ECSS-E-HB-20-02A Aerospace Engineering - Lithium-Ion Battery Test Guide

The document entitled “ECSS-E-HB-20-02A Aerospace Engineering - Lithium-ion Battery Test Guide,” developed by the European Aerospace Standardization Cooperation (ECSS), supports the testing of lithium-ion batteries and the creation of related test documentation.

The purpose of this guide is as follows:

• To explain the most relevant characterization tests.
• Providing guidelines for lithium-ion battery testing.
• To provide guidelines for documentation relating to lithium-ion battery or battery testing.
• To provide an overview of suitable testing methods.
• To offer best practices

Every cell or battery used in space applications undergoes various tests, such as acceptance and qualification. These tests are described in detail in a supporting test plan, relevant procedures (including test criteria and test methodology), and a test report.

A battery consists of electrically connected cells, arrays, or modules. Single cells are electrically connected to form an array of cells. Arrays are then connected to form a building block. Building blocks are then assembled to form a module. Modules are then assembled together in a battery. And the tests described in this document are performed on different test items, which can be single cells, arrays, building blocks, modules, or complete batteries.

The test plan details the characteristics of the cell or battery to be tested, the test criteria, and the test conditions. The test procedure provides all the test methods and different steps for applying the tests given in the plan to measure and verify the characteristics of the batteries or cells.

The test report specifies the test items and test conditions. Test data and test data analysis are provided. All nonconformity reports related to the test item and their status are explained in the report. Separate test reports can be provided to cover the following main test topics:

• Electrical tests
• Environmental tests
• Life span tests
• Safety tests

For example, in an environmental test report, test conditions, specific details regarding the test setup (i.e., connection, thermal control, equipment used, accelerometer type and location), test data, and test data analysis are usually provided separately in spreadsheet format.

The tests described in this guide are as follows:

• tests
• Initial electrical characterization tests
• Standard capacity and energy measurements
• Internal resistance measurement
• AC impedance measurement
• Spontaneous discharge test
• Charge hold test
• Cell speed capacity
• Cell EMF measurement
• Battery magnetic moment measurement
• Battery corona test
• Environmental tests:
• The purposes of environmental testing are as follows:
• To identify the limitations of the technology and verify the suitability of the battery or battery pack for the target application and task.
• To verify the initial capabilities of the batteries or module.
• Mechanical tests: Vibration (low-level sine, random, sine) and shock.
• Thermal vacuum test
• Leak test
• Sealing test (Helium test)
• Radiation test
• Life span tests:
• The purposes of survival tests are as follows:
• To identify technology limitations and validate requirements for the target application.
• To determine long-term performance and degradation factors to be applied to battery sizing and performance calculations.

A fully representative lifetime test is performed on the selected cell type. A sufficient number of cells are used to account for design or process variability.

• Calendar tests (survival tests)
• Cycle tests
• Security tests:
• The purpose of these tests is as follows:
• To characterize the security protections of the tested item.

Potential hazards of lithium-ion batteries include:

• Ventilation
• Fire
• Explosion
• Infection
• Electrolyte leak.

Detailed explanations of the hazards associated with different battery chemistries are provided in the reference document.

The purposes of battery or battery safety testing are as follows:

• Identifying technology limitations,
• Verifying battery or battery-level safety features.
• Overcharge
• Excessive discharge
• Short circuit test
• Ventilation and blast tests
• Protective devices
• Storage, handling, transport, assembly integration testing.
• Storage, handling, and transportation operations are carried out in accordance with the requirements of ECSS-Q-ST-20-08.
• Storage and maintenance conditions
• handling
• Transport
• Assembly integration test

ECSS-E-HB-20-02A is a supplementary, non-mandatory manual. It provides practical guidance for testing lithium-ion batteries (both cells and packs/batteries) designed for use in space projects and applications. It supports compliance with relevant ECSS standards (specifically the ECSS-E-ST-20 series on electrical and electronic engineering and power systems).

The purpose of this guide is as follows:

• To establish standardized approaches for testing lithium-ion batteries in space contexts.
• To guide the creation of relevant test documentation.
• This includes testing related to electrical characterization, performance, environmental suitability, and safety.

The main sections of this guide include:

• Scope and references
• Terms, definitions, and abbreviations specific to lithium-ion batteries used in space.
• Cell or battery test:
• Test documentation (test plans, procedures, reports)
• Initial electrical characterization (capacity, energy, internal resistance, AC impedance, self-discharge, charge holding, rate capacity, EMF)
• Specialized tests (e.g., battery magnetic moment, corona test)
• Environmental tests (vibration, shock, thermal vacuum)
• Detailed test applicability tables (e.g., which tests apply to cells and packages, proficiency and acceptance levels)
• Leak tests, safety considerations, and other space-specific considerations (vacuum compatibility, gas release)

This guide is especially important for:

• Qualification and acceptance testing of lithium-ion batteries for satellites, probes, launch vehicles, or other spacecraft.
• Ensuring reliability under space environmental conditions (vacuum, extreme temperatures, radiation, mechanical loads during launch).

In short, ECSS-E-HB-20-02A supports ECSS engineering standards related to electrical and electronic subsystems and aims to assist engineers in planning, conducting, and documenting lithium-ion battery testing. Its main objectives are:

• Summary of key battery characterization tests.
• Providing guidelines for lithium-ion battery testing procedures.
• Explanation of test documentation and reporting practices.
• Presentation of proposed test methods.
• Sharing best practices and lessons learned from European space programs.

In short, ECSS-E-HB-20-02A is a technical manual that provides comprehensive guidelines for testing, verifying, and ensuring the safety and reliability of lithium-ion batteries used in space systems, assisting engineers in designing and qualifying spacecraft power systems.

For many years, our organization, with its competent and experienced team, has been understanding the needs of its clients, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services compliant with the ECSS-E-HB-20-02A standard.