AABC Europe 2017, Mainz, Germany Safety Testing for xEV...
Transcript of AABC Europe 2017, Mainz, Germany Safety Testing for xEV...
TÜV SÜD Battery Testing GmbH
AABC Europe 2017, Mainz, Germany
Safety Testing for xEV Batteries –Comparison of Test Standards and
Validation Procedures
31 January 2017
Dipl.-Ing. (FH) Alexander Stadler
TÜV SÜD Battery Testing GmbH
Agenda
TÜV SÜD Battery Testing GmbH Slide 2
1 Introduction TÜV SÜD
2Safety Testing for xEV Batteries -
Overview of Test Standards
3 GTR on Electrical Vehicle Safety
AABC Europe 2017
Agenda
TÜV SÜD Battery Testing GmbH Slide 3
1 Introduction TÜV SÜD
2Safety Testing for xEV Batteries -
Overview of Test Standards
3 GTR on Electrical Vehicle Safety
AABC Europe 2017
TÜV SÜD Battery Testing GmbH Slide 4
TÜV SÜD Facts & Figures
Li-Ion Battery Testing – Global Approach
U.S.A.
CANADA
CHINASOUTH
KOREA
SINGAPORE
GERMANY
Complete service
portfolio for cell,
module and system
testing
Performance and
environmental
testing on cell,
module and system
level
Singapore
Performance,
environmental and
abuse testing on cell
level
Shenzhen, China
• Performance
testing on cell,
module and
systems level
• Abuse testing on
cell level
Seoul, Korea
Complete service
portfolio for cell,
module and system
testing
Toronto, Canada
Auburn Hills, USA
Garching,
Germany
Complete service
portfolio for cell,
module and system
testing
Tokyo, Japan
JAPAN
Performance
Lifetime Cycling /
Ageing, Power,
Performance,
Calendaric Ageing
Abuse / SafetyElectrical, Thermal,
Mechanical,
Customer Specific
EnvironmentalThermal, Mechanical,
Climatic, Chemical,
EMC, UN38.3
AABC Europe 2017
TÜV SÜD Battery Testing GmbH Slide 5
TÜV SÜD – Battery Testing Laboratory Garching
Performance
• Cell level up to
6V / ±960A
• Module level up
to 80V / ±1.200A
• Pack level up to
1.200V/±800kW
• Temperature
-70°C to +180°C
Environmental
• Shaker
• Shock machine
• Altitude
simulation
• Temperature
shock
• Salt spray / Dust
• EMC
Abuse / Safety
• Separate explosion proof test rooms, gas scrubber
• Electrical safety tests up to 1.200V / 800kW
• Short Circuit >10kA, <1mΩ to >100mΩ
• Nail-Penetration (100µm/s to 200mm/s)
• Crush 100t, horizontally, very large DUTs possible
• Shock of large DUTs (Sled)
• 10m drop tower e.g. for dynamic crush test
• Customer specific test setups…
AABC Europe 2017
Agenda
TÜV SÜD Battery Testing GmbH Slide 6
1 Introduction TÜV SÜD
2Safety Testing for xEV Batteries -
Overview of Test Standards
3 GTR on Electrical Vehicle Safety
AABC Europe 2017
Introduction
TÜV SÜD Battery Testing GmbH Slide 7
Presentation ofEU
Car Sales:2015: 13,7 Million
xEV Sales:2015: >75k EV +
USA
Car Sales:2015: 17,3 Million
xEV Sales:2015: >100k PEV
China
Car Sales:2015: 24,6 Million
xEV Sales:2015: >90k EV + >50k PHEV
Validation standards:
Various sets of tests to prove the safety of
a product
Outlook on upcoming Global Technical
Regulation (GTR):
Status of the work in process and
comparison of current draft to existing
regulations
AABC Europe 2017
Sources for validation standards & regulations for xEVs
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EU
• USA
USA China
International Standardization Organisations (e.g. ISO, IEC)
Deutsches Institut
für Normung
Standardization Administration
of the P.R. of ChinaSACAmerican National
Standards Institute
National / Industry standards National / Industry standards National / Industry standards
ANSIDIN
e.g. DIN, VDI, VDE, VDA e.g. ANSI, SAE, UL e.g. SAC, GB/T, QC/T
Mandatory Regulations Mandatory Regulations Mandatory Regulations
ECE FMVSS GB
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Mandatory Regulations
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EU
• UN ECE regulations
• Type approval
• Conformity tested and confirmed
by accredited service provider
• Accreditation by national
authority, e.g. KBA in Germany
ECE R100
USA
• FMVSS (NHTSA)
• Self certification
• “It is the responsibility of a
manufacturer of vehicles and/or
items of motor vehicle
equipment to certify that each
motor vehicle and/or equipment
item is in full compliance with
the minimum performance
requirements of all applicable
Federal Motor Vehicle Safety
Standards (FMVSSs).”
FMVSS 305
China
• CCC to GB standards (AQSIQ,
SAC)
• Need to be performed by
specified execution bodies
(CATARC, SMVIC…)
• GB/T 31484, GB/T 31485 ,
GB/T 31486, GB/T 31647.3
need to be tested
• QC/T 746 will be replaced by
new GB standards
• Additional requirements by local
provinces
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Key standards / regulations
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EU USA China
ISO 12405-1/2/3: Electrically propelled road vehicles -- Test specification for lithium-ion traction battery packs and systems -- Part 1: High-power
applications. Part 2: High-energy applications Performance & Abuse (SC, OC, OD)
Part 3: Safety requirements for tests of part 1&2 + Additional Tests & clarifications
IEC 62660-1/2/3: Secondary lithium-ion cells for the propulsion of electric road vehicles –
Performance tests / Abuse tests / Safety requirements
ECE R 100 Rev. 2
Mandatory from 07/2016Annex 8: 9 tests for batteries / vehicle
8A Vibration
8B Thermal Shock
8C Mechanical Shock
8D Mechanical Integrity
8E Fire resistance
8F Ext. Short circuit protection
8G Overcharge protection
8H Over-discharge protection
8I Over-temperature protection
FMVSS 305Limits allowed electrolyte leakage and
isolation for xEVs tested according to
FMVSS208, FMVSS214, FMVSS301
SAE J246415 abuse tests on cell / module / pack
Mechanical / thermal / electrical tests
SAE J2929Defines safety requirements for tests of
SAE J2464 + additional tests &
clarifications
GB/T 31485Abuse tests on cell / module +
safety requirements
GB/T 31467-3Based on ISO 12405-3 +
Additional Tests AND/OR
changed parameters
GB/T 31484, GB/T 31486Performance cell / module
UN 38.3
AABC Europe 2017
Agenda
TÜV SÜD Battery Testing GmbH Slide 11
1 Introduction TÜV SÜD
3
2Safety Testing for xEV Batteries -
Overview of Test Standards
GTR on Electrical Vehicle Safety
AABC Europe 2017
GTR on Electrical Vehicle Satefy (EVS)
TÜV SÜD Battery Testing GmbH Slide 12
1958 Agreement - UNECE
• “Agreement concerning the adoption of uniform technical prescriptions for wheeled vehicles, equipment and parts which can be fitted and/or be used on wheeled vehicles and the conditions for reciprocal recognition of approvals granted on the basis of these prescriptions”
• Basis for the UNECE Regulations
• Based on principle of type approval
• Not signed by the USA and China
1998 Agreement - GTR
• “Agreement concerning the Establishing of Global Technical Regulations for Wheeled Vehicles, Equipment and Parts which can be fitted and/or be used on Wheeled Vehicles”
– 36 contracting parties including USA and China
– GTR No. 5 Technical requirements for on board diagnostic
systems– GTR No. 13 Regulation on hydrogen and fuel cell vehicles
• In 2012: Initial proposal submitted, followed by the establishing of the
electric vehicle safety (EVS) working group
Effort to develop one or more GTRs to address the safety of EVs
• GTR Draft submitted (Dec. 2016) – end of Phase 1
• Including near term safety requirements (consensus of working group)
Goal: acceptance of GTR by the end of 2017
AABC Europe 2017
New GTR proposal
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Requirements of a vehicle with regard to its electrical
safety - in-use
Requirements of a vehicle with regard to its electrical
safety - post-crash
Requirements with regard to installation and
functionality of REESS in a vehicle
Requirements with regard to the safety of REESS in-
use
Requirements with regard to the safety of REESS –
post-crash
Protection against
water effects
Additional
requirements
concerning post-crash
safety und
functionality
Seperate section for
Heavy duty vehicles
AABC Europe 2017
RESS safety requirements in use
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Test SoC and SoC adjustment
• All tests done at maximum, during operation
possible SoC.
• Temperature range for SoC adjustment
defined
– 20 ± 10°C (vehicle level)
– 22 ± 5°C (component level)
Vibration
• RESS fixed using original mounting points and holders as in the vehicle– Taking into account resonance effects; also
testing fixation structures an holders– R100 vibration profile (for the moment)
Thermal shock and cycling test
• According to R100
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Comparison of existing vibration requirements
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UN ECE R100
• Sinusoidal waveform with a logarithmic
sweep
• Only Z-Axis
• 3 hours
GB/T 31467.3
• Random vibration profile (PSD)
• All three axis
• 21 hours per axis
Frequency (Hz) Acceleration (m/s²)
7 – 18 10
18 – 30 gradually reduced from 10 to 2
30 - 50 2
Frequency (Hz) Power spectrum density
(m/s²)²/Hz
5 4.81
10 5.77
20 5.77
200 0.08
RMS 14.13 m/s²
AABC Europe 2017
RESS safety requirements in use
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Fire resistance
• Use of LPG Burner allowed– 2 minutes fire exposure at 800 – 1100 °C
• More uniform temperature distribution, more reproducibility
• Reducing high risk of performing test with gasoline fuel on large DUT‘s– Large volume and resulting gasoline surface pose
high risk, even for specialized labs
Courtesy of Dr. Dietmar Schelb FFB/KIT
AABC Europe 2017
RESS safety requirements in use
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External short circuit protection
Overcharge protection test
Over-discharge protection test
Over-temperature protection test
• Additional posibility to conduct tests on
vehicle level
– Breakout harness
– Dynanometer (charging, discharging)
– External power supply
– External resistor
AABC Europe 2017
RESS safety requirements in use
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Overcurrent protection
Low-temperature protection
Management of gases emitted
Thermal propagation
• Overcurrent during external DC charging
• Test on vehicle basis or with breakout
harness
• Functional safety proof requested
• Only open type batteries– Hydrogen emission
• Detection of single cell thermal runaway– Description of the warning and detection
system– Risk analisis and mitigation– Tests or simulation
Equipment
Nail penetration device in safety area
Press force: 20 kN
Feed speed: 0 - 80 mm/sec
AABC Europe 2017
RESS safety requirements in use
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Mechanical shock
Mechanical integrity
• RESS tests based on R100• Possibilty to conduct vehicle crash test under
relevant crash regulations
Equipment
Press with spindel drive in safety area
Press force: max. 100t
Feed speed: 0.5 - 90 mm/ min
Stroke: 1,50m
Equipment
Crash sled with Metal Bar Deformation Brake
0 − 150g
Safety concept for RESS tests
AABC Europe 2017
Comparison of existing crush requirements
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UN ECE R100
• Room temperature
• Start-SOC > 50 %
• Press force: 100 kN
• Intrusion with profile plate
• Requirement: No explosion / fire / leakage
GB/T 31467.3
• Room temperature
• Start-SOC 100 %
• Up to 30% deformation or 200 kN
• ø150mm semicylinder, 1m length
• Requirement: No explosion / fire
Radius 75 mm Spacing 30 mm
600 mm
AABC Europe 2017
Possible further work in Phase 2
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Phase 2 for GTR
• Possible further test scenarios / improvements
–Rollover Test As already required by:
SAE J2464 / GB/T 31467-3
–Water immersion test SAE J2464 / GB/T 31467-3
–Extended fire resistance test
–Post-crash RESS satefy asessment and stabilisation Condition of battery after crash
Discharging / stabilizing battery after an accident
–Change in vibration profile
–Probably updates on Phase 1 requirements
AABC Europe 2017
Adoption of GTRs
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1998 Agreement – Article 7
• Contracting parties voting in favor of a GTR are
obligated to start the process to adopt the
regulation and make a final decision
expeditiously.
• Yearly status reports if GTR has not been
adopted so far
AABC Europe 2017
Conclusions
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Conclusions & Take-aways
• All three markets EU, USA and China provide
extensive standards for battery testing
• Standardization and regulation of xEV is still a
dynamic field with changes to existing
standards an the development of new
regulations
•A future GTR could provide a world wide basis
for EV/RESS standardization
• Possible acceptance of Global Technical
Regulation for EV Safety by the end of 2017
AABC Europe 2017
TÜV SÜD Battery Testing GmbH Slide 24
Thank you!
Alexander Stadler
Phone: +49 89-32950-715
Email: [email protected],
More information is available at
http://www.tuev-sued.de/home-en/focus-
topics/e-mobility/battery-testing AABC Europe 2017