World’s First AI-Controlled Thermal Runaway Testing System

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Energy storage systems are springing up like mushrooms after rain — in factories, logistics centers, office buildings, and even single-family homes. They are an inseparable element of the energy transition, but also a potential source of serious hazards. One of them is thermal runaway — a chain reaction inside a cell in which temperature and pressure rise uncontrollably, leading to fire or explosion. This phenomenon has long kept engineers and battery manufacturers awake at night. The answer to this growing threat is an innovative solution presented by SGS.

Automation, precision, and safety in a single system
SGS, in cooperation with Chongqing Energy College, has developed the world’s first fully automated and AI-powered battery thermal runaway test platform. The system was designed in compliance with the ANSI/CAN/UL 9540A:2025 standard, enabling precise assessment of fire propagation in energy storage systems and delivering reliable data on potential hazards.

At the heart of the solution is deep learning. Algorithms based on models such as YOLO, TensorFlow, ResNet, and VGG analyze temperature, voltage, gas emissions, and combustion dynamics in real time, while automatically adjusting test settings. The system’s camera can “see” the first signs of smoke or fire faster than the human eye, with data immediately cataloged and analyzed.

Central control software manages the entire procedure — from initialization and parameter adjustment to data collection. This enables:

  • Faster certification – automation and real-time analysis significantly shorten time-to-market.
  • Cost reduction – optimized processes lower expenses for testing and retesting.
  • Greater accuracy – intelligent algorithms eliminate human error, ensuring consistent and reliable results.
  • Higher safety levels – reduced exposure of personnel to high-risk conditions.

The Chongqing laboratory, where the new system operates, obtained ISO/IEC 17025 accreditation as early as 2022, becoming the first facility in China authorized to test according to the UL9540A standard.

From EV charger testing to energy storage systems
The new SGS solution is part of the broader TeREES® L2 (Testing Resource eco-Efficiency Enhancement Solutions) program — a digital platform integrating laboratory operational technologies, IT, and expert knowledge in testing, inspection, and certification. Within this initiative, automated test systems have been developed for electric vehicle chargers and energy conversion systems.

The goal of TeREES® L2 is full process transparency, intelligent test planning, and advanced data analytics. This makes it possible to shorten product launch times, lower compliance costs, and ensure higher quality. In the context of the global energy transition, this not only provides a competitive edge for manufacturers but also makes a tangible contribution to safety and the sustainable development of the renewable energy sector.

Source: sgs.com

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