How to Test the Reliability of Explosion Proof Valve for Battery

1. Pressure Cycle Testing

• Procedure:
  • Subject the valve to cyclic pressure changes within its operational range (e.g., 0 to 10 bar) using a hydraulic or pneumatic test rig.
  • Use sensors to monitor pressure release thresholds and record leakage rates during each cycle.
• Criteria:
  • The valve must activate at the specified pressure (e.g., 5 bar) with a tolerance of ±5%.
  • Leakage should remain below acceptable limits (e.g., <0.1 mL/min) in both closed and open states.

2. Thermal Endurance Testing

• Procedure:
  • Place the valve in a climatic chamber and expose it to temperature ranges from -40°C to 125°C (or higher for high-risk applications).
  • Apply pressure cycles at each temperature plateau and measure response time and seal integrity.
• Criteria:
  • No deformation, cracking, or material degradation should occur after 1,000+ thermal cycles.
  • Activation pressure must remain consistent across the temperature range.

3. Chemical Resistance Testing

• Procedure:
  • Immerse valve components (seals, diaphragms, springs) in electrolyte solutions for 72+ hours.
  • Conduct visual inspections, hardness tests, and tensile strength measurements before and after exposure.
• Criteria:
  • Weight loss or dimensional change should be <2%.
  • Seals must retain ≥90% of their original elasticity after chemical exposure.

4. Explosion Simulation Testing

• Procedure:
  • Use a sealed chamber to generate a controlled explosion (e.g., mixing air with 5–15% hydrogen by volume).
  • Measure peak pressure, venting time, and flame propagation outside the chamber.
• Criteria:
  • The valve must activate within 50 ms of pressure surge.
  • No external flame or sustained combustion should occur during or after venting.

5. Vibration and Mechanical Shock Testing

• Procedure:
  • Mount the valve on a shaker table and apply sinusoidal or random vibration profiles (e.g., 10–2000 Hz, 3 g RMS).
  • Subject it to mechanical shocks (e.g., 50 g, 11 ms half-sine wave).
• Criteria:
  • No loose components or structural damage should occur after 24 hours of vibration.
  • Sealing performance must remain within specifications post-shock.

6. Long-Term Aging Testing

• Procedure:
  • Age components at elevated temperatures (e.g., 85°C, 85% RH) for 1,000 hours (equivalent to ~5 years of real-world use).
  • Test pressure activation, leakage, and mechanical properties periodically.
• Criteria:
  • Activation pressure deviation should be <10% of the nominal value.
  • Seals must pass bubble leak tests (e.g., submerged in water at 1 bar) without visible bubbles.

7. Compliance with Standards

• ATEX/IECEx: For explosion-proof certification in hazardous areas.
• UN38.3: For lithium battery safety (applicable to valve integration in battery packs).
• ISO 16750: For automotive environmental loads (vibration, temperature, etc.).