Battery Abuse Testing – AEI Presentation at Generac

About the Event:


  • Lithium Ion Batteries (LIB) are quickly becoming the new source of energy for on-road and off-road vehicles.  As LIB energy densities increase, so too do the level of hazards, such as in the form of heat and gas.  Regulating agencies are becoming aware of these hazards and are reacting by creating protocols to test the safety integrity of LIB packs. 

Companies who’ve tested liquid and gaseous vehicles within their facilities have a deep understanding of the risks associated with those types of energy sources within their building.  Now, however, many are questioning the similarities and differences between testing with traditional fuels and testing with LIB packs.  We will compare the differences between designing a traditional fuel source test cell and the design of a test cell that contains a LIB.  We will discuss abuse bunkers and what cautions to be aware of when designing a LIB abuse bunker.  We will share heat and gas release data used to determine the air exchange rate in a LIB test cell and abuse bunker, and touch upon the emissions mitigation techniques, such as a scrubber or RTO system, used to manage the gas and particles expelled during a LIB thermal runaway event.  We will discuss the defense-in-depth strategy used to protect a LIB testing facility and its personnel, including blast panel area, gas/heat detection, air exchange rates, electrical classification and the abundance of water, to name a few.  Finally, how we consider prevention, detection, and reaction techniques to ensure a safe and effective testing environment.

This presentation is unique in that we will share heat and gas related information that is difficult to acquire given the emerging nature of LIB abuse testing.  We will reference many white papers and national lab studies used in our calculations, information that was used to extrapolate pack level data from single cell data.   

Guest Speakers:

Jeremy Lang, Project Manager and Jacob Weber, Mechanical Engineer (PE) from Affiliated Engineers, Inc.

Jeremy has spent the past 20 years in the engine and vehicle testing market.  Starting in controls and automation, Jeremy traveled globally installing, programming and commissioning test cells, and more recently, leading the design of those facilities. Now, following the market trend to full electrification, Jeremy is applying the facility design practices learned in engine and vehicle test cells containing hazardous fuels to the lithium ion battery testing market, with some caveats. 

Generac and AEI have been partners for years. AEI has enabled growth in Generac’s engineering test and development facilities, driving record expansion. Come learn about AEI’s technology hosted by Generac at their Kern Auditorium.

Event Agenda

  • Registration………….5:00-5:30pm
  • Networking…………..5:00-6:00pm
  • Dinner…………..………6:00-6:45pm
  • Presentations…..…..7:00-8:00pm

Registration Fees

SAE Members…………………….$35
Retirees …………………………….$25
Guests/Non-members………… $40
Students ………………………….. $10

SAE May 2019 Event – Snap-on InnovationWorks

What: May 2019 Section Event – Snap-on InnovationWorks

When: Tuesday May 28th, 2019 – 4:30pm -7:30pm

Where: Snap-on, Inc. – InnovationWorks, 2801 80th Street, Kenosha, WI 53143

Cost: $35 (non-member), $25 (member), $20 (retiree), $5 (student)

Registration Contact: Garrett Herning @ (856)-313-0581,, or website: Event Calendar for the Milwaukee Section of SAE

Deadline: May 24th at Noon – Max attendance 75

About the Event :
The presentation will include a brief overview of Snap-On including their history and current product line up. Presenters Gary Wollert & John Fuhreck (Both SAE Milwaukee Section Members) will then talk about what has changed in both the business model and product design cycle in the last 10 years? Especially with other tool companies who used to be more of a complimentary tool or non-competitor, who may now be competing on some product lines. Also, automotive technology changes at a very rapid pace and with so many electric vehicles coming out, what effect is this having on product lines? A Q&A session will follow.

About the Tour :
Our host, Patrick Donohue will give us a guided tour of the Snap-on museum and the InnovationWorks facility.  InnovationWorks is the centerpiece of the innovation network at Snap-on. The facility utilizes several distinct areas – each designed to support and enhance a vibrant, user-centered innovation process.

SAE April 2019 Event – Wells Vehicle Electronics

What: April Section Event – Wells Vehicle Electronics

When: Tuesday April 9th, 2019 – 4:30pm -7:45pm

Where: Wells Vehicle Electronics, 385 West Rolling Meadows, Fond Du Lac, WI 54937

Cost: $35 (non-member), $25 (member), $20 (retiree), $5 (student)

Registration Contact: Garrett Herning @ (856)-313-0581,, or website: Event Calendar for the Milwaukee Section of SAE

Deadline: April 5th at Noon – Max attendance 60

About the Event :
Wells Vehicle Electronics is manufacturer of engine & vehicle management components such as electronic ignition modules, ignition coils, voltage regulators, camshaft sensors, crankshaft sensors, throttle position sensors, and a variety of custom electronic components. We are divided into two business units – an aftermarket unit that supplies components to aftermarket parts retailers and distributors. In addition, Wells designs and manufactures OE components for non-automotive OEM vehicle and engine manufacturers.
Wells has been in business since 1903. One of our first customers was Henry Ford for who we developed and built a magneto ignition coil. In 2015 we were purchased by and became a wholly owned subsidiary of NGK Sparkplugs based in Nagoya Japan. NGK is a worldwide leader in sparkplugs, oxygen sensors, and technical ceramics. On the tour you will see and hear about the design and manufacturing of electronic modules for vehicles including sensors and voltage regulators.

For the evening presentation, we will cover the following:

Part 1: Wells Overview – Greg Burneske

Wells manufactures a wide variety of sensors for automotive, powersports, and stationary power applications. This session will provide you with an overview of Wells engine management product portfolio including ignitions, sensors, voltage regulators, emissions and custom electronic products.

Part 2: Ignition Coils – Dallas Kissinger

Wells manufactures a line of ignition coils for various automotive applications. This session outlines the design engineering and manufacturing challenges of supplying ignition coils.

Part 3: Sensors – Tim Reitmeyer

Wells manufactures a wide variety of sensors for automotive, powersports, and stationary power applications. This session will provide an overview of sensor types that Wells manufactures and how an oil pressure sensor is made.

Part 4: Voltage Regulators – Dave Hansen

Wells manufactures a line of voltage regulators for non-automotive vehicle applications. This session outlines the design engineering and manufacturing challenges of supplying voltage regulators for non-automotive applications.

SAE February 2019 Event – DeltaHawk Engines

What: February Section Event – Delta Hawk Engines

When: Wednesday 27th, 2019 – 5:00pm -7:30pm

Where: DeltaHawk Engines, Inc., 2300 South Street, Racine, WI 53404

Cost: $35 (non-member), $25 (member), $20 (retiree), $5 (student)

Registration Contact: Garrett Herning @ (856)-313-0581,, or website: Event Calendar for the Milwaukee Section of SAE

Deadline: Friday February 22nd – Max attendance 65

The development of a lightweight, compact, simple and reliable Heavy Fuel reciprocating engine for aerospace applications has been attempted by numerous companies.  Most of these engines are derivatives of automotive engines. DeltaHawk Engines, Inc. of Racine, Wisconsin has spent well over a decade developing a purpose-built aviation engine targeted both for General Aviation and UAS applications.  The goals of this project have been to produce an engine that burns heavy fuels with high fuel efficiency, manned-aircraft reliability and very low maintenance.  With sufficient funding now in-hand, the engine is nearing completion, with FAA Certification and commencement of production targeted in 2019.

Aviation engines present a challenging set of problems for engineers, many of which are unique to aviation. The engine requirements include race-engine like performance, combined with very low weight, compact size, and extraordinary reliability and durability.  The added challenge is that these engines must meet extremely high regulatory standards and oversight from aviation authorities. Light General Aviation aircraft have historically utilized air-cooled, spark-ignition engines, literally derivatives of World War II technology.  These engines burn specialized aviation gasoline, which is under environmental pressure.  

DeltaHawk has developed a Jet-Fuel powered General Aviation engine that brings the advantages of diesel technology to aviation.

This presentation will give an overview of the history of aviation diesels, the market drivers, and a look at the DeltaHawk engine architecture.


Dennis Webb; PE, Director of Certification and Marketing

Paul Olesen;  Director of Engineering

Dennis Webb, Director of Certification and Marketing, holds a BS in Electrical Engineering from University of Missouri-Rolla and completed the Executive Program at University of Virginia – Darden School of Business.  He holds a Professional Engineer (PE) license and is an FAA Designated Engineering Representative (DER).  He is a voting member of ASTM F44 Small Airplane Standards and J02 Aviation Fuels Committees, Co-Founder of ASTM Jet-Diesel Committee, and a voting member of SAE E-34 Propulsion Lubricants, E-38 Aviation Piston Engine Fuels and Lubricants, and E-39 Unmanned Aircraft Propulsion Committees. He is also a 2000-hour Instrument-Rated Private Pilot.

Paul Olesen, Director of Engineering, holds a BEng in Motorcycle Engineering from the University of Wales Trinity St. David, specializing in two-stroke engines. He has designed and built a clean-sheet 70 hp 250cc two-stroke engine, built a racing motorcycle, and is a published book author on dirt bike engine building. He also co-built a Van’s RV10 aircraft and is a Private Pilot.

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