Thomas Hucke, Leiter des DEKRA Batterie Test Centers in Klettwitz. Foto: DEKRA

Interview with Thomas Hucke – Head of the DEKRA Battery Test Centre in Klettwitz

Batteries are the centrepiece of electromobility – and as with any heart, you want to know whether it beats reliably. But what happens when things get hot? This is exactly what is tested in specialised test laboratories. This is where it gets down to business: pressing, perforating, igniting – under strictly controlled conditions, of course. No wonder, because according to the Federal Motor Transport Authority, over 800,000 new electric cars will be on German roads in 2023 alone. And they all need a storage system that not only supplies electricity but also remains safe. According to the Federal Institute for Materials Research and Testing, battery fires are now very rare. This is also thanks to the strict regulatory requirements and tests. In the meantime, stationary storage systems, for example for private homes, are also being tested more frequently. Since 2024, the EU wants to know exactly what it means. This means more tests, more laboratories – and above all more safety for all of us, as Thomas Hucke, Head of the DEKRA Battery Test Centre in Klettwitz, Brandenburg, confirms. An interview in the current eMove360° magazine in german language.

What is tested at the new DEKRA Battery Test Centre?

Thomas Hucke: We test batteries under real, extreme conditions: from nail penetration and crush tests to cold and heat simulation. On the one hand, the tests serve the legally required type approval, but on the other hand, they are also offered to accompany development. What makes it special: Everything takes place in one place – from crash tests to environmental testing. DEKRA is an accredited test centre and notified body for vehicle and component testing as well as homologation tests, offering a complete package that is unique in Europe.

How is the topic of sustainability implemented at the centre?

Hucke: The test centre will use solar energy from its own premises, as well as an intelligent system for energy recovery: batteries in the discharge feed other test benches so that as little new energy as possible is drawn from the grid. A flue gas scrubber filters harmful emissions during fire tests. We also use CO₂ instead of climate-damaging gases as a refrigerant – sustainability is a technical consideration here. In addition, the BTC, like the entire site, is supplied with heat from a biogas plant.

Are modern batteries still a fire hazard?

Hucke: No. Although safety limits are deliberately exceeded in order to simulate risks, today’s storage systems are considered very safe in regular use. New generations of batteries are increasingly dispensing with critical electrolytes, which significantly reduces the risk of thermal runaway. Fires like those in the past are rare isolated incidents – usually the result of an accident or improper use.

How is DEKRA preparing for the next generation of batteries?

Hucke: Solid-state batteries are seen as the future of electromobility – with higher energy densities and voltages. Our test benches are prepared for these developments. Although electrolytes are changing – for example through the use of ceramics or polymers – the basic test standards remain the same. DEKRA continuously adapts its test capacities and can also reliably test large storage systems, for example for lorries or agricultural machinery.

What new areas of application for batteries are coming into focus?

Hucke: Ultimately, we don’t care where the battery is used – the main thing is that it is safe. In addition to vehicle batteries, DEKRA will also be testing stationary storage systems for households or grids as well as batteries for ships, trains or work machines in the future. The EU has required new certifications since 2024 – and the need for testing is therefore constantly increasing. Even smaller storage systems are subject to strict requirements. DEKRA covers all fields with modular test systems.

When will the new battery test centre at the Lausitzring start?

Hucke: The opening is planned for autumn 2025. The construction of the buildings and infrastructure and the installation of the test systems are currently running in parallel. We want to show that we can deliver. The goal: full order books and satisfied pilot customers. The ‘Safe Battery Experience’ on 8 and 9 October will present the centre to the professional public. This is a good opportunity to find out about DEKRA’s capabilities.