Battery pressure relief safety tester DR-T5

The safety of battery pressure relief mainly involves overcharging a fully charged battery in an electronic cigarette device that has been assembled for use. The overvoltage is increased in 0.1V steps, with each step maintained for 5 minutes, until it reaches n x 6.0V. Visual inspection is conducted to determine if pressure relief occurs. If pressure relief occurs, visual inspection is used to determine whether the direction of pressure relief is the same as the direction of inhalation. This can meet the pressure relief safety test requirements of the electronic cigarette testing standard GB41700-2022. 

Product Features and Characteristics

1. Initial voltage, target voltage, and voltage increment intervals can be set to increase the charging voltage in steps for overcharge testing.

2. Real-time curves of charging voltage and current can be plotted.

3. It has the functions of storing and exporting test data, and can generate Excel data sheets or analysis reports.

4. The test cabinet door can be closed, and the test product can be monitored through the camera monitoring software on the PC, with the ability to save the monitoring video.

5. An embedded intelligent PC monitoring system is provided.

Instrument parameters

Core Technology Highlights and Functional Design

✅ Multi-condition Simulation: Covering all scenarios of anomalies, ensuring more comprehensive testing

✦ Extreme Condition Occurrence Module:

Overvoltage Simulation: Adjustable constant current source (0–10A), simulating overcharging of the battery to over 4.5V;

High Temperature Acceleration: Constant temperature chamber (room temperature–200℃, accuracy ±1℃), simulating high battery temperature (such as prolonged use or high ambient temperature);

Mechanical Shock: Pneumatic shock device (0–50kPa), simulating the instantaneous pressure surge when the battery drops or is compressed.

✦ Dynamic Coupled Testing:

Supports multi-condition combination tests such as "overvoltage + high temperature" and "shock + overvoltage" (e.g., overcharging to 4.7V and temperature rising to 120℃), replicating the compound risks in real usage scenarios. 

✅ Multi-dimensional parameter monitoring: Precisely capture the entire pressure relief process

✦ Core measurement system:

Pressure sensor (range 0–1 MPa, accuracy ±0.005 MPa): Real-time monitoring of internal battery pressure changes, recording the critical pressure at the moment the pressure relief valve opens;

Flow sensor (range 0–100 ml/s, accuracy ±0.1 ml/s): Measures the gas discharge rate during pressure relief, evaluating the pressure relief efficiency;

Temperature sensor (range 0–300°C, accuracy ±0.5°C): Monitors the temperature changes on the battery surface after pressure relief, determining if thermal runaway is triggered.

✦ Millisecond-level data acquisition:

Sampling frequency 1000 Hz, fully recording the dynamic curve of the pressure relief process "pressure rise - valve opening - gas discharge - pressure drop", with data resolution of 0.001 MPa/ms. 

✅ Safety protection design: Risk-free testing, more reassuring operation

✦ Explosion-proof chamber:

Double-layer chamber made of 304 stainless steel and tempered glass (8mm thick), capable of withstanding an internal explosion pressure of 10MPa;

The chamber door is equipped with an electromagnetic lock (automatically locked during testing), and in case of abnormality, it triggers a "emergency stop + pressure relief" dual safety mechanism.

✦ Harmful gas treatment:

Built-in activated carbon filter (adsorption efficiency ≥ 99%), real-time purification of CO, VOCs and other harmful gases released during pressure relief;

Gas concentration sensor (accuracy ±0.1ppm), automatically alarms and activates the forced exhaust system when the concentration exceeds the limit. 

✅ Intelligent Data Management: Traceable and Compliant

✦ Full-process Data Recording:

Store up to 100,000 sets of test records (time/sample number/simulation conditions/pressure curve/flow value/temperature value);

Support "abnormal sample comparison" function (such as batteries with pressure relief deviation > 5% in the same batch) to quickly identify production defects.

✦ Multi-format Report Output:

Export Excel/CSV reports via USB (including original curves and compliance determination results);

Optional LIMS system interface for real-time interaction between test data and R&D/production line systems (suitable for smart factories). 

Application scenarios and customer value

✅ Full inspection of battery production lines: Intercepting safety hazards from the source

✦ Production line compatibility:

Forming a closed loop with battery packaging machines and formation cabinets for "packaging - formation - safety inspection", with a single battery inspection time of less than 15 minutes;

The full inspection coverage rate of the production line has increased from 10% (manual spot checks) to 100%, and the interception rate of non-conforming batteries is ≥ 99.5% (such as missing pressure relief valves, failed sealant, etc.). 

✅ Verification during the R&D stage: Accelerating safety design optimization

✦ Multi-variable comparative testing:

Simultaneously test 4 groups of batteries with different designs (such as different materials for pressure relief valves and thicknesses of sealing gels);

Output "pressure-time" and "flow-temperature" correlation curves to assist the R&D team in optimizing the balance between the opening pressure of the pressure relief valve and battery capacity (such as reducing the opening pressure to enhance safety or increasing the pressure to extend battery life). 

✅ Third-party Testing: The "Golden Certificate" of Authoritative Certification

✦ Compliance Support:

Complies with global mainstream safety standards such as GB 31241 (Chinese National Standard), UL 1642 (USA), and IEC 62133 (International);

The test report includes original test curves and environmental parameter records, which can be directly used for product export certification (such as EU CE, Japan PSE). 

Reliability and Maintenance

✅ Structural Durability:

✦ The lifespan of the pressure sensor is ≥ 500,000 tests (20 groups tested daily can last for 68 years);

✦ The explosion-proof housing has undergone 100,000 opening and closing tests (no deformation, stable sealing performance). 

✅ Easy-to-maintain design:

✦ The sensor module supports quick disassembly (no tools required, replacement completed within 5 minutes);

✦ Annual calibration takes only 2 hours (original factory standard pressure gauge/flow generator provided);

✦ Self-diagnostic function for faults (displaying error codes such as "sensor drift" and "poor cabin door seal"), guiding quick repair. 

✅ Operating Procedure (5 Steps to Learn and Use Immediately)

✦ Sample Clamping → Secure the battery in the 4-position fixture (with elastic silicone pads to prevent deformation), and connect the charging cable/temperature probe;

✦ Parameter Setting → Select the test mode (e.g., "Overcharge + High Temperature"), and set the target voltage (4.7V) and temperature (120°C);

✦ Start Test → Close the explosion-proof cabin door (the electromagnetic lock will automatically engage), and click the "Start" button. The system will automatically perform charging/heating/shock;

✦ Real-time Monitoring → The 10-inch touch screen will simultaneously display the pressure/flow/temperature curves of the 4 groups of batteries. Abnormalities (such as pressure exceeding the threshold) will be automatically marked;

✦ Result Output → After the test is completed, the cabin door will automatically unlock. Qualified batteries will be marked with a "green label" (if the pressure relief is within the range of 1.2–1.5 MPa), and unqualified ones will be marked with a "red label" and a defect analysis report will be generated. 

Manufacturer and Customization Services and Precautions

Services and Certifications

✦ 1-year full machine warranty: Lifetime technical support for key components (cylinder body/sealing ring);

✦ Compliance with standards: Meets the "Technical Conditions for Centralized Lubrication Systems" JB/T 5000.10 and the oil injection accuracy requirements for electronic cigarettes;

✦ Customization services: Supports customization of oil cylinder capacity (e.g., 30ml×2), oil outlet direction (left/right/dual ports) as per requirements;

✦ Manufacturer information: According to search results, such equipment is typically provided by professional testing equipment manufacturers (such as Zhongzhou Measurement and Control), supporting customization of the number of workstations, suction parameters, and structural dimensions;

✦ Calibration traceability: Optional NIST-certified calibration certificate;

✦ Military-grade reliability: MTBF ≥ 50,000 hours, adaptable to temperature and humidity fluctuations;

✦ Lifetime technical support: Software remote upgrade, hardware modular replacement. Notes to be Observed

✦ Operating Specifications: One-click start for testing after sample installation. Automatic buzzer alarm and machine stop in case of abnormality.

✦ The detection mechanism ensures stable data and is compatible with the environment of CMA-certified laboratories. 

Multi-dimensional simulation, precise monitoring - with data-driven detection, the safety of every e-cigarette battery becomes a "reliable promise". 

Full-condition simulation · Multi-dimensional parameter monitoring · Intelligent safety protection