Battery Inspection and Testing Standards Introduction - Inspection, Audit and Certification Services for Warehousing and Factory Inspection

September 16, 2025

Batteries, as core components widely used in consumer electronics, electric vehicles, energy storage systems, etc., their quality and safety directly affect the overall performance of the equipment and the safety of users. In the face of increasingly strict market supervision and environmental protection requirements, battery manufacturers and purchasers must establish a systematic quality control system, implementing full-process management from factory inspection to product inspection. This article will, in combination with international standards and industry practices, systematically introduce the key items, testing methods, and compliance points for battery inspection, providing references for quality managers, inspectors, and supply chain professionals.
I. Factory Audit and Quality System Requirements
Before the batch production of batteries, it is recommended to conduct supplier evaluation and pre-production factory inspection. The focus should be on assessing whether the factory has established a quality management system that complies with ISO 9001, IEC 62133, etc., and whether it has a complete incoming material inspection (IQC), process inspection (IPQC), and finished product inspection (FRI) mechanism. The inspectors should clearly define the product type (such as lithium-ion, nickel-metal-hydride, lead-acid, etc.), applicable standards (such as GB, IEC, UL, UN 38.3, etc.) and customer technical agreements in advance, and prepare the testing equipment and tools.
II. Key Inspection Items and Standards for Batteries
1. Hazardous Substance Testing:
In accordance with the standards of the European Union 2006/66/EC, the United States Battery Act, and GB/T 20155, the content of lead, cadmium, mercury, etc. is strictly restricted;
Common detection methods: EPA 3052 digestion + ICP-MS method (EPA 200.8) is used for trace element analysis.
2. Safety and Performance Testing:
Lithium-ion batteries: Must meet safety requirements such as UL 1642, IEC 62133, and GB 31241, including abuse tests such as short circuit, overcharge, compression, and thermal shock;
Nickel-metal hydride / nickel-cadmium batteries: Tested in accordance with the IEC 61951 series standards for capacity, cycle life and safety performance;
Lead-acid batteries: Verified for start-up capability, capacity and sealing reaction efficiency in accordance with IEC 61056 and GB/T 5008;
Transportation Safety: All lithium batteries must pass the UN 38.3 certification (including 8 tests such as vibration, shock, overcharge, short circuit, etc.).
3. Electrical performance and reliability tests:
Capacity test: Verify whether the actual capacity is consistent with the nominal value (for example, lithium-ion batteries often require 0.2C/1C discharge tests);
Internal resistance and cycle life: Monitoring battery aging characteristics and evaluating long-term reliability;
Environmental adaptability: High and low temperature charge and discharge tests, temperature shock, humidity storage, etc.
4. Structural and Process Inspection:
Visual inspection: The shell is free from deformation and rust; the markings are clear and durable (including rated voltage, capacity, polarity and warning messages);
Internal structure: The sampling units were disassembled and analyzed to confirm that the electrodes, separators, electrolytes, etc. met the design specifications.
Welding and packaging quality: Check the welding strength of the tabs and the sealing performance of the packaging to avoid the risk of leakage.
5. Label and Document Review:
Verify that the battery labeling complies with the regulations of the target market (such as CE, WEEE, and RoHS labels);
Check the accompanying documents such as MSDS (Material Safety Data Sheet), test reports and certificates of conformity.
III. Common Defects and AQL Defect Classification
Serious Defects (Critical Defects): Severe mislabeling of capacity, failure of safety tests (such as fire, explosion), excessive hazardous substances, insulation failure;
Major Defects: Insufficient capacity, failure to meet cycle life requirements, abnormal internal resistance, shell rupture;
Minor Defects: Indicate minor blurriness, slight scratches or stains on the appearance.
IV. Inspection Process and Sampling Suggestions
Strictly follow the AQL sampling plan (such as ISO 2859-1) for sampling inspection. For high-risk products, the sampling can be tightened.
Focus on monitoring the key process points of the production line (such as charging, capacity measurement, and packaging), and implement Statistical Process Control (SPC).
For the first batch of supply or batches with design changes, it is recommended to introduce a third-party inspection service for independent verification of safety and performance.
The inspection report should clearly record the type of defects, test results and images of non-conformities, facilitating traceability and improvement.
V. Summary and Recommendations
Battery inspection is a specialized task that integrates chemical, electrical, mechanical, and environmental safety. Enterprises should establish a multi-level protection system through regular supplier audits, process quality inspections, and terminal product verifications. Special attention should be paid to the safety and compliance of lithium batteries, and it is strictly prohibited to use inferior battery cells or secondary processed products. Only by deeply integrating international standards, customer requirements, and internal quality control can the reliability, safety, and market competitiveness of battery products be continuously improved.