1.Introduction
Electric vehicle (EV) sales are experiencing unprecedented growth worldwide. According to the IEA’s Global EV Outlook 2025, global electric car sales surpassed 17 million units in 2024, marking a year-on-year increase of over 25%. This momentum is set to continue, with sales projected to exceed 20 million units in 2025—accounting for more than one-quarter of all new passenger vehicle sales globally. Looking ahead, EV sales are expected to reach 30 million units by 2027 as adoption accelerates across markets.
This rapid expansion presents significant challenges and opportunities for battery manufacturers and testing laboratories. As the cornerstone of EV performance, batteries not only define driving range and power output but also critically influence vehicle safety and durability. Consequently, rigorous, standardized battery testing protocols have never been more essential to ensure quality, reliability, and long-term performance.
2.Why EV Battery Testing is Important?
Safety Assurance
EV batteries store a large amount of energy. Proper testing prevents risks such as overheating, short circuits, and thermal runaway, ensuring safety for users and vehicles.
Performance Verification
Testing verifies battery capacity, charging/discharging efficiency, and cycle life, which directly affect driving range and vehicle performance.
Quality Control
Systematic testing detects manufacturing defects early, ensuring consistent product quality and reliability.
Regulatory Compliance
Adhering to international and local standards through testing is essential for market access and legal compliance.
Longevity and Reliability
Accelerated aging and cycle tests help predict battery lifespan and support design improvements for longer-lasting batteries.
3.Common Testing Items for International EV Battery Standards
|
Testing Item |
Description |
Relevant Standards |
| Capacity Test | Measures the actual energy storage capacity of the battery. | IEC 62660-1, ISO 12405-1 |
| Internal Resistance Test | Determines battery internal resistance affecting efficiency and heat. | IEC 62660-1, ISO 12405-1 |
| Cycle Life Test | Evaluates battery durability over repeated charge-discharge cycles. | IEC 62660-2, ISO 12405-2 |
| Safety Test | Includes overcharge, short circuit, nail penetration, thermal, mechanical abuse tests. | UN 38.3, SAE J2464, IEC 62660-3 |
| Environmental Test | Tests battery performance under temperature and humidity variations. | IEC 60068 series, ISO 12405-4 |
| Self-Discharge Test | Measures how fast battery loses charge when idle. | IEC 62660-1 |
| High and Low Temperature Performance Test | Assesses battery function and safety at extreme temperatures. | IEC 62660-3, ISO 12405-4 |
| Battery Management System (BMS) Functional Test | Verifies BMS communication, balancing, and protection features. | ISO 26262, SAE J1939, ISO 15118 |
4.Common International EV Battery Testing Systems
Summary Table: EV Battery Test Equipment Overview
| Equipment | Application |
| Battery Cycler | Capacity, Cycle Life |
| Battery Internal Resistance Tester | Resistance, Grading |
| Battery Simulator | Charger/BMS Test |
| Environmental Chamber | Temperature/Humidity |
| Safety Abuse System | Short, Overcharge, Nail |
| BMS Tester | Protection, Balancing |
| Power Analyzer | Power & Efficiency |
| EIS/Impedance Tester | Degradation Analysis |
5.Conclusion
Establishing a globally compliant EV battery testing framework is crucial for automotive OEMs, battery manufacturers, and energy storage companies to succeed in international markets. Nebula is committed to supporting this goal by providing comprehensive battery testing solutions that ensure safety, reliability, and performance. With Nebula’s advanced technologies and expertise, industry players can accelerate innovation and confidently meet the growing demands of the global EV market.
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Post time: Nov-24-2025