Differences between Lithium-ion batteries and Hydrogen fuel cells ?
LITHIUM-ION BATTERIES
In the world of electric vehicles, two technologies dominate the landscape: lithium-ion batteries and hydrogen fuel cells. Each of these technologies presents unique challenges in terms of testing and safety.
- Lithium-Ion Batteries
Lithium-ion batteries are ubiquitous in battery electric vehicles (BEVs). They store the energy needed to power the vehicles and, therefore, require rigorous testing to ensure their safety and efficiency.
- Battery Packs and Subassemblies
Battery packs contain lithium-ion cells that store energy. Consequently, it is crucial to test each subassembly to detect any electrolyte leaks. Leaks can not only diminish battery performance but also pose significant safety risks, such as uncontrolled heating or fires. The F620 and F670LV excel in this area, providing highly accurate results.
- Charging Systems
The charging systems of electric 
vehicles, including charging cables, connectors, and seals, must undergo rigorous leak testing. This helps prevent electrical hazards, ensures efficient energy transfer, and maintains the integrity of the charging infrastructure. The D620 and F620 complement each other and enable effective leak testing of charging systems.
- Powertrain Components
Electric motors, inverters, and power electronics are essential for the operation of electric vehicles. Testing the seals and connections of these components for fluid leaks (such as coolants and lubricants) is vital. This helps avoid performance degradation and potential system failures. The F620 can be used for these tests.
- HVAC Systems
Heating, ventilation, and air conditioning (HVAC) systems, meanwhile, play a crucial role in ensuring passenger comfort and safety. Testing the components of HVAC systems, such as evaporators, condensers, and refrigerant lines, for leaks helps maintain system efficiency, prevent refrigerant leaks, and ensure optimal climate control within the cabin.
- Cooling Systems
As electric vehicles rely on cooling systems to maintain optimal operating temperatures for batteries, motors, and power electronics, testing the cooling circuits and connections for leaks using the F620 helps identify potential leaks that could lead to system inefficiencies, overheating, or even damage to components.
- Hydraulic Systems
In hybrid vehicles or those equipped with hydraulic components, testing hydraulic circuits for leaks is essential to maintaining system efficiency and reliability. Identifying and repairing leaks in hydraulic systems prevents fluid loss, ensures proper component operation, and extends the lifespan of hydraulic components. The F620 is highly effective in testing these hydraulic systems.
On the other hand, fuel cell electric vehicles (FCEVs) use hydrogen to generate electricity through a chemical reaction, powering the electric motor. This technology requires specific testing procedures to ensure safety and efficiency.
- Hydrogen Tanks
High-pressure hydrogen tanks are critical components that must be leak-free. These tanks, often made of carbon fiber, undergo rigorous testing to prevent accidental hydrogen release, which could pose significant risks. The F620 is indispensable for testing these components.
- Hydrogen Lines and Connections
The pipelines and connections that transport hydrogen from the tanks to the fuel cell must be meticulously tested for leaks. Leaks in these lines could compromise the efficiency and safety of the hydrogen system.
- Fuel Cell
The fuel cell is the heart of the FCEV, where hydrogen reacts with oxygen to produce electricity. Leak testing on the fuel cell itself and its auxiliary components is, therefore, essential to ensure optimal performance and system integrity, achievable with the F620.
- Hydrogen Seals and Fittings
Since hydrogen transport systems have numerous connection points, leak testing on these interfaces is crucial to prevent any leaks at the connection points, thereby ensuring the safety and efficiency of the system.
- Storage and Refueling Infrastructure
Vehicles equipped with their own refueling systems or those interacting with external infrastructures, such as hydrogen refueling stations, require leak testing on these components. This ensures the safe handling and transfer of hydrogen gas.
- Bipolar Plates
Bipolar plates are multifunctional components within the PEM fuel cell stack. They connect and separate individual cells to form a stack with the required voltage, assist in the uniform distribution of H2 and oxygen, conduct electrical current, facilitate water management, and support thin membranes and electrodes. ATEQ leads in leak testing of the three main circuits: O2, H2, and the cooling circuit, using the F620.
- Fuel Cell Stack
A single fuel cell consists of a membrane electrode assembly (MEA) and two flow field plates, providing about 0.5 to 1V, which is too low for most applications. Like batteries, individual cells are stacked to achieve higher voltage and power. This assembly of cells is called a fuel cell stack, or simply a stack. The F620 is the most effective for stack testing.
TEST ENVIRONMENT AND CONDITIONS
The testing of EV batteries and hydrogen tanks is conducted in very different environments and conditions due to their distinct natures.
- EV Battery
- Temperature Control: Tests often need to be performed at various temperatures to simulate real-world operating conditions.
- Controlled Environment: To avoid contamination of the electrolyte or sensitive components.
- Hydrogen Tank
- High-Security Environment: Due to explosive risks, tests must be conducted in facilities specially designed to handle flammable gases.
- Simulation of Extreme Conditions: Tanks must be tested to withstand extreme pressure and temperature conditions.
If there’s one thing lithium-ion batteries and hydrogen fuel cells have in common, it’s that ATEQ can test any application. We look forward to meeting you.
