In-situ Gas Analysis System
Category：Battery Performance Tester
Introduction
The In-situ Gas Analysis System for Lithium Battery Thermal Runaway is an advanced testing platform designed to trigger and monitor battery thermal runaway events within a controlled environment. Using a battery cell pressure vessel as the primary trigger carrier, the system integrates real-time signal detection, gas sampling, and online gas composition analysis. It enables flexible sample loading, thermal runaway initiation, and precise monitoring of generated gases, while providing reliable measurement data for gas volume, gas evolution rate, and explosion pressure. This system supports research, production, and safety assessment of lithium batteries, contributing to effective hazard evaluation across multiple applications.
Application
Battery Research and Development
Provides controlled thermal runaway testing for lithium battery cells, enabling analysis of gas composition, pressure evolution, and reaction kinetics.
Battery Manufacturing and Quality Control
Evaluates battery safety and consistency under abuse conditions, supporting process improvements and production safety verification.
Battery Safety Certification
Offers standardized testing aligned with UL 9540A for thermal runaway fire propagation, supporting regulatory compliance.
Academic and Industrial Research
Enables detailed study of battery thermal behavior, including gas generation, explosion pressure, and component analysis, facilitating material and system-level research.
Standards
The system is compliant with the following standard:
(1) UL 9540A-2025 – Standard for Testing Thermal Runaway Fire Propagation in Battery Energy Storage Systems
Parameters
| Item | Specification |
|---|---|
| Platform Dimensions | Determined by sample volume requirements |
| Control Cabinet | 650(L) × 675(W) × 1750(H) mm |
| Fourier Transform Infrared (FTIR) System | 650(W) × 675(D) × 1750(H) mm |
| Power Supply | AC 220 V, 30 A |
| Weight | Approximately 900 kg |
| Backup Gas Source | Nitrogen ≥ 99.99% |
Features
High-Strength Stainless Steel Vessel
304 stainless steel chamber ensures corrosion resistance, high-temperature durability, and mechanical integrity. Design pressure 3 MPa, constant operating pressure 2.5 MPa, with a safety valve for rapid pressure relief.
Multi-Channel Battery Parameter Monitoring
Supports online monitoring of voltage, temperature, and pressure through K-type high-temperature thermocouples and high-precision imported sensors, covering heating, overcharge, and nail penetration trigger modes.
Integrated Environmental Control
Vacuum extraction, nitrogen filling, exhaust, and oxygen concentration detection (0–100% Vol.) are included. Video monitoring allows real-time observation of thermal runaway events.
Automated Gas Sampling System
Multi-layer sample lines with real-time pressure monitoring ensure continuous, accurate gas sampling. Automatic switching prevents blockage and maintains system integrity.
Heated Sampling Lines
Prevents intrusion of liquid electrolyte into analytical instruments, reducing interference and improving gas composition measurement accuracy.
Advanced Gas Analysis
FTIR spectrometer and electrochemical sensors, combined with a professional analysis model, enable precise online measurement of complex gases produced during battery thermal runaway.
User-Friendly Control Software
Intuitive interface, low latency, real-time monitoring of gas composition, battery parameters, and environmental conditions.
Extended Data Processing
Automatic calculation modules for gas evolution rate and total gas volume, with seamless integration into the software for data visualization and reporting.
Accessories
(1) Multi-layer gas sampling lines
(2) Pressure and temperature sensors
(3) Vacuum pump and nitrogen supply interface
(4) FTIR spectrometer
(5) Electrochemical gas sensors
(6) Heated pipeline assembly
(7) Video monitoring system
(8) Control cabinet with PLC and touchscreen
Maintenance Information
Inspect vessel seals, flanges, and sampling connections regularly for integrity.
Calibrate temperature, pressure, and gas sensors periodically.
Clean sampling lines and FTIR components to prevent contamination and measurement errors.
Verify nitrogen supply, vacuum pump operation, and safety valve function before each test.
Backup all acquired test data and system logs for traceability and reporting purposes.
FAQ
1. What is the primary function of this gas analysis system?
The system triggers lithium battery thermal runaway events within a controlled pressure vessel, while continuously monitoring gas composition, temperature, pressure, and battery parameters. It integrates vacuum, nitrogen filling, and automated gas sampling, providing real-time data for safety evaluation and research purposes.
2. How does the system prevent sampling errors caused by liquid electrolyte intrusion?
Heated sampling lines automatically maintain elevated temperatures, preventing liquid electrolyte from entering the analytical instruments. This reduces measurement interference, ensuring accurate real-time gas composition analysis and reliable data collection throughout thermal runaway tests.
3. What monitoring capabilities are included for battery parameters?
Multi-channel K-type high-temperature thermocouples and imported pressure and mass sensors allow simultaneous monitoring of voltage, temperature, and pressure. The system supports multiple thermal runaway triggers, including heating, overcharge, and nail penetration, capturing comprehensive data during extreme test conditions.
4. Can this system calculate gas evolution rates and total gas volume?
Yes, the software includes modules that automatically calculate gas evolution rate and total gas volume. Test data from sensors and analytical instruments are continuously processed and integrated, providing accurate quantitative analysis during thermal runaway events.
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