Trends of EV Battery Testing...Trends of EV Battery Testing and The EV’s Battery Validation Solution in UL Laurie Florence Primary Designated Engineer (PDE) Batteries (Large Format),

© 2011 Underwriters Laboratories Inc.

Trends of EV Battery Testing

and The EV’s Battery

Validation Solution in UL Laurie Florence

Primary Designated Engineer (PDE)

Batteries (Large Format), Fuel Cells & Capacitors

847-664-3782

[email protected]

Agenda

Introduction

Developing Trends of SAE Test Standards for EV Batteries • SAE 1766, SAE J2380, SAE J2344, SAE J2464, SAE J2929

Developing Trends of UL Test Standards for EV Batteries • UL Subject 2580, UL Subject 2271, ANSI/UL 2580, ANSI/UL

2271

Developing Trends of ISO and IEC Test Standards in EV Batteries • ISO 1649-1, ISO 1649 -3, IEC 62660-2, ISO 12405-1, ISO 12405-2

Conclusion

2

Introduction

3

UL - Working for a Safer World Since 1894

Underwriters Laboratories

began in the 19th century and

enters the 21st century with

the same purpose…

to help make the world safer

in the places where people

live and work

4

UL Involvement in Global EV Battery

Standards Development

UL participates in the following committees involved with developing EV battery standards:

• UL: 2580-2271 STP (UL 2580, UL 2271)

• SAE: TEVVBC1 (J2929), TEVHYB4, TEVHYB5, SAE J2464

• ISO: TC 22/SC21 (ISO 12405-1, -2)

• IEC: TC69/TC21/SC21A: JWG Li-ion (IEC 62660-1, -2)

5

Timeline of Standards Development

6

1985

1990

1995

2000

2005

2010

2015

SAE J1766

SAE J2344 & J2380

SAE J2464

ISO 1649-1 & 1649-2

UL Sbj. 2580

UL Sbj. 2271

IEC 62660-2

SAE J2929

ISO 12405-1

UL 2580

ISO 12405-2

UL 2271

Developing Trends of SAE Test

Standards for EV Batteries

7





SAE J1766, Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Integrity Testing Published in 1996, revised 2005 •describes methods for evaluating the vehicle high voltage system performance when subjected to various FMVSS crash test procedures •Requirements

• 500Ω/Volt isolation for AC circuits, DC circuits that are not isolated and circuits not monitored for isolation

• 100Ω/Volt isolation for isolated and monitored DC circuits

•Electrolyte spillage • None in passenger compartment

• Energy limit • 0.2J within 5 secs after crash

test

9



SAE J2380, Vibration Testing of

Electric Vehicle Batteries

Published in 1998

•provides a test procedure for

characterizing the effect of long-term,

road-induced vibration and shock on

the performance and service life of

electric vehicle batteries

Test Method

•swept sine wave

•vibration at 0% DOD to 80% DOD

over the course of the test

•minimum of 13.6 h and a maximum

of 92.6 h of testing

Vibration Spectra

10



SAE J2344, Guidelines

For Electric Vehicle Safety Published in 1998 •identifies and defines the preferred

technical guidelines relating to safety

for Electric Vehicles (EVs) during

normal operation and charging

11

Electrical Safety

• Isolation

• Automatic hazardous voltage disconnect

• Manual Disconnect

• Interlocks

• Grounding

• Fault Monitoring

• High-voltage Wiring Assemblies

• Hazardous Liquid Leakage

• Vehicle Immersion

• Electromagnetic Compatibility (EMC) and Electrical Transient

• Safety Labeling

• Mechanical Safety

• Battery State-Of-Charge



SAE J2464, Electric and Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing Published in 1999 and revised in 2009 • characterize the response of a

Rechargeable Energy Storage System (RESS) to off-normal conditions or environments.

• Mechanical Abuse Tests • Shock • Drop • Penetration • Roll-over • Immersion • Crush

•Thermal Abuse Tests • High Temperature Hazard • Thermal Stability • Cycling Without Thermal Management • Thermal Shock Cycling • Passive Propagation Resistance

•Electrical Abuse Tests • Short Circuit • Overcharge • Overdischarge • Separator Shutdown Integrity

12

13

Hazard

Severity

Level

Description Classification Criteria and Effect

0 No effect No effect. No loss of functionality

1 Passive

protection

activated

No damage or hazard; reversible loss of function. Replacement or re-

setting of protection device is sufficient to restore normal functionality

2 Defect/

Damage

No hazard but damage to RESS; irreversible loss of function.

Replacement or repair needed

3 Minor Leakage/

Venting

Evidence of cell leakage or venting with RESS weight loss < 50% of

electrolyte weight

4 Major Leakage/

Venting

Evidence of cell leakage or venting with RESS weight loss > 50% of

electrolyte weight

5 Rupture Loss of mechanical integrity of the RESS container, resulting in release

of contents. The kinetic energy of released material is not sufficient to

cause physical damage external to the RESS

6 Fire or Flame Ignition and sustained combustion of flammable gas or liquid

(approximately more than one second). Sparks are not flames

7 Explosion Very fast release of energy sufficient to cause pressure waves and/or

projectiles that may cause considerable structural and/or bodily damage,

depending on the size of the RESS. The kinetic energy of flying debris

from the RESS may be sufficient to cause damage as well



SAE J2929, Electric and Hybrid Vehicle Propulsion Battery System Safety Standard – Lithium-based Rechargeable Cells Published in 2011, under revision •defines a minimum set of acceptable safety criteria for a lithium-based rechargeable battery •assure that a single point fault will not result in fire, explosion or a battery enclosure rupture. Normal Operation •Vibration •UN Test T.3; or the vibration profile defined in SAE J2380; or a profile from the responsible organization which reflects the actual application •Thermal Shock • UN Test T.2; or the thermal shock profile

defined in SAE J2464, 4.4.4 •Humidity / Moisture Exposure •IEC 60068-2-30 with a severity of 55°C

• Mechanical Shock

• Alternative 1: Battery System-Level

Evaluation

• UN Test T.4; or SAE J2464, 4.3.1

• Alternative 2: Vehicle-Level

Evaluation

• FMVSS 305, S6.1, 6.2, 6.3

• Battery Enclosure Integrity


Evaluation – Application-Specific

• SAE J2464, 4.3.6


Evaluation – Generic

• SAE J2464, 4.3.6 except 100 kN

• Alternative 3: Vehicle-Level

Evaluation

• FMVSS 305, S6.1, 6.2, 6.3

14



•Single Point Over Discharge Protection

System Failure

•Discharge at 1C rate for HEV/PHEV or at

C/3 rate for EV applications

•Active discharge control shall be disabled /

disconnected

•Single Point Thermal Control System

Failure

• SAE J2464, section 4.4.3

• Fault Analysis

• SAE J1739

•Manual Disconnects

• Protection against Direct High

Voltage Contact

• ISO/DIS 6469-3.2, Section 7.6

15

• Drop

• tested per SAE J2464, 4.3.2

• Immersion

• Tested per SAE J2464, 4.3.5

• Exposure to Simulated Vehicle Fire

• SAE J2464 (Section 4.4.1), ECE R34

(Annex 5, Sections 5.3-5.8), SAE

J2579 (Appendix C.8), or FMVSS 304

(S8.3) may be useful

• Electrical Short Circuit

• SAE J2464, Section 4.5.1

• Single Point Overcharge Protection

System Failure

• Charge with active charge controls

disabled

Developing Trends UL Test Standards

for EV Batteries

16

Developing Trends of UL Test Standards

for EV Batteries


for EV Batteries

UL Subject 2580, Outline for Batteries for Use in Electric Vehicles Published in 2009 •nickel, lithium ion, and lithium ion polymer cells, cell modules, and battery packs for use in battery-powered vehicles Construction •Non-metallic materials •Metallic parts resistance to corrosion •Battery pack enclosures •Wiring and terminals •Spacings and separation of circuits •Battery pack protective circuit •Integral cooling systems •Lithium ion cells •Nickel cells Mechanical Tests •Rotation • Vibration Endurance •Shock •Drop •Nail Penetration •Crush

Electrical Tests •Overcharge Test

•Short Circuit

•Partial Short Circuit

•Overdischarge

•Charger/System Compatibility

•Imbalanced Charging

•Reverse Charge

•Dielectric Voltage Withstand

•Insulation Resistance

•Abnormal Operation

Environmental Tests •Resistance to Moisture

•Thermal Abuse

•Fire (Cell Module)

•Low Temperature

18


for EV Batteries

UL Subject 2271, Outline for Batteries for Use in Light Electric Vehicle (LEV) Applications Published in 2010 •cover nickel, lithium ion and lithium ion polymer batteries and battery packs for use in light electric vehicles (LEVs) Construction •Non-metallic materials •Metallic parts resistance to corrosion •Battery pack enclosures •Wiring and terminals •Spacings •Battery pack protective circuit •Lithium ion cells •Nickel cells

Electrical Tests •Abnormal (high rate) charge •Abusive overcharge •Short circuit •Normal temperature •Charger/system compatibility •Imbalanced pack •Reverse charge •Insulation resistance Mechanical Tests •Vibration endurance •Shock •Impact •Crush •Drop •Mold Stress Relief •Nail Environmental Tests •Resistance to moisture

19


for EV Batteries

ANSI/UL 2580, Batteries for Use in

Electric Vehicles To be published in 2011

• cover electrical energy storage

assemblies such as battery packs and

combination battery pack-

electrochemical capacitor assemblies

and the subassembly/modules that

make up these assemblies for use in

electric-powered vehicles

Scope Differences from UL Subject

2580:

• Scope is non-chemistry specific

• Includes industrial off-road vehicles

Differences in Construction:

•Polymeric enclosure 100ºC RTI

•High voltage wiring – orange colored

•Manual disconnect

•System Safety Analysis (FMEA)

•Insulation levels and protective

grounding

•Cooling thermal management

system

20


for EV Batteries

21

Electrical Tests: • Overcharge

• Maximum charge rate with single fault in charging circuit

• Short Circuit • ≤20 mΩ • Single fault in discharge circuit

• Overdischarge Protection • Temperature • Imbalanced Charging • Dielectric Voltage Withstand

• 2 x volt • Isolation Resistance

• 100Ω/volt • Continuity • Failure of Cooling/Thermal

Stability System • Cycle with fault in thermal stability

system at maximum limits

Mechanical Tests: • Rotation

• Off road vehicles • Vibration Endurance

• SAE J2380 • End use application

• Shock • SAE J2464, 4.3.1

• Drop • SAE 2464, 4.3.1, 1 meter

• Crush • SAE J2464, 4.3.6 • 100 kN

Environmental Tests • Thermal Cycling

• SAE J2464, 4.4.3, 85ºC to -40C • Salt Spray • Immersion

• SAE J2464, 4.3.5 • External Fire Exposure

‒ SAE J2579 • Internal Fire Exposure

‒ SAE J2464, 4.4.4


for EV Batteries

ANSI/UL 2271, Batteries for Use in Light Electric Vehicle (LEV)

Applications

To be published in 2012

• Scope • Non chemistry specific

• Remove voltage limit (or limit to 120Vdc)

• Define LEV as device that cannot be driven on highways

• Construction • Add spacings, wiring criteria, insulation concerns related to hazardous

voltage

• Tests • More closely resemble UL 2580 program with differences:

• Concerns related to smaller vehicles and off road type conveyances • Removable batteries

• Vibration profiles different

22


for EV Batteries

UL has a certification program for EV batteries:

UL 2580: BBAS, BBAS2

UL 2271: BBCA, BBCA2

23

Developing Trends of ISO and IEC Test

Standards in EV Batteries

–



25



ISO 6469-1, Electrically propelled road vehicles — Safety specifications — Part 1: On-board rechargeable energy storage system (RESS) Published in 2001 and revised in 2009 • rechargeable energy storage systems (RESS), for the protection of persons inside and outside the vehicle and the vehicle environment •Isolation resistance

• 100 Ω/V, if not containing a.c., or 500 Ω/V, if containing a.c.

•Creepage and Clearance •Emission of hazardous substances •Overcurrent interruption •Crash test requirements

• Protection of occupants (electrolyte leakage, shock hazard, etc.), protection of 3rd party (projectiles), short circuit

ISO 6469-3, Electric road vehicles — Safety specifications — Part 3: Protection of persons against electric hazards Published in 2001, under revision •protection of persons against electrical hazards on exclusively battery-powered electric road vehicles. On board electric circuits lower than 1000 a.c. or 1500 d.c. •Protection against electrical Hazards

• Protection from direct contact ‒ Insulation or Barriers, accessibility

to hazardous parts • Protection under fault condition of

basic insulation ‒ Double insulation, grounding

26

Voltage

class

d.c. (vdc) a.c. (Vrms)

A 0<U≤60 0<U≤25

B 60<U≤1500 25<U≤1000



IEC 62660-2, Secondary Lithium-

ion Cells For The Propulsion Of

Electric Road Vehicles – Part 2:

Reliability And Abuse Testing

Published in 2010

•test procedures to observe the

reliability and abuse behavior of

secondary lithium-ion cells used for

propulsion of electric vehicles

including battery electric vehicles

(BEV) and hybrid electric vehicles

(HEV)

•Mechanical Tests

• Vibration


• Crush

•Thermal Tests

• High Temperature Endurance

• Temperature cycling

•Electrical tests

• External short circuit

• Overcharge

• Forced discharge

27


Standards in EV Batteries ISO 12405-1, Electrically propelled road

vehicles — Test specification for lithium-ion

traction battery packs and systems — Part 1:

High-power applications

Published in 2011

•specifies standard test procedures for basic

characteristics of performance, reliability and

abuse of lithium-ion battery packs and systems

•High Power: the numerical ratio between

maximum allowed electric power output (power

in W) and electric energy output (energy in Wh)

at 1C discharge rate at RT is typically equal or

greater than 10

•Performance Tests

• Energy & capacity at RT

• Energy & capacity at different

temperatures and discharge rates

• Power & internal resistance

• No load SOC

• SOC loss at storage

• Cranking power at low temperature

• Cranking power at high temperature

• Energy Efficiency

• Cycle life

•Reliability Tests

• Dewing-Temperature

• Thermal Shock Cycling

• Vibration


•Abuse Tests

• Short Circuit Protection

• Overcharge Protection

• Overdischarge Protection

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ISO 12405-2, Electrically propelled road vehicles — Test specification for lithium-Ion traction battery systems — Part 2: High energy applications Under development •determine the essential characteristics on performance, reliability and abuse of lithium-ion battery packs and systems. The user is also supported to compare the test results achieved for different battery packs or systems •High energy: the numerical ratio between maximum allowed electric power output (power in W) and electric energy output (energy in Wh) at 1C discharge rate at RT is typically lower than 10

Performance • Energy & capacity at RT • Energy & capacity at different temps

and discharge rates • Power & Internal Resistance • Energy Efficiency at fast charging • No load SOC loss • SOC loss at storage • Cycle life

Reliability • Dewing (temperature change) • Thermal shock cycling • Vibration • Mechanical Shock

Abuse • Short circuit protection • Overcharge • Overdischarge

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Conclusion

The development of standards related to EV batteries is ongoing. •SAE has several battery standards projects way including:

• Revision of SAE J2929, development of standards for recycling, transportation of used batteries, etc.

•ISO has the following EV battery standards development underway:

• ISO 12405-2, ISO 1649-3 (revision)

•UL has the following projects underway: • UL 2580 will be published before the

end of 2011 and the UL 2271 standard is under development

•IEC is working on EV charging standard

UL is currently involved in an ANSI Electric Vehicle Roadmap Task Group:

• The purpose of this task group is to identify standards GAPs to support the development of electric vehicle technology

• Groups represented in task group

are SDOs, Mfgs, Industry Groups

• to identify currently published standards and standards under development for EV batteries

• identify gaps where standards are

needed and identify standard development organizations (SDOs) to address these gaps

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Conclusion

Safety standards for EV batteries have been under development some time

There is some level of harmonization between standards at an informal level

Gaps in Electric vehicle standards are being identified and SDOs will be identified and tasked to fill the gap.

• Handling used batteries

• Safety for swapping batteries and servicing batteries

• Addressing labeling and requirements for emergency disconnect

• 2nd life of batteries

Much of the identified gaps identified are to address long term issues associated with electric batteries

31

THANK YOU.

Documents

Trends of EV Battery Testing...Trends of EV Battery Testing and The EV’s Battery Validation Solution in UL Laurie Florence Primary Designated Engineer (PDE) Batteries (Large Format),