Stadler Alexander - Tuv-Sud PDF

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
TÜV SÜD Battery Testing GmbH

Agenda
1 Introduction TÜV SÜD
Safety Testing for xEV Batteries -

2
Overview of Test Standards
3 GTR on Electrical Vehicle Safety
TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 2

Agenda

2

TÜV SÜD Facts & Figures
Li-Ion Battery Testing – Global Approach
Lifetime Cycling /
Ageing, Power,
Performance Performance,
Calendaric Ageing GERMANY
CANADA
U.S.A. JAPAN
Thermal, Mechanical, CHINA
Environmental Climatic, Chemical, SOUTH
KOREA
EMC, UN38.3
Electrical, Thermal, SINGAPORE

Abuse / Safety Mechanical,
Customer Specific
Toronto, Canada Garching,

Germany Shenzhen, China Singapore Seoul, Korea Tokyo, Japan
Auburn Hills, USA
Complete service Complete service Performance, Performance and • Performance Complete service
portfolio for cell, portfolio for cell, environmental and environmental testing on cell, portfolio for cell,
module and system module and system abuse testing on cell testing on cell, module and module and system
testing testing level module and system systems level testing
level • Abuse testing on
cell level

TÜV SÜD – Battery Testing Laboratory Garching
Performance Environmental Abuse / Safety
• Cell level up to • Shaker • Separate explosion proof test rooms, gas scrubber
6V / ±960A • Shock machine • Electrical safety tests up to 1.200V / 800kW
• Module level up • Altitude • Short Circuit >10kA, <1mΩ to >100mΩ
to 80V / ±1.200A simulation • Nail-Penetration (100µm/s to 200mm/s)
• Pack level up to • Temperature • Crush 100t, horizontally, very large DUTs possible
1.200V/±800kW shock • Shock of large DUTs (Sled)
• Temperature • Salt spray / Dust • 10m drop tower e.g. for dynamic crush test
-70°C to +180°C • EMC • Customer specific test setups…

Agenda

2

Introduction
EU
Presentation of
Car Sales:
2015: 13,7 Million
xEV Sales:
Validation standards: 2015: >75k EV +
Various sets of tests to prove the safety of
a product USA
Car Sales:
2015: 17,3 Million
Outlook on upcoming Global Technical
Regulation (GTR): xEV Sales:
Status of the work in process and 2015: >100k PEV
comparison of current draft to existing
China
regulations
Car Sales:
2015: 24,6 Million
xEV Sales:
2015: >90k EV + >50k PHEV
Sources for validation standards & regulations for xEVs
EU USA China
International Standardization Organisations (e.g. ISO, IEC)
American National
DIN Deutsches Institut
für Normung
ANSI Standards Institute SAC Standardization Administration
of the P.R. of China
• USA
Mandatory Regulations Mandatory Regulations Mandatory Regulations
ECE FMVSS GB
National / Industry standards National / Industry standards National / Industry standards
e.g. DIN, VDI, VDE, VDA e.g. ANSI, SAE, UL e.g. SAC, GB/T, QC/T

Mandatory Regulations
EU USA China
• UN ECE regulations • FMVSS (NHTSA) • CCC to GB standards (AQSIQ,

• Type approval • Self certification SAC)
• Conformity tested and confirmed • “It is the responsibility of a • Need to be performed by
by accredited service provider manufacturer of vehicles and/or specified execution bodies
• Accreditation by national items of motor vehicle (CATARC, SMVIC…)
authority, e.g. KBA in Germany equipment to certify that each • GB/T 31484, GB/T 31485 ,
ECE R100 motor vehicle and/or equipment GB/T 31486, GB/T 31647.3
item is in full compliance with need to be tested
the minimum performance • QC/T 746 will be replaced by
requirements of all applicable new GB standards
Federal Motor Vehicle Safety • Additional requirements by local
Standards (FMVSSs).” provinces
FMVSS 305

Key standards / regulations
EU USA China
UN 38.3
IEC 62660-1/2/3: Secondary lithium-ion cells for the propulsion of electric road vehicles –
Performance tests / Abuse tests / Safety requirements
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
ECE R 100 Rev. 2 FMVSS 305 GB/T 31484, GB/T 31486

Limits allowed electrolyte leakage and Performance cell / module
Mandatory from 07/2016 isolation for xEVs tested according to
Annex 8: 9 tests for batteries / vehicle FMVSS208, FMVSS214, FMVSS301
8A Vibration GB/T 31485
8B Thermal Shock Abuse tests on cell / module +
8C Mechanical Shock SAE J2464
15 abuse tests on cell / module / pack safety requirements
8D Mechanical Integrity
8E Fire resistance Mechanical / thermal / electrical tests
8F Ext. Short circuit protection GB/T 31467-3
8G Overcharge protection SAE J2929 Based on ISO 12405-3 +
8H Over-discharge protection Defines safety requirements for tests of Additional Tests AND/OR
8I Over-temperature protection SAE J2464 + additional tests & changed parameters
clarifications

Agenda

2

GTR on Electrical Vehicle Satefy (EVS)
1958 Agreement - UNECE 1998 Agreement - GTR
• “Agreement concerning the adoption of uniform • “Agreement concerning the Establishing of

technical prescriptions for wheeled vehicles, Global Technical Regulations for Wheeled
equipment and parts which can be fitted and/or Vehicles, Equipment and Parts which can be
be used on wheeled vehicles and the conditions fitted and/or be used on Wheeled Vehicles”
for reciprocal recognition of approvals granted
on the basis of these prescriptions” – 36 contracting parties including USA and
China
• Basis for the UNECE Regulations – GTR No. 5

• Based on principle of type approval  Technical requirements for on board diagnostic
systems
• Not signed by the USA and China – 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
New GTR proposal
Protection against Requirements of a vehicle with regard to its electrical

water effects safety - in-use
Requirements of a vehicle with regard to its electrical

Additional
requirements safety - post-crash
concerning post-crash
safety und
Requirements with regard to installation and
functionality
functionality of REESS in a vehicle
Requirements with regard to the safety of REESS in-

Seperate section for use
Heavy duty vehicles
Requirements with regard to the safety of REESS –

post-crash

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

Comparison of existing vibration requirements
UN ECE R100 GB/T 31467.3
Frequency (Hz) Power spectrum density

Frequency (Hz) Acceleration (m/s²)
(m/s²)²/Hz
7 – 18 10 5 4.81
18 – 30 gradually reduced from 10 to 2 10 5.77
30 - 50 2 20 5.77
200 0.08
RMS 14.13 m/s²
• Sinusoidal waveform with a logarithmic • Random vibration profile (PSD)

sweep • All three axis
• Only Z-Axis • 21 hours per axis
• 3 hours

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

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

Overcurrent protection
• Overcurrent during external DC charging

• Test on vehicle basis or with breakout
harness
Low-temperature protection
• Functional safety proof requested
Management of gases emitted

• Only open type batteries
– Hydrogen emission
Thermal propagation Equipment

• Detection of single cell thermal runaway Nail penetration device in safety area
– Description of the warning and detection Press force: 20 kN
system Feed speed: 0 - 80 mm/sec
– Risk analisis and mitigation
– Tests or simulation

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

Comparison of existing crush requirements
UN ECE R100 GB/T 31467.3
• Room temperature • Room temperature

• Start-SOC > 50 % • Start-SOC 100 %
• Press force: 100 kN • Up to 30% deformation or 200 kN
• Intrusion with profile plate • ø150mm semicylinder, 1m length
• Requirement: No explosion / fire / leakage • Requirement: No explosion / fire
 600 mm
Radius 75 mm Spacing 30 mm

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

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

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

Thank you!
Alexander Stadler
Phone: +49 89-32950-715
Email: alexander.stadler@tuev-sued.de,
More information is available at

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

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AABC Europe 2017, Mainz, Germany

Safety Testing for xEV Batteries –

Dipl.-Ing. (FH) Alexander Stadler

TÜV SÜD Battery Testing GmbH

1 Introduction TÜV SÜD

Safety Testing for xEV Batteries -

3 GTR on Electrical Vehicle Safety

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 2

1 Introduction TÜV SÜD

Safety Testing for xEV Batteries -

3 GTR on Electrical Vehicle Safety

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 3

Electrical, Thermal, SINGAPORE

Toronto, Canada Garching,

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 4

Performance Environmental Abuse / Safety

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 5

1 Introduction TÜV SÜD

Safety Testing for xEV Batteries -

3 GTR on Electrical Vehicle Safety

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 6

International Standardization Organisations (e.g. ISO, IEC)

National / Industry standards National / Industry standards National / Industry standards

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 8

• UN ECE regulations • FMVSS (NHTSA) • CCC to GB standards (AQSIQ,

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 9

ECE R 100 Rev. 2 FMVSS 305 GB/T 31484, GB/T 31486

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 10

1 Introduction TÜV SÜD

Safety Testing for xEV Batteries -

3 GTR on Electrical Vehicle Safety

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 11

1958 Agreement - UNECE 1998 Agreement - GTR

• “Agreement concerning the adoption of uniform • “Agreement concerning the Establishing of

• Basis for the UNECE Regulations – GTR No. 5

• In 2012: Initial proposal submitted, followed by the establishing of the

Protection against Requirements of a vehicle with regard to its electrical

Requirements of a vehicle with regard to its electrical

Requirements with regard to the safety of REESS in-

Requirements with regard to the safety of REESS –

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 13

Test SoC and SoC adjustment

• All tests done at maximum, during operation

• RESS fixed using original mounting points

Thermal shock and cycling test

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 14

UN ECE R100 GB/T 31467.3

Frequency (Hz) Power spectrum density

• Sinusoidal waveform with a logarithmic • Random vibration profile (PSD)

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 15

• Use of LPG Burner allowed

Courtesy of Dr. Dietmar Schelb FFB/KIT

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 16

External short circuit protection

Overcharge protection test

Over-discharge protection test

Over-temperature protection test

• Additional posibility to conduct tests on

TÜV SÜD Battery Testing GmbH AABC Europe 2017 Slide 17

• Overcurrent during external DC charging

• Functional safety proof requested

Management of gases emitted

Thermal propagation Equipment