery Pack and provide basis for product quality assurance.

II. Introduction to UN38.3 standard

UN38.3 is the abbreviation of clause 38.3 of the United Nations "proposal on the transport of dangerous goods", aiming at the test requirements formulated for the safety of lithium battery transportation. This standard is a prerequisite for compliance with lithium battery transportation worldwide.

1. UN38.3 test content

UN38.3 covers a number of tests for lithium batteries, mainly including:

• height simulation test: simulate the low air pressure environment that the battery may encounter during transportation to prevent the battery from being damaged due to air pressure changes.
• Thermal cycle test: investigate the safety of the battery in the alternating environment of high and low temperature.
• Vibration Test: simulate the influence of transportation vibration on battery structure and performance.
• Impact test: test the battery's tolerance to mechanical impact during transportation.
• Short circuit test: assess the safety risks in case of short circuit of the battery.
• Overcharge test: verify the safety performance of the battery under overcharging conditions.
• Forced discharge test: test the safety performance of the battery in abnormal discharge state.

2. Certification requirements

passing the UN38.3 test is a prerequisite for lithium battery products to enter the international market for transportation. The battery Pack must complete relevant tests in a laboratory that meets the requirements of UN38.3, and obtain test reports and certificates of conformity before it can be legally transported by air, sea and land.

III. Standard applications in the battery Pack development and verification process

during the development and verification of battery Pack, ISO 12405 and UN38.3 standards complement each other, covering the whole life cycle from design verification to transportation safety.

1. Design phase

the development team shall conduct performance and safety tests of the battery Pack according to ISO 12405-1 and 12405-2 to ensure that the design meets the electrical performance and safety indicators. At this stage, the design defects are identified and optimized by simulating safety tests under extreme working conditions.

2. Test verification phase

after completing the design optimization, perform ISO 12405-3And 12405-4 environmental adaptability and life test to verify the reliability of battery Pack in different use environments. Test data is an important basis for design improvement and quality control.

3. Transportation verification phase

after completing the product design and performance verification, the transportation safety test should be conducted according to the UN38.3 standard to ensure that the battery Pack can safely pass all kinds of transportation links. UN38.3 test qualification report is a necessary document for product transportation license.

4. Production and quality control stage

in the process of batch production, the production inspection and quality control process shall be formulated according to ISO 12405 standard to ensure that each batch of products continuously meet the design and safety requirements. At the same time, combined with the test requirements of UN38.3, the transportation safety risks are continuously controllable.

IV. Key considerations in standard implementation

• test Lab selection: select a third-party testing organization with qualifications to ensure that the test results are authoritative and reliable.
• Sample preparation: the sample should meet the design specifications, representing the characteristics of batch products, and should be fully pre-processed before testing.
• Data recording and analysis: Strictly remember the whole processRecord test data, conduct system analysis, and timely feedback to the design team when potential problems are found.
• Regulatory compliance: in addition to ISO 12405 and UN38.3, attention should also be paid to transportation regulations and industry standards in various regions to ensure full compliance of products.

The full set of ISO 12405 standards and UN38.3 transportation safety standards together constitute the core framework for the development and verification of battery Pack. ISO 12405 ensures the technical reliability and safety of battery Pack design through system performance, safety and environmental adaptability tests; UN38.3 ensures the safety and compliance of battery Pack in global transportation.