Road debris strikes remain one of the most overlooked risks to electric vehicles (EV) battery integrity (https://www.evfiresafe.com/research-ev-fire-charging). Without proper testing, a single underbody impact can lead to thermal events, costly recalls, or compliance failures.

With the ever-increasing number of EVs on the road, it is of the utmost importance that manufacturers conduct comprehensive testing to ensure the safety of operators and pedestrians, as well as the mechanical components of the vehicle itself.

That’s why MGA Research Corporation has multiple labs dedicated to testing EV battery systems for safety and performance. These locations include Holly, Michigan; Burlington, Wisconsin; and Akron, New York.

Why Understrike Testing Matters

Among MGA’s capabilities is Battery Understrike Testing. These tests are designed to ensure an EV’s battery system can withstand impacts from road debris while remaining safe and operational.

Testing is designed to replicate a wide range of real-world scenarios, including sharp objects and various obstacles. MGA’s fully adjustable understrike testing rig features a modular design capable of attaching full packs from any manufacturer and striking at any location with the desired energy and load form. Load form, mass, and velocity are controlled variables that can be defined to satisfy the desired test targets.

In addition to the capability of designing and fabricating various load forms, MGA also has the flexibility to fabricate a wide range of fixturing solutions. These include fixturing setups for understrike, drop impact, etc.  The photos below illustrate a universal style test system intended to elevate the battery for controlled impacts on the underside enclosure surface.  Custom designs can also be offered to mount a battery or module upside down (with the lower surface facing up).  This style is useful for lowering the overall height of the battery during testing and allows for impacts from the top as opposed to the bottom.

Get in touch with our fixtures and fabrication team for custom solutions today!

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MGA’s State-of-the-Art Equipment

• The structure allows for full access of the underside of the battery due to elevated mount design.
• MGA’s dynamic impactor is mounted to allow for free movement to any impact location needed.
• Impact forms can be custom designed and fabricated by MGA to mimic most real-world impact geometries (Pictured: 25mm round)
• Mounting rails can be fabricated to attach batteries in actual vehicle mounting conditions.
• Testing is performed within MGA’s battery test bunkers for a safe testing environment.

Why Partner with MGA

MGA takes pride in its team of personnel with the knowledge and experience to assist EV manufacturers in ensuring the safety and performance of their products and their compliance with all motor vehicle safety standards.

Common functional checks following testing can include isolation measurements, leak checks, full charge/discharge cycling procedures, and other measurements as defined by our customers.  These activities can be supported by MGA’s experienced battery technicians and engineers, helping to ensure consistent and reliable results.  

MGA’s customers also have access to various facility tools and lab space for post-test tear down evaluations for immediate diagnosis.  This provides quick feedback and eliminates potential additional factors that could arise from transporting the battery to a different location for tear down. The advantage of handling the full process under one roof also improves test flow, reduces shipping costs, and provides a more efficient experience for customers as travel needs are minimized.

Contact MGA Research today to learn more about our battery testing capabilities and services.