Pack and system tests¶

Section 8.2 of GB 38031-2025 defines 17 safety tests for battery packs and systems (clauses 8.2.1 through 8.2.16, with thermal stability split into 8.2.7.1 and 8.2.7.2). Pass criteria live one section earlier (clauses 5.2.x). The 17 tests fall into four sub-domains:

Sub-domain	Count	Clauses	Index
Mechanical	5	8.2.1, 8.2.2, 8.2.3, 8.2.4, 8.2.16	Mechanical tests
Environmental	5	8.2.5, 8.2.6, 8.2.8, 8.2.9, 8.2.10	Environmental tests
Electrical protection	5	8.2.11, 8.2.12, 8.2.13, 8.2.14, 8.2.15	Electrical tests
Thermal stability	2	8.2.7.1, 8.2.7.2	Thermal stability tests

Conventions for pack and system tests¶

Universal STD pass criterion (unless a clause says otherwise): after the test, no leakage, no housing crack, no fire, no explosion, plus insulation resistance ≥ 100 Ω/V (DC) and ≥ 500 Ω/V if an AC circuit is present. From clauses 5.2.x.
Test environment: 22 °C ± 5 °C, RH 10–90 %, 86–106 kPa (clause 6.1.1).
SOC: Highest working SOC per clause 6.1.10.
Insulation method: Per Appendix B (Method 1 voltage-divider; Method 2 insulation-resistance meter at ≥ 1.5× nominal V or 500 V DC).
Pre-treatment: Standard, per clause 7.2.

Notable exceptions to the universal STD criterion: compression (5.2.4 drops leakage and housing crack), immersion Method 1 (5.2.6 a — only no fire/explosion), thermal stability (5.2.7 — separate criteria for external fire and thermal propagation including the 5-minute warning rule).