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Dongguan Juneng New Energy Technology Co., Ltd.
137 5142 6524（Miss Gao）
susiegao@power-ing.com
Xinghuiyuan High tech Industrial Park, Dalang Town, Dongguan City, Guangdong Province
72 Hours for a Piece of Battery Pack: from Offline to Loading, What Has It Gone through-the Documentary of the Whole Process of Factory Testing of Juneng New Energy
time：2026-07-28
At six o'clock in the morning, the test center of Juneng new energy PACK factory was brightly lit. A piece of power PN20260728001 numbered battery pack has just been offline, and its "graduation exam" is about to begin. In the next 72 hours, this battery pack will undergo dozens of rigorous tests, and any failure to meet the standards will be intercepted before loading. Let's follow its steps and witness a test of safety and quality.
Day 1: electrical performance "physical examination"-accurate calibration of energy and efficiency
Hour 0-8: capacity and energy efficiency test
battery pack is connected to the charge and discharge test cabinet to start the first complete 0.5C charge and discharge cycle. The test cabinet records the voltage, current and temperature data every second with milliampere accuracy. After 8 hours, the measured capacity is 101.2% of the nominal value, and the energy efficiency reaches 91.5%, both of which are better than the design goal.
"The capacity exceeding 100% is not 'profiting', but we reserve the attenuation margin. "The test engineer explained," the new battery pack slightly exceeded the design value when leaving the factory, in order to offset the irreversible capacity loss in the early cycle and ensure that the client always 'enough cats '. "
Hour 8-16: DC internal resistance and self-discharge rate test
the pulse current is injected into battery pack, and the internal resistance curve is accurately drawn under different SOC States. Then, battery pack enters the static mode, and the voltage monitoring system will record the self-discharge data for 7 consecutive days. Internally controlled Standard of the new energy source is twice as strict as that of the national standard-the self-discharge rate must be less than 0.3%/month, and any abnormality means potential micro short circuit risk.
The next day: Safety "stress test"-life and death test under extreme working conditions
Hour 24-32: overcharge and overdischarge protection verification
the test system simulates the BMS failure scenario and forcibly charges battery pack to 110% of the rated voltage. When the voltage reaches the threshold, the hardware protection circuit cuts off the loop in milliseconds, and the temperature of the battery pack only rises by 1.2 ℃, without drum bag or leakage. The over-discharge test is also rigorous-after discharging to 0V, the voltage balance of cell is still good without irreversible damage.
Hour 32-40: short circuit test
the positive and negative electrodes are shorted through low resistance wires, and the instantaneous current peak exceeds 2000A. The fuse and relay double protection of the new energy source respond within 5 milliseconds. The temperature of the battery pack shell does not exceed 40 ℃, and there is no fire or explosion. After the test, disassemble and check. Busbar solder joints are intact without melting marks.
Hour 40-48: thermal runaway spread test
this is the most breath-taking link. The tester triggers the thermal runaway of a single heater band in the module through cell, and the infrared thermal imager tracks the temperature propagation path throughout the process. Aerogel heat proof mat locks the heat in the local area. The temperature of adjacent cell does not exceed 80℃. The pressure relief channel releases high temperature gas directionally. There is no sign of spreading within 5 minutes. After 30 minutes, the whole package structure is complete.
"This test directly determines the escape window in the accident. "The safety test director stressed," Our goal is not to 'pass the national standard', but to 'surpass the national standard '. "
day 3: environmental "hardening"--Reliability endorsement across four seasons
Hour 48-56: high and low temperature performance test
battery pack was moved into the environment thermal shock test chamber, and the 0.3C charging test was conducted under the extremely cold condition of-20℃, and the charging acceptance rate reached 78%; In the high temperature environment of 55℃, 1C was discharged, and the capacity retention rate was 96.%. The temperature cycle test followed closely-10 round trips between-40℃ and 85℃, and the sealing ring of the box has no deformation and embrittlement.
Hour 56-64: vibration and mechanical shock test
vibrating table simulate the 100000-kilometer driving condition of the whole vehicle, and random vibration and semi-sinusoidal impact are alternately applied. After the test, the three-Coordinate Measuring instrument detects that the deformation of the box is less than 0.1mm, the displacement of the cell is zero, and the torque attenuation of all bolts is less than 5%. The air tightness has passed the retest, and the IP67 protection level has not been degraded.
Hour 64-72: final inspection of insulation, air tightness and BMS
the high voltage insulation resistance test is carried out at 1000V DC. The insulation resistance of the positive and negative poles to the box exceeds 2mΩ, far exceeding the national standard requirements of 500 Ω/V. Helium mass spectrometer leak detector scan all-inclusive, the leakage rate is less than 10 **** Pa · m & sup3;/s, which is equivalent to blocking a molecular-level gap on the needle tip.
The final check of the BMS function is the last pass. SOC estimation accuracy verification, balance function test, fault diagnosis response, communication protocol compatibility-dozens of software functions punch in item by item, after all green lights, battery pack obtain a unique "electronic ID card", data is permanently uploaded and traceable throughout the lifecycle.
End: 72 hours, loading
72 hours later, PN20260728001 battery pack was labeled as "qualified", waiting for the logistics to be sent to the vehicle factory. From capacity calibration to thermal runaway verification, from extremely cold quenching to vibration baptism, this piece battery pack prove yourself with data.
"Testing is not cost, but investment. "The quality director of Juneng New Energy repeatedly stressed at the morning meeting every day," every offline battery pack bears users' trust in safety. The 72-hour trial is our understanding of thisTrust the most basic response. "
Contact us
Dongguan Juneng New Energy Technology Co., Ltd.
137 5142 6524（Miss Gao）
susiegao@power-ing.com
Xinghuiyuan High tech Industrial Park, Dalang Town, Dongguan City, Guangdong Province
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Yue Gong Wang An Bei No. 4419002007491