An illustration of EVS-GTR Battery System Test Project and

Test Methods’ Adaption to Commercial Vehicles

Peter Wu, BYD

CONTENTS

2

Introduction

Current situation of related standards

Case analysis

1

2

3

EVS-GTR draft analysis4

Conclusion5

3

Introduction

About EVS-GTR

For electric drive road vehicles, EVS-GTR is an important standard, which is

related to safety performance and RESS(rechargeable energy storage

system). From the perspective of principle and technique, EVS-GTR made

clear safety requirements and test methods for cars and RESS in two

processes: in the process of using and after collision. In addition, safety

requirements and test methods for RESS are stipulated in EVS-GTR.

4

Introduction

Heavy-duty Electric Commercial Vehicles

Heavy-duty electric commercial vehicles(e.g. e-buses, electric industrial

vehicles) play an important role in road vehicles. For the principle of voltage

platform , electrical system and RESS, there are no differences between

heavy-duty electric commercial vehicles and passenger cars .

As an important standard for electric drive road vehicles related to safety

performance and RESS, EVS-GTR should cover heavy-duty electric

commercial vehicles(e.g. e-buses, electric industrial vehicles) , and provide

with guidance in the process of design and manufacturing.

Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles.

5

Current situation of related standards

It is a file specifically aimed at on-board energy storage device of electric road vehicle. It has made specific and detailed requirements on these test items below and test methods: isolation resistance, clearance and creep age distance, requirements for the emission of hazardous gases and other hazardous substances, heat generation from RESS, over-current interruption, specific RESS crash-test requirements of electric vehicle storage system.

Apparently, electric commercial vehicles are involved in ISO 6469-1.

1. ISO 6469-1:Electically propelled road vehicles-safety specifications Part 1: On-board rechargeable energy storage system

Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles.

6

Current situation of related standards

It is a standard specifically aimed at electric vehicle structure and functional safety . It has made specific and detailed requirements on these test items below and test methods: vibration, thermal shock and cycling, mechanical impact, fire resistance, external short circuit protection, overcharge protection, over-discharge protection, over-temperature protection, emission.

Apparently, electric commercial vehicles are involved in Addendum 99: Regulation No. 100 Revision 1/ Revision 2.

2. Addendum 99: Regulation No. 100 Revision 1/ Revision 2: Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train

Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles.

7

Current situation of related standards

It is a specialized security requirements for electric vehicle energy storage system. There are clear requirements and test methods for energy storage system and cell level, overcharge, short circuit, over discharge protection temperature, imbalanced charging test, dielectric voltage withstand test, isolation resistance test, continuity test failure of cooling/thermal stability system test, rotation test vibration endurance test, shock test, drop test, crush test, and it has been included commercial vehicles

As a result, electric commercial vehicles are involved in UL 2580.

3. UL 2580 : Standard for Safety for Batteries for Use In Electric Vehicles

8

Current situation of related standards

NAME OF THE STANDARDS

COUNTRY/AREA

SCOPE IF COMMERCIAL VEHICLES WAS INCLUDED

ISO 6469-1 ： :Electically propelled road vehicles-safty specifications

international

Battery-electric vehicles/fuel-cell vehicles/hybrid electric vehicles

YES

Addendum 99: Regulation No. 100 Revision 1/ Revision 2: Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train

Europe Road vehicles of categories M and N1, with a maximum design speed exceeding 25km/h YES

UL 2580 : Standard for Safety for Batteries for Use In Electric Vehicles

U.S electrical energy storage assemblies such as battery packs and combination battery pack-electrochemical capacitor assemblies and the subassembly/modules that makeup these assemblies for use in electric-powered vehicles as defined in this standard.

YES

GB/T 18384.1 Electrically propelled road vehicles - Safety specifications

China Electric vehicles YES

Take electric buses and electric cars from some company for example:

Similarities:

1 、 DC voltage of vehicle energy storage system ： 60V~1500V;

2 、 Requirements of electrical performance are the same;

3 、 Energy storage systems: telecommunications lithium iron phosphate battery.

Difference: PACK quantity and PACK arrangement.

electric CAR electric BUS

Battery type telecommunications lithium iron phosphate battery

Cell voltage 3.2V 3.2V

Voltage 320V 540V

Battery capacity 250Ah*1 pack 250Ah*3 packs

Charging power 0.5C 0.5C

PACK number 1 3

Case analysis

1010

Case analysis

RESS on commercial vehicles Battery arrangement on cars and buses

For RESS function and principle, there is no difference for car and buses.

The differences are electric quantity of each PACK, PACK quantity and PACK arrangement.

cells in series/parallel —modulemodules in series — PACK

RESS includes: one or more PACK in parallel, along with additional equipments

Each PACK, along with additional devices compose an independent system.

11

EVS-GTR draft analysis

Test items and test methods on EVS draft:

1 、 VibrationIt can be replaced by subsystem. For commercial vehicles, vibration test can be done individually on each PACK or multi-PACK, which can fully satisfy the requirements of this test method.

2 、 Thermal shock and cyclingIt can be replaced by subsystem . For commercial vehicles, this test can be done on modules or individual PACK instead of RESS, which can fully satisfy the requirements of test method.

3 、 Fire resistanceThis test is not required if the lowest surface of RESS casing is more than 1.5m above ground. And if the height is less than 1.5m, this test can be done by the supplier. For commercial vehicles, this test can be done on module or individual PACK instead of RESS, which can fully satisfy the requirements of test method

4 、 External short circuit protectionIt can be replaced by subsystem. For commercial vehicles, this test can be done individually on each module, each PACK or multi-PACK, which can fully satisfy the requirements of this test method.

EVS-GTR

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5 、 Overcharge protectionIt can be replaced by subsystem. For commercial vehicles, this test can be done individually on each cell, each module or each PACK, which can fully satisfy the requirements of this test method.

6 、 Over-discharge protection It can be replaced by subsystem. For commercial vehicles, this test can be done individually on each cell, each module or each PACK, which can fully satisfy the requirements of this test method.

7 、 Over-temperature protection It can be replaced by subsystem. For commercial vehicles, this test can be done individually on each PACK or multi-PACK, which can fully satisfy the requirements of this test method.

Test items and test methods on EVS draft:

EVS-GTR draft analysis

13

Conclusion

After analyzing related standards and EVS draft, we can get:

According to international main standards about safety of electric vehicles

and RESS, there are no difference between commercial vehicles and

passenger cars.

All the test items about RESS on commercial vehicles can satisfy its

requirement except the collision.In consideration of current situation of electric vehicles market, battery

types, electrical system and voltage platform of electric commercial

vehicles and electric passenger cars are the same.

In conclusion, we suggest that EVS-GTR Battery System Test

Project and Test Methods can apply to electric commercial

vehicles.

Thanks！