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Currently lithium-batteries are the most promising electrical-energy storage technology in fully-electric and hybrid vehicles. A crashworthy battery-design is among the numerous challenges development of electric-vehicles has to face. Besides of safe normal operation, the battery-design shall provide marginal threat to human health and environment in case of mechanical damage. Numerous mechanical abuse-tests were performed to identify load limits and the battery's response to damage. Cost-efficient testing is provided by taking into account that the battery-system's response to abuse might already be observed at a lower integration-level, not requiring testing of the entire pack. The most feasible tests and configurations were compiled and discussed. Adaptions of and additions to existing requirements and test-procedures as defined in standards are pointed out. Critical conditions that can occur during and after testing set new requirements to labs and test-rigs.

The aim of this study was to assess the feasibility of using a high speed x-ray system (capable of 1000 frames/sec) to evaluate the bony kinematics of post mortem human surrogate (PMHS) cervical spines at real world speeds during frontal impact. Whole body frontal impact sled tests were performed on two fresh PMHS specimens. Screws were inserted into the tips of the spinal processes to optimize contrast on the high speed cine x-ray. Head, T1 and sternum accelerations, as well as shoulder, and lap belt forces were recorded. Vertebral motion was captured using a modified mobile c arm x-ray system, and an image intensifier linked to a high speed camera (Kodak motion corder analyzer, model SR 1000C, Kodak, San Diego, CA, USA) The variable parameters for the tests were camera frame rate and sled velocity. Tests were performed with delta-V’s (Δv) of approximately 15 kph (8G) and 21 kph (10G). Cine x-rays of the tests were recorded at 250, 500 and 1000 frames/sec.