Attachment_E_Appendix_A_IV_V_Test_Plan.docx
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- Solicitation number
- DARPA-PS-26-118
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This is a Test Plan appendix that specifies validation and characterization testing requirements for advanced battery technology being developed under the DARPA ExPEDitions program. The document outlines comprehensive testing protocols organized into four primary categories: Performance Characterization, Safety & Abuse Testing, Cycle Life & Aging, and Prototype Sub-System Functional & Integration Testing, with additional Operational & Environmental Readiness testing requirements.
Performance Characterization testing includes capacity verification at multiple charge rates (0.2C, 1C, 2C), DC internal resistance measurement across various states of charge and temperatures, and Hybrid Pulse Power Characterization to evaluate power capability. Safety & Abuse Testing requires overcharge/over-discharge tests, external short circuit tests, thermal stability exposure, and nail penetration/crush tests to simulate mechanical damage, with documentation of fail-safe behavior compared against established lithium-ion cell standards. Cycle Life & Aging testing mandates accelerated cycle life testing until capacity degrades to 80% of initial capacity with projected lifecycle analysis. Prototype Sub-System testing includes physical and electrical integration verification, hotel load sustainability testing through continuous discharge at steady rates, Design Reference Mission simulation using dynamic power profiles replicating proposed operational end-use conditions, and Battery Management System (BMS) validation of sensor accuracy and State of Charge/State of Health algorithms. Environmental testing requirements encompass vibration and shock testing replicating transit conditions, thermal-vacuum and atmospheric cycling in humid salt-fog environments to assess corrosion resistance, and pressure testing to verify enclosure protection against water ingress. All testing requires comprehensive data logging and post-test reporting demonstrating that the battery technology successfully meets peak power demands and completes full operational cycles without performance degradation.
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Other files
| File | Type | Posted |
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| Attachment_D_Controlled_Unclassified_Information__CUI__Guide.pdf | ||
| Attachment_B_Abstract_Instructions_and_Template.docx | DOCX document | |
| Attachment_A_Abstract_Summary_Side_Template.pptx | PPTX presentation | |
| DARPA-PS-26-118.pdf | ||
| Attachment_F_Associate_Performer_Agreement.docx | DOCX document | |
| Attachment_C_ExPEDitions_Full_Proposal_Guidance_Planning_Purposes.docx | DOCX document |
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Text version
Appendix A. ExPEDitions IV&V Testing Cell and Chemistry Validation
| Test Category |
| Potential Tests |
| Data to Collect & Results to Present |
| Performance Characterization |
| · Capacity Test: Charge/discharge at various C-rates (e.g., 0.2C, 1C, 2C) to confirm capacity |
· DC Internal Resistance (DCIR): Measure at various states of charge (SoC) and temperatures
· Hybrid Pulse Power Characterization (HPPC): Evaluate power capability at different SoCs
· Verified energy density (Wh/kg) and volumetric density (Wh/L)
· Charge/discharge efficiency curves
· DCIR vs. SoC and temperature charts
· Reports confirming power delivery capabilities meet or exceed those of standard Li-ion cells
| Safety & Abuse Testing |
| · Overcharge/Over-discharge Tests: Push cells beyond their specified voltage limits |
· External Short Circuit Test
· Thermal Stability Test: Expose cells to extreme temperatures
· Nail Penetration/Crush Test (to simulate mechanical damage)
· Report detailing cell behavior under abuse conditions
· Evidence of "fail-safe" behavior (e.g., venting without thermal runaway)
· Comparison of safety performance against established Li-ion cell standards
| Cycle Life & Aging |
| · Accelerated Cycle Life Test: Cycle the cells continuously under a simulated load profile until capacity degrades to a set threshold (e.g., 80% of initial capacity) |
· Plot of capacity fade over extended cycles
· Projected cycle life under expected operational conditions
Prototype Sub-System Functional & Integration Testing
| Test Category |
| Potential Tests |
| Data to Collect & Results to Present |
| Physical & Electrical Integration |
| · Physical Measurement Check: Verify all physical dimensions, mounting points, and connector placements against the user manual specifications |
· Electrical Interface Verification: Confirm voltage levels, connector compatibility, and communication protocol integration with the end use application’s power distribution and control systems
· A signed-off report confirming the prototype meets all mechanical drawing requirements
· Data logs showing successful "handshakes" and communication between the prototype BMS and the end use application’s control systems
| Hotel Load Sustainability |
| · Continuous Discharge Test: Discharge the battery at a steady rate typical of an average hotel load for the proposed end use |
· Plot of voltage and temperature stability over the full duration of the test
· Total energy delivered (kWh) and evaluation against typical end use requirements
| Design Reference Mission Simulation |
| · Dynamic Power Profile Test: Cycle the battery using a profile that simulates proposed end use. This may include high-power operational loads (e.g., acoustic communications), hotel loads, and charging periods |
| · Real-time logs of voltage, current, power, and temperature throughout the simulation |
· Confirmation that the battery meets all peak power demands
· Post-mission report on SoC, efficiency, and thermal performance
· The results should demonstrate that the battery can successfully power the end use application through a complete operational cycle
| BMS Validation |
| · Sensor Accuracy Test: Compare BMS readings (voltage, current, temperature) against calibrated external sensors |
· SoC and SoH Algorithm Validation: Verify the accuracy of the State of Charge and State of Health estimations
· Report on the accuracy of all BMS sensors
· Comparison of BMS-reported SoC/SoH against measured data to prove algorithm accuracy
Operational & Environmental Readiness:
| Test Category |
| Potential Tests |
| Data to Collect & Results to Present |
| Environmental Testing |
| · Vibration and Shock: Subject the prototype to vibration profiles and shock tests that replicate conditions during transit and typical use |
· (where appropriate) Thermal-Vacuum/Atmospheric Cycling: Cycle the battery's temperature between operational extremes in a humid, salt-fog environment to test for corrosion and performance in adverse weather
· (where appropriate) Pressure Test: Verify the enclosure's ability to protect against water ingress and / or depth requirements
· Pre- and post-test performance data showing no degradation
· Inspection reports confirming no mechanical or corrosion damage
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