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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
12
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.