An illustration of EVSGTR Battery System Test Project

An illustration of EVS-GTR Battery System Test Project and Test Methods’ Adaption to Commercial Vehicles Peter Wu, BYD

CONTENTS 1 Introduction 2 Current situation of related standards 3 Case analysis 4 EVS-GTR draft analysis 5 Conclusion 2

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. 3

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. 4

Current situation of related standards Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles. 1. ISO 6469 -1: Electically propelled road vehicles-safety specifications Part 1: On-board rechargeable energy storage system 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. 5

Current situation of related standards Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles. 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 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. 6

Current situation of related standards Electric Commercial Vehicles are now in the scope of current international standards for electric vehicles. 3. UL 2580 : Standard for Safety for Batteries for Use In Electric Vehicles 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. 7

Current situation of related standards NAME OF THE STANDARDS ISO 6469 -1：: Electically propelled road vehicles-safty specifications COUNT SCOPE RY/ARE A internation al 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 UL 2580 : Standard for Safety for Batteries for Use In Electric Vehicles U. S GB/T 18384. 1 Electrically propelled road vehicles - Safety specifications China IF COMMERCIAL VEHICLES WAS INCLUDED Battery-electric vehicles/fuel-cell vehicles/hybrid electric vehicles YES Road vehicles of categories M and N 1, with a maximum design speed exceeding 25 km/h YES 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 electricpowered vehicles as defined in this standard. Electric vehicles YES 8

Case analysis Take electric buses and electric cars from some company for example: Similarities: 1、DC voltage of vehicle energy storage system： 60 V~1500 V; 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 Battery type electric BUS telecommunications lithium iron phosphate battery Cell voltage 3. 2 V Voltage 320 V 540 V Battery capacity 250 Ah*1 pack 250 Ah*3 packs Charging power 0. 5 C PACK number 1 3

Case analysis RESS on commercial vehicles Battery arrangement on cars and buses cells in series/parallel —modules 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. 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. 10 10

EVS-GTR draft analysis Test items and test methods on EVS draft: 1、 Vibration It 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 cycling It 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 resistance This test is not required if the lowest surface of RESS casing is more than 1. 5 m above ground. And if the height is less than 1. 5 m, 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 protection It 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. 11

EVS-GTR draft analysis Test items and test methods on EVS draft: 5、Overcharge 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. 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. 12

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. 13

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