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Intertek Germany Expands Facility to Support ECE-R 100 & LV 124 Testing

New testing capabilities for the European automotive industry at Intertek's European Competence Center in Kaufbeuren

(PresseBox) (Kaufbeuren, Germany, ) Intertek, a leading provider of quality and safety solutions for a wide range of industries worldwide, is expanding its Competence Center for E-Mobility and Transportation Technologies in Kaufbeuren, Germany. As a technical service for the e1/E1 Mark in the field of ECE-R 10 and ECE-R 100, Intertek Germany expands their related testing capabilities to include the updated legal requirements of Lithium Ion batteries for transportation applications (ECE-R 100 Rev.2: mandatory, July 2016). As a result, the German laboratory is now able to perform all relevant safety and abuse testing inclusive fuel fire testing on large Lithium Ion battery packs (REESS).

Today, all automotive OEMs and suppliers are putting a tremendous amount of effort and resources into the development of safe Lithium Ion batteries. However, the actual status of standardization lags behind this development. Currently, only one international legal requirement exists for the approval of vehicles with regard to specific requirements for the electric power train (UN ECE-R 100 issued: December 2010). The international community recognized that this directive does not cover the current technical stage of development for Lithium Ion batteries.

As a result, ECE-R 100 Rev.2 goes into force in the middle of July, 2016. In addition to the already existing requirements within the ECE-R 100, the Rev.2 will cover basic safety and testing aspects in the area of shock, vibration, crush, fire resistance and electrical abuse.

To help the automotive OEMs to understand and fulfil the ECE-R 100 Rev.2 requirements, Intertek Germany expanded their capabilities with several new facilities and equipment, including shock and vibration tables, an open area fireside, large abuse bunker and engineering staff. With this step forward, the Kaufbeuren laboratory is now able to handle all Lithium Ion applications on module and pack level (REESS), which are in the scope of the ECE-R 100 Rev.2. As a technical service for the e1/E1 Mark, this extension of capability is included in the Intertek Germany ISO/IEC 17025 accreditation scope.

In addition to the existing laboratories, Intertek built a new abuse bunker at the Kaufbeuren site with a capacity of approximately 150 cubic meters, with inner dimensions of 8 meters (length) x 4 meters (width) x 4 meters (height). The bunker, equipped with a 200 kN electromechanical press, 16 kA short circuit switch and an 2 cubic meters oven for sample preparation, will be available by September. Also a fireside area with a 100 x 100 meter dimension, including burners up to 600 kW heating capacity and an explosion area, is available.

Based on the inadequate standards available for automotive application of Lithium Ion batteries (module or pack level), the central European car manufacturers often create their own test programs for Lithium Ion batteries compliance testing. To proof actual safety and performance aspects, the LV 124 and the AK-LH 5.21 (April 2011) will be primarily adopted. The standard LV 124 is the result of a basis agreement for testing electrical, electronic and mechanical components and systems, even for Lithium Ion cells, modules and battery packs. The LV 124 applies for the application in motor vehicles up to 3,5 tons.

In general, the AK-LH 5.21 defines endurance requirements, test conditions and tests to high voltage battery systems for the application in motor vehicles. To complete Intertek's service for LV 124 and AK-LH 5.21, the European Competence Center in Kaufbeuren added advanced testing equipment. The new automatic splash water and salt water immersion tester, suitable for Lithium Ion packs (RESS) up to 500 kg, adds the capabilities of the Intertek Kaufbeuren site. Also two new HV battery charging/discharging unit (1000V/600A) will be installed beside the existing 4 channels.

To provide an excellent service quality for current and future customer inquiries, the Kaufbeuren laboratory increased the number of engineers in the TT team significantly.

"The market for all kinds of Lithium-Ion-Batteries including charging units grows rapidly. The authorities can't keep up to this fast development. We support our customers to not lose insight on things. Therefore we identify and interpret relevant changes, which are decisive for them," explained Roger Grumpelt, Business Development Manager for E-Mobility, Intertek Germany. "The decisive factor is being able to reliably test and certify key components for these electric vehicles. We are proud to be a global test and certification partner for many renowned European vehicle manufacturers and component suppliers. Our Competence Center in Kaufbeuren offers an extensive range of tests in the areas of e-mobility, storage media, and transportation technologies close to their locations."

The European Competence Center for E-Mobility and Transportation Technologies in Kaufbeuren acts as an important element of Intertek's global laboratory network for Transportation Technologies, with locations in Leatherhead (United Kingdom), Stockholm (Sweden), Detroit (U.S.A.), and Shanghai (China). In proximity to the global automotive manufacturing hotspots, Intertek offers its independent testing and certification services in a quick and flexible way for all notable component and automotive companies and is key to Intertek expanding its leading role as a development and testing partner for the automobile industry.

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