Cylindrical Battery In-Situ Volume Swelling Testing System

The Cylindrical Battery In-Situ Volume Swelling Testing System is designed for real-time measurement and analysis of volume and dimensional changes of cylindrical lithium-ion cells during charge and discharge processes. The system uses non-contact laser displacement technology to accurately capture micro-level swelling behavior under controlled temperature and pressure conditions. It provides reliable data support for safety evaluation, reliability testing, and structural optimization of cylindrical batteries.

Application

(1) In-situ volume swelling analysis of cylindrical lithium-ion batteries during cycling.

(2) Expansion behavior evaluation of 18650, 21700, and similar cylindrical cell formats.

(3) Safety and reliability assessment under fast charge, overcharge, and abuse conditions.

(4) Thermal-mechanical coupling analysis under elevated or low-temperature environments.

(5) Fatigue and pressure response testing during long-term cycling.

(6) R&D validation and quality comparison for different cell designs and materials.

Standards

(1) UL 1642 – Standard for Lithium Batteries.

(2) IEC 62660-2 – Secondary Lithium-Ion Cells for the Propulsion of Electric Road Vehicles – Reliability and Abuse Testing.

(3) ASTM E83 – Verification of Linear Displacement Measuring Systems.

(4) ISO 12417-1 – Mechanical Testing of Metals – Dilation Test (reference method).

(5) CE Certification – Conformité Européenne.

Features

(1) Sub-micron non-contact displacement measurement with laser-based sensors.

(2) High-resolution detection of radial and axial swelling during rapid cycling.

(3) Multi-environment testing with integrated temperature chamber.

(4) Dynamic pressure loading capability for fatigue and structural response testing.

(5) Four-channel parallel testing for improved efficiency and data consistency.

(6) Real-time volumetric strain visualization using structured light scanning.

(7) Automatic thermal drift compensation for long-term stability.

(8) Dual redundant safety protection with emergency stop system.

Parameters

Parameter	Specification
Displacement Range	±1 mm (linear), ±0.5° (angular)
Linear Measurement Accuracy	±0.1 μm
Angular Measurement Accuracy	±0.01°
Displacement Resolution	0.05 μm
Temperature Range	-20°C to 150°C
Temperature Ramp Rate	≤ 2°C/min
Pressure Range	0–30 bar
Test Channels	4 channels
Data Acquisition Rate	5,000 points/s/channel
Power Supply	AC 100–240 V, 50/60 Hz
Dimensions (W×D×H)	600 × 500 × 1000 mm
Weight	150 kg (net) / 180 kg (gross)

Accessories

(1) Non-magnetic cylindrical battery holders (18650, 21700).

(2) Laser displacement sensor modules.

(3) Structured light scanning unit.

(4) Temperature-controlled environmental chamber.

(5) Data acquisition and analysis software.

(6) NIST-traceable displacement calibration standards.

Test Procedures

(1) Mount the cylindrical battery into the designated non-magnetic holder.

(2) Align the battery position using the laser-guided positioning system.

(3) Set temperature, pressure, and cycling parameters according to test requirements.

(4) Start the charge/discharge process and initiate in-situ displacement monitoring.

(5) Record real-time swelling data and volumetric strain evolution.

(6) Export and analyze test data for safety evaluation and performance assessment.

Maintenance Information

(1) Periodically calibrate laser displacement sensors using certified standards.

(2) Inspect battery holders and mechanical fixtures for wear or deformation.

(3) Clean optical components to maintain measurement accuracy.

(4) Verify temperature and pressure control modules at regular intervals.

(5) Perform routine software updates and data backups according to laboratory protocols.

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