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






AABC Europe 2017


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 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






AABC Europe 2017

Introduction


Presentation ofEU

Car Sales:2015: 13,7 Million

xEV Sales:2015: >75k EV +

USA


xEV Sales:2015: >100k PEV

China


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


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

AABC Europe 2017

Mandatory Regulations


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

AABC Europe 2017

Key standards / regulations


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



3



GTR on Electrical Vehicle Safety

AABC Europe 2017

GTR on Electrical Vehicle Satefy (EVS)


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


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


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

AABC Europe 2017

Comparison of existing vibration requirements


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



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



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



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



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


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


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


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


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


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

mailto:[email protected]

http://www.tuev-sued.de/home-en/focus-topics/e-mobility/battery-testing

aabc europe 2017, mainz, germany safety testing for xev...

Documents