SAE J2758 Electric Vehicle Battery Cycling Test

The SAE J2758 test is a critical procedure used to evaluate and certify batteries for electric vehicles (EVs). This standard, developed by the Society of Automotive Engineers (SAE), provides a standardized method for assessing the performance, durability, and safety of EV batteries. The test involves subjecting the battery pack to repeated charge-discharge cycles under controlled conditions that simulate real-world driving scenarios.

The SAE J2758 cycling test is particularly important because it ensures that the battery can withstand a significant number of charges and discharges over its lifetime, which is crucial for EVs. The test is designed to mimic the stressors encountered during typical vehicle operation, including cold starts, high-speed driving, and long trips. By subjecting batteries to these conditions, manufacturers can ensure their products meet safety standards and perform consistently.

The SAE J2758 test protocol consists of several key steps, each aimed at evaluating different aspects of the battery's performance:

Initial conditioning: The battery is initially conditioned to a specific state-of-charge (SOC) level before testing.
Cycling: The battery undergoes repeated charge-discharge cycles under controlled conditions. The number of cycles can vary depending on the test requirements, but it typically ranges from 500 to 1000.
Rest periods: Between each cycle, the battery is allowed a rest period to recover fully before the next cycle begins.
Data collection and analysis: Throughout the testing process, various parameters are monitored, including voltage, current, temperature, and internal resistance. These data points are used to assess the battery's performance during each cycle.

The results of the SAE J2758 test provide valuable insights into the battery's performance characteristics, such as its energy retention capacity, power delivery capability, and thermal management effectiveness. The test is essential for ensuring that EV batteries meet stringent safety standards set by regulatory bodies like the National Highway Traffic Safety Administration (NHTSA) in the United States.

One of the primary goals of the SAE J2758 cycling test is to identify any potential issues with the battery before it reaches the market. This helps manufacturers address any design flaws or manufacturing defects that could lead to safety concerns. By conducting this test, companies can ensure that their products are reliable and safe for consumers.

The SAE J2758 test also plays a crucial role in advancing the development of new battery technologies. By subjecting batteries to rigorous testing conditions, researchers and engineers can identify areas for improvement and innovate solutions to enhance performance and safety. This collaborative approach fosters continuous improvement within the industry.

In conclusion, the SAE J2758 electric vehicle battery cycling test is a vital tool in ensuring the reliability and safety of EV batteries. Its standardized protocol allows manufacturers to assess their products' performance under real-world conditions, thereby enhancing consumer confidence in EV technology.

Applied Standards

The SAE J2758 test is based on several international standards that are widely recognized and respected within the automotive industry. These include:

ISO 12196: This standard provides guidelines for testing and evaluating secondary batteries used in electric vehicles.
- SAE J2929 EV Battery Safety Testing
- SAE J2288 Electric Vehicle Battery Endurance Test
- SAE J2380 Lithium Ion Battery Vibration Test
- SAE J1725 Battery Pack Performance Testing
- SAE J1797 Battery Module Durability Test
- SAE J2710 Hybrid Battery Performance Testing
- SAE J2801 Plug In Hybrid Battery Performance Test
- SAE J2927 Electric Vehicle Battery Safety Test
- ISO 12405 1 EV Battery Performance Test
- ISO 12405 2 Hybrid Vehicle Battery Testing
- ISO 12405 4 Lithium Ion Battery Module Test
- ISO 12405 5 High Voltage Battery Pack Testing
- ISO 6469 1 Battery Safety Performance Test
- ISO 6469 4 EV Rechargeable Battery Safety Testing
- ISO 16750 2 Battery Environmental Durability Test
- ISO 18243 Electrically Propelled Vehicle Battery Test
- ISO 21498 Lithium Ion Battery Pack Abuse Testing
- ISO 23751 EV Battery Thermal Management Test
- IEC 62660 1 Lithium Ion Battery Cell Test
- IEC 62660 2 Battery Pack Reliability Testing
- IEC 62660 3 Lithium Ion Safety and Abuse Test
- IEC 61960 Secondary Lithium Battery Performance Testing
- IEC 62133 Rechargeable Battery Safety Test
- IEC 62923 EV Battery Thermal Runaway Testing
- IEC 62984 High Voltage Battery Safety Test
- IEC 63218 Lithium Ion Cycle Life Test
- IEC 63057 Battery System Reliability Testing
- ASTM D4632 Battery Separator Tensile Strength Test
- ASTM D547 Battery Internal Resistance Testing
- ASTM D3418 Thermal Properties of Battery Materials Test
- ASTM E1922 Battery Pack Fire Resistance Test
- ASTM F303 Battery Abuse Performance Testing
- ASTM F3149 EV Battery Pack Crush Test
- ASTM F3178 Lithium Ion Battery Drop Testing
- ASTM F339 Battery Thermal Runaway Simulation Test
- UL 1642 Lithium Ion Cell Safety Testing
- UL 2054 Household and Commercial Battery Safety Test
- UL 2580 Electric Vehicle Battery Pack Test
- UL 1973 Energy Storage Battery System Testing
- UL 2271 Light EV Battery Safety Test
- UL 9540A Thermal Runaway Fire Propagation Test
- UN 38.3 Lithium Ion Battery Transportation Test
- UN 3090 Lithium Battery Safety Testing
- UN 3480 Lithium Ion Battery Pack Abuse Test
- UN ECE R100 Battery Safety and Endurance Test
- UN ECE R136 Electric Vehicle Battery Safety Testing
- JIS C8712 Secondary Lithium Battery Test
- JIS C8714 Lithium Ion Cycle Life Testing
- JIS C8715 Hybrid Vehicle Battery Safety Test
- JIS D5301 Automotive Lead Acid Battery Testing
- EN 50342 Lead Acid Starter Battery Endurance Test
- EN 62133 Rechargeable Battery Pack Testing
- EN 62619 Lithium Ion Battery Industrial Safety Test
- EN 62928 High Voltage Battery Pack Performance Testing
- EN 62841 Battery Module Fire Propagation Test
- SAE J3068 EV Battery Fast Charging Test
- SAE J2847 Battery Communication Protocol Testing
- SAE J2931 Wireless Battery Charging System Test
- SAE J2954 Inductive Charging Battery Performance Test
- SAE J3105 Overhead Conductive Battery Charging Test
- ISO 17409 EV Battery Charging System Safety Test
- ISO 18243 EV Battery Thermal Management Testing
- ISO 21498 Lithium Ion Battery Module Fire Resistance Test
- ISO 21782 EV Battery Electrical Performance Test
- ISO 23274 Hybrid Battery Fuel Economy Impact Test
- ISO 23828 EV Battery Exhaust Emission Impact Test
- ISO 6469 Battery Abuse Protection Testing
- IEC 61851 EV Battery Charging Compatibility Test
- IEC 62196 EV Battery Connector Safety Testing
- IEC 62923 EV Battery Thermal Runaway Resistance Test
- IEC 63218 Lithium Ion Cycle Life Performance Test
- IEC 63219 Battery Abuse Crush Test
- IEC 63330 Battery Short Circuit Safety Testing
- IEC 63552 Battery Module Fire Safety Test
- ASTM D792 EV Battery Casing Density Test
- ASTM E2929 Lithium Ion Thermal Stability Testing
- ASTM F3399 Battery Crash Safety Test
- ASTM F3416 EV Battery Impact Resistance Test
- ASTM F3450 Battery Drop Performance Test
- ASTM F3472 Lithium Ion Venting and Gassing Test
- ASTM F3490 EV Battery Nail Penetration Testing
- ASTM F3519 Battery Thermal Abuse Simulation Test
- UL 2581 High Voltage Battery Pack Endurance Test
- UL 2849 EV Battery System Safety Testing
- UL 9540 Battery Energy Storage Fire Testing
- UL 9540A EV Battery Thermal Propagation Test
- UN 38.3 Transport Safety Battery Module Testing
- UN ECE R100 EV Battery Shock and Vibration Test
- UN ECE R136 Battery Fire Resistance Testing
- SAE J3411 EV Battery Fire Resistance Test
- SAE J2927 Battery Management System Communication Testing
- SAE J3237 Lithium Ion Battery Abuse Resistance Test
- SAE J3293 EV Battery Cold Soak Endurance Test
- SAE J3329 Battery Thermal Management Efficiency Testing
- ISO 6469 5 Rechargeable Energy Storage Battery Safety Test
- ISO 18300 Battery Pack Electrical Performance Testing
- ISO 21498 2 High Voltage Battery Module Crush Test
- ISO 23634 EV Battery Thermal Runaway Testing
- ISO 23999 Battery Abuse Vibration Endurance Test
- IEC 60749 Battery Thermal Shock Test
- IEC 62619 Lithium Ion Industrial Battery Safety Testing
- IEC 63056 Rechargeable Battery Cycle Life Test
- IEC 63209 EV Battery Pack Propagation Resistance Test
- IEC 63342 Battery Short Circuit Safety Test
- ASTM D8205 Battery Thermal Abuse Simulation Testing
- ASTM D8232 Battery Separator Puncture Resistance Test
- ASTM E2112 Battery Fire Containment Testing
- ASTM F3451 EV Battery Drop Performance Test
- ASTM F3482 Lithium Ion Battery Venting Safety Test
- UL 2267 Electric Vehicle Battery Fire Exposure Test
- UL 2587 EV Battery Crush Resistance Testing
- UL 2743 High Voltage Battery Abuse Resistance Test
- UL 9540 EV Battery Energy Storage Safety Test
- UN 3481 Lithium Ion Battery Pack Performance Testing
- UN ECE R12 Battery Safety Crash Impact Test
- UN ECE R136 EV Battery Vibration Endurance Test
- UN 38.3 Battery Shipping Fire Resistance Test