D Report on safety topics with respect to Hybrid Commercial Vehicles

Transcription

1 Responsible (Name, Organisation) Mark Nievelstein, DAF trucks N.V. DELIVERABLE REPORT Date WP No Issuer (Name, Organisation) Mark Nievelstein, DAF trucks N.V. Subject Report on Safety topics with respect to Hybrid commercial vehicles Page 1(88) Report No D Dissem. Level PUBLIC D Report on safety topics with respect to Hybrid Commercial Vehicles HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 1 of 88

2 Summary Hybrid technology introduces new safety concerns for heavy duty vehicles. Crash behaviour is changed (e.g. effect of addition of a large mass such as the battery), electrical safety needs to be considered due to the high voltage system and risks may be associated with the high density energy storage of the batteries. There are none to little statistical data available for accidents with hybrid commercial vehicles. This makes it difficult to define specific safety issues. In this project DAF has chosen to use the expertise of DEKRA Certification BV (former KEMA Quality), an independent company specialized in safety of electric powered products in wide variety of applications predominantly outside the automotive industry. DAF has requested DEKRA Certification BV to assist them with respect to attention issues for high voltage safety of electric/hybrid-electric trucks. Dekra was asked to make a report on standards identification and considerations concerning the following topics: Design guidelines for safe high-voltage systems. Design guidelines for safe electrical energy storage and charging of lithium-ion batteries. Crashworthiness of currently available electrical energy storage systems, more specific lithium-ion batteries and super-capacitors. Dedicated hazard analysis techniques for designing safe high-voltage systems. Safe electric and hybrid-electric vehicle operation in traffic related to the noise level. Dismantling (of the electric parts/energy storage systems) of the vehicle at the end of its life The result of the study performed by DEKRA documented under the internal Dekra number PEP, is shown in this report and gives a useful overview of the standards to be used to develop a safe Hybrid Electric Commercial Vehicle. The available standards are mostly redundant but there are still gaps that have been identified by DEKRA. Fortunately new standards to close these gaps are already under development. The recommended standards to be used: Safe high voltage systems EC 661/2009 UN ECE R100 ISO Electrical energy storage ISO SAE J2929 Crashworthiness SAE J2929 (see also chapter 4 of this report) SAE J2464, UL 2580 ISO and IEC Functional safety ISO Combined with the hazard techniques to fill in the gaps mentioned in the observations for each standard an OEM should be able to safely design, develop, build, operate, service, and dismantle a hybrid commercial vehicle. Furthermore, the recommendations on safety aspects from the operator s point of view have been gathered by VERI. These results are based on feedbacks collected from maintenance teams in different countries working with electric hybrid buses. The report of Veolia is included in this document as chapter 10. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 2 of 88

3 Table of contents Summary... 2 Table of contents... 3 Abreviations... 5 Foreword Introduction Standardization Guidelines for safe high voltage systems Standards to be considered Observations Guidelines for safe electrical energy storage and charging lithium-ion batteries Standards to be considered Observations Crashworthiness of electrical energy storage systems SAE J SAE J UL ISO and IEC Observations Functional Safety ISO Observations Hazard analysis techniques for designing safe High Voltage systems Hazard analysis and Risk Assessment Hazard based safety engineering Safe electric and hybrid-electric vehicle operation in traffic related to the noise level Dismantle (of the electric parts/electric storage systems) of the vehicle at the end of its life Directive 2000/53/CE (End of Life of Vehicles) Directive 2006/66/CE (Waste Battery Directive) Observations Veolia operators point of view Results and discussion Conclusions Results and discussion Conclusions Bibliography ANNE 1: Standards overview HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 3 of 88

4 ANNE2: Management of functional safety according ISO ANNE 3: DEKRA profile HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 4 of 88

5 Abreviations ASIL Automotive Safety Integrity Levels CEN Comité Européen de Normalisation CENELEC Comité Européen de Normalisation Electrotechnique E/E systems Electric/Electronic systems EMC Electro Magnetic Compatibility ETSI European Telecommunications Standards Institute EV FMEA HCV HEV HV IEC ISO ITU-T PPE SAE UL WEEE Electric vehicle Failure Mode and Effects Analysis Hybrid Commercial Vehicles FP& project Hybrid electric vehicle High Voltage The International Electrotechnical Commission is concerned with standards mainly related to electrical equipment and electric components. The International Organization for Standardization is an organization that covers a broad area of topics and technologies. The International Telecommunication Union (ITU) is a United Nations agency for information and communication technologies. The ITU-T is the global standardization organization in the telecommunication domain. Personal Protective Equipment Society of Automotive Engineers Underwriters Laboratory Waste Electronic and Electrical Equipment Foreword Within the Hybrid Commercial Vehicle (HCV) FP7 project, DAF is challenged with the identification of workable standards to safely design, develop, use and dismantle hybrid commercial vehicles. In an early stage of the investigation it already became clear that the large amount of available standards does not guarantee the development of yet one more. On the other hand, there was not a single standard identified that covered the complete lifecycle of a hybrid electric vehicle sufficiently. A good review and guideline how to use the available standards is needed to warrant a consistent safe development of a hybrid commercial vehicle. Therefore it was chosen to have Dekra perform a study to review the available standards and propose a guideline of which standard or combination of standards to use for the development of a safe hybrid commercial vehicle. Hybrid technology introduces new safety concerns for heavy duty vehicles. Crash behaviour is changed (e.g. effect of addition of a large mass such as the battery), electrical safety needs to be considered due to the high voltage system and risks may be associated with the high density energy storage of the batteries. There are none to little statistical data available for accidents with hybrid commercial vehicles. This makes it difficult to define specific safety issues. In this project DAF has chosen to use the expertise of DEKRA Certification BV (former KEMA Quality), an independent company specialized in safety of electric powered HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 5 of 88

6 products in wide variety of applications predominantly outside the automotive industry (see Annex 3). The main section chapter 1-9 of this report is a result of the work done with/by Dekra on request of DAF and is extracted from Dekra report PEP Report on attention issues and standards identification for Safety of High Voltage System of Hybrid Commercial Vehicle (HCV). Sub Project HCV SP 6000'. Arnhem, March 22, 2012 Author: A.G.H. Bergervoet. Common practice and issues from an operator s point of view have been gathered through a questionnaire internally at Veolia. The results as reported from Veolia have been included in chapter 10. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 6 of 88

7 1. Introduction DAF has requested DEKRA Certification BV to assist with respect to attention issues for high voltage safety of electric/hybrid-electric commercial vehicles. More specifically, it should include standards identification and considerations concerning the following topics: Design guidelines for safe high-voltage systems Design guidelines for safe electrical energy storage and charging of lithium-ion batteries. Crashworthiness of currently available electrical energy storage systems, more specifically lithium-ion batteries and super-capacitors Dedicated hazard analysis techniques for designing safe high-voltage systems Safe electric and hybrid-electric vehicle operation in traffic related to the noise level Dismantling (of the electric parts/energy storage systems) of the vehicle at the end of its life DEKRA's role and approach: It was agreed with DAF that on basis of known existing standards, regulations, studies and current knowledge present at DEKRA Certification BV, the one or two most appropriate standards per topic should be considered. This includes tests and requirements which could be used as (or as a basis for developing) safety guidelines for design, testing and other life cycle phases of the high voltage system of electric/hybrid-electric trucks. For the particular requirements and tests in these standards it should, as far as possible, be indicated whether they most likely (would) apply to the component or to the component built in a vehicle and whether they reflect normal use, a crash situation or a maintenance situation. In addition, where particular requirements were considered to be insufficient or missing this should be indicated as well. Such considerations are included in the "observations" sections in this report and contain the, not in all cases (technically) substantiated, opinions and conclusions of the author and consulted technical experts within DEKRA Certification BV. In identifying the most appropriate standard(s) per topic, considerations were given to: Existing regulations Known publications and international standards for the intended use or product scope Known publications and international standards, not necessarily automotive related, for the technology involved Since considerations and attention issues concerning the topics have been given on basis of known existing standards and studies, the current knowledge present at DEKRA Certification BV and to the extent possible within the agreed scope and budget of the order, it can be concluded beforehand that the contents of this report will not be comprehensive. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 7 of 88

8 2. Standardization Standardization for electric vehicles has started about 20 years ago. The activity never ceased but its intensity was rather low compared to other technology areas. Only recently (some years ago) the enormous potential of electric vehicles has resulted in high accelerating and intense developments, forcing standardization to speed up its activities. Standards development is done by different organizations at national level, European level and international level. At international level the three principal standards organizations are: 1) IEC: The International Electrotechnical Commission is concerned with standards mainly related to electrical equipment and electric components. 2) ISO: The International Organization for Standardization is an organization that covers a broad area of topics and technologies. 3) ITU-T: The International Telecommunication Union (ITU) is a United Nations agency for information and communication technologies. The ITU-T is the global standardization organization in the telecommunication domain. Standardization work related to Electric vehicles is divided over both IEC and ISO. IEC TC 69 covers the work on charging of electric vehicles, other IEC committees cover work on specific electric vehicle components. ISO TC 22 covers work on all road vehicles including electric vehicles and its components. At European level CENELEC, CEN and ETSI are the 3 principal standards organizations: 1) CENELEC (Comité Européen de Normalisation Electrotechnique) is the European counterpart of IEC. 2) CEN (Comité Européen de Normalisation) is the European counterpart of ISO. 3) ETSI (European Telecommunications Standards Institute) can be seen as the European counterpart of ITU-T. There is a close cooperation on standardization within Europe. Europe normally adopts the international work on standards, unless: The international standards do not meet specific European requirements The international standards are not available within reasonable time The requirements are only European and IEC or ISO have no current interest in the topic. At national level countries have their own national standardization organizations, responsible for national standards e.g. covering national regulation. The members of the national standardization committees are close co-operating with the European CEN/CENELEC and international IEC/ISO organizations. In most situations the CEN/CENELEC and IEC/ISO members are also the members of the respectively national committees. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 8 of 88

9 Other (inter)national standards organizations which are active in the area of electric vehicles are e.g. the North America based organizations UL and SAE. UL (Underwriters Laboratory) is an independent testing, certification and standards organization mainly active in the field of safety (standards) in a very broad area including electric vehicles. SAE (Society of Automotive Engineers) is much more than UL active in standards for (electric) vehicles. Manufacturers who import their vehicles to the US market, in most cases, have to demonstrate compliance to SAE standards. In figure 1, the relationship between the different standardization organizations has been illustrated. Figure 1: Standardization HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 9 of 88

10 3. Guidelines for safe high voltage systems Electric vehicles and hybrid-electric vehicles in general are subject to the same constraints as the internal combustion engine vehicles. In Europe the automotive directive 2007/46/EC defines the framework for the regulatory requirements and approval of motor vehicles. Electric and hybrid-electric vehicles pose an additional risk with respect to the high voltage system. The hazards related to high voltage systems are a new area of concern within the automotive sector. Many standards are available for the safety of electric shock and other electrically caused related hazards. For Europe, most of these standards are not within the domain of the automotive directive but other directives such as the low voltage directive. For electric vehicles and hybrid-electric vehicles falling under the automotive directive 2007/46/EC it can be presumed that the low voltage directive is not applicable. In this way the automotive sector is prevented from extra (maybe unnecessary) requirements which do apply for products falling under the low voltage directive. On the other hand there is a lack of requirements and clear guidelines for the safety of electric shock and other electrically caused related hazards within the automotive directive. With respect to 'general' safety requirements of high voltage systems for electrically propelled road vehicles only few automotive related standards are available. For components and subassemblies part of the power train, e.g. rechargeable energy storage systems, electronic inverters/converters, wiring and traction motors, individual automotive and/or industrial standards are available. ANNE 1 contains a list of European and internationally available standards addressing specific topics related to electric vehicles and hybrid-electric vehicles. This list includes both automotive related standards and references to industrial and commercial equipment and component standards. It is beyond the scope of this document to analyse and describe all of these standards. 3.1 Standards to be considered Within the general safety regulation EC 661/2009 (EU directive) it is included that "manufacturers shall ensure that vehicles, systems, components and separate technical units comply with the relevant requirements set out in this regulation". This is including requirements related to electrical safety. Furthermore, recommendations have been done and proposals have been made to include, for the purpose of electric vehicles, UN ECE R100 in the automotive framework directive 2007/46/EC. In addition some European countries (e.g. The Netherlands) require the UN ECE R100 for the approval of electric vehicles. This UN ECE R100 includes requirements for the high voltage components connected to the power train, e.g. rechargeable energy storage systems, electronic inverters/converters, wiring and traction motors. Since this is a regulation, as a minimum the safety requirements in this R100 document shall always be complied with. Therefore the R100 has been selected as one of the standards to be considered within the scope of this document, more specific within this chapter. Another standard which has been considered to be appropriate for the purpose is ISO The 2001 edition of this standard has been technically revised and was recently (2011) published. It's a standard concerned with vehicle safety and person protection. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 10 of 88

11 For both R 100 and ISO (2011) an overview (see table 1 and table 2) is included in this chapter with the main requirements/tests of the standard. For the particular requirements/tests, it has been indicated whether they most likely (would) apply to the component or to the component built in a vehicle and whether they reflect normal use, a crash situation or a maintenance situation UN ECE R100 This standard (regulation) prescribes safety requirements with respect to the electric power train of road vehicles of categories M and N, with a maximum design speed exceeding 25 km/h, equipped with one or more traction motor(s) operated by electric power and not permanently connected to the grid, as well as their high voltage components and systems which are galvanically connected to the high voltage bus of the electric power train. Table 1: UN ECE R100. Cl. UN ECE R100: Description of test/requirement Applicable to Requirements for 5 Specifications and tests: Co Ve No Cr Ma Fc Traction battery: Overall general requirements: - Installation of the traction battery in the vehicle shall not allow any potential dangerous accumulation of gas. - Hazardous gasses shall be safety ventilated - The traction battery and power train shall be protected by fuses or circuit breakers HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 11 of 88

12 Cl. UN ECE R100: Description of test/requirement Applicable to Requirements for Protection against electric shock: Overall general requirements + tests: - Protection against direct contact. Accessibility of hazardous voltage parts. Tests with testfinger and/or testwire. - Vehicle markings: marking of high voltage symbol where required cables of HV buses not located within enclosures shall be identified with the colour orange - Protection against indirect contact (protection under fault condition) by equipotential bonding with sufficient low resistance. Eventual earthing resistance test to be performed. When connected to external charging station a connection between chassis and earth ground to be provided. - Insulation resistance. Measurements to be performed after humidity conditioning and between HV busses and accessible parts/electrical chassis & between HV AC and DC busses. - Connection of the vehicle to the mains. Vehicle movement is not allowed when the charger is connected. Components which can be disconnected under load shall be suitable to break the current in case of disconnection Protection against direct access of hazardous voltages to be provided Overcurrent protection in case of excessive currents to be provided. Co Ve No Cr Ma Fc HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 12 of 88

13 Cl. UN ECE R100: Description of test/requirement Applicable to Requirements for 5.2 Functional safety requirements: Overall general requirements for: - Power on procedure - Running and stopping conditions - Indication of active driving mode - Warning for low battery thus enabling the driver to move the vehicle to a safe zone - Unintentional acceleration, deceleration and reversal to be prevented - When leaving the vehicle an alarm signal is required to inform the driver in case the vehicle is still in active driving mode - Reversing Reversing shall be possible only after operation of a specific control/actuator - Emergency power reduction: If the vehicle is equipped with a device to limit the power in an emergency ( e.g. overheating of a component) the user shall be informed by an obvious signal 5.3 Determination of hydrogen emission: Overall general requirements. Where applicable and dependent on type and technology of the used batteries. Co Ve No Cr Ma Fc Notes to table: Cl. Indicates the applicable clause number of the standard Co : applicable to the component, test/evaluation on component level Ve : applicable to the vehicle, test/evaluation on vehicle level No : requirements for normal operation Cr : requirements for crash situation Ma: requirements for maintenance Fc: (simulated) single fault condition/single point of failure HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 13 of 88

14 3.1.2 ISO (2011) This standard specifies requirements for the electric propulsion systems and conductively connected auxiliary electric systems of electrically propelled road vehicles for the protection of persons inside and outside the vehicle against electric shock. It covers requirements for protection against voltages up to 1000 Vac or 1500 Vdc. Table2: ISO (2011) Cl. ISO : Description of test/requirement Applicable to 6 Marking: Requirements for Co Ve No Cr Ma Fc 6.1 Marking on components: The high voltage symbol shall be marked on or near high voltage power sources (HV power source defined as > 60 Vdc and < 1500 Vdc; > 30 Vac and <1000 Vac) 6.2 Marking wiring: The high voltage wiring shall be marked with orange colour 7 Measures and requirements for protection of persons against electric shock 7.2 Basic protection measures: Protection against direct contact with live parts to be provided 7.3 Protection under single fault conditions: Measures: - Potential equalization (equipotential bonding) - Maintaining of isolation resistance ( e.g. monitoring devices) - Stored charged and touch currents due to capacitive couplings - Enhanced insulation requirements ( e.g. double or reinforced insulation) - De-energization ( disconnection of the supply) HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 14 of 88

15 Cl. ISO : Description of test/requirement Applicable to 7.7 Isolation resistance requirements: Measurements between HV busses and accessible parts/electrical chassis & between HV AC and DC busses. In addition where required additional protection measures to be applied to provide protection against electric shock under single fault condition Requirements for Co Ve No Cr Ma Fc 7.8 Requirements for insulation co-ordination Note: only reference is made to basic safety publication IEC Requirements for potential equalization: equipotential bonding with sufficient low resistance. Earthing resistance test to be performed Requirements for vehicle power inlet: - Protection against direct contact - De-energization - Grounding and isolation resistance requirements 8 Test procedures for the protection measures against electric shock: This clause describes the tests to verify the protection measures according to Clause 7 9 Safety requirements at vehicle crash test: Only a wording that crash tests and the requirements shall be according to applicable national and/or international standards or regulations. No requirements are given, no references are given HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 15 of 88

16 Cl. ISO : Description of test/requirement Applicable to Notes to table: Cl. Indicates the applicable clause number of the standard Co : applicable to the component, test/evaluation on component level Ve : applicable to the vehicle, test/evaluation on vehicle level No : requirements for normal operation Cr : requirements for crash situation Ma: requirements for maintenance Fc: (simulated) single fault condition/single point of failure Requirements for Co Ve No Cr Ma Fc 3.2 Observations Modern electrical safety standards include requirements to reduce the risk of injury or damage due to electrically caused hazards. These requirements take into account normal operating conditions, likely fault conditions, consequential faults, foreseeable misuse and external influences. By applying such standards designers should be able to design safe equipment. It can be observed that for both UN ECE R100 and ISO elementary requirements, essential for designers, to support them in engineering safe high voltage systems, are missing. The following is a list of observations applicable to UN ECE R100: Requirements and tests to be performed are very basic. Only requirements with reference to electric shock are addressed, which are very basic: - No insulation co-ordination is addressed (e.g. the determination of and requirements for creepage and clearance distances). - No requirements for touch currents/leakage currents. - No insulation voltage tests are defined. - No requirements for solid insulation. No specific earthing and bonding requirements. No requirements for safety critical components e.g. switches, interlocks, fuses, protection devices etc. No references to specific component safety standards. Almost no requirements for wiring and connections/connectors. No mechanical strength requirements. No thermal strength and no temperature requirements. No requirements for protection against mechanical hazards, e.g. rotating parts. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 16 of 88

17 No requirements for protection against electrically caused fire hazards. No requirements for protection against hazards from eventual chemical substances. No requirements for protection against explosion hazards. For protection against indirect contact (protection under fault condition) only equipotential bonding is addressed, other options such as enhanced insulation methods, disconnection of supply are not addressed. Protection against environmental conditions (moisture, dust, UV radiation etc.), are not taken into account. Functional safety, E/E systems (hardware and linked software), are not addressed. No requirements for safety related instructions, instructional safeguards. No requirements for manufacturing, maintenance and repair (no life cycle). Applies only to the whole vehicle not to individual components. Does not include crash conditions and no references to national and/or international standards or regulations where such conditions can be found. Note: electric vehicles are subjected to the same lawful constraints as the internal combustion engine vehicle. It may be that one or more of the above mentioned observations are covered by regulations or standards falling under the automotive directive 2007/46/EC. It is beyond the scope of this document to analyse these regulations and standards falling under the automotive directive. The following is a list of observations applicable to ISO (2011): Requirements and tests to be performed are basic. Only requirements with reference to electric shock are addressed. Insulation co-ordination is addressed, but reference is given to basic safety publication IEC for insulation co-ordination, no specific constraints are given with respect to vehicle application (e.g. pollution degrees, overvoltage categories, altitudes etc.) which makes it difficult to apply this rather complex basic safety publication. No insulation voltage tests are defined, only reference to basic publication IEC No specific requirements for solid insulation, only reference to basic publication IEC No specific earthing and bonding requirements. Only few references to other (component) standards, considered to be not sufficient. No requirements for safety critical components e.g. switches, interlocks, fuses, protection devices etc. Almost no requirements for wiring and connections. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 17 of 88

18 No mechanical strength requirements. No thermal strength and no temperature requirements. No requirements for protection against mechanical hazards, e.g. rotating parts. No requirements for protection against electrically caused fire hazards. No requirements for protection against hazards from eventual chemical substances. No requirements for protection against explosion hazards. For environmental and operational conditions reference is given to ISO series for guidance, which is good (see note 2). Functional safety, E/E systems (hardware and linked software) are not addressed. No requirements for safety related instructions, instructional safeguards. No requirements for manufacturing, maintenance and repair (no life cycle). Applies only to the whole vehicle not to individual components. Only a wording that crash tests and the requirements shall be according to applicable national and/or international standards or regulations. No requirements are given, no references are given. Note 1: electric vehicles are subjected to the same lawful constraints as the internal combustion engine vehicle. It may be that one or more of the above mentioned observations are covered by regulations or standards falling under the automotive directive 2007/46/EC. It is beyond the scope of this document to analyse these regulations and standards falling under the automotive directive. Note 2: The objective of ISO as a whole is to assist the user in systematically defining and/or applying a set of internationally accepted environmental conditions, tests and operating requirements, based on the anticipated actual environment in which the equipment/vehicle will be operated and to which it will be exposed during its life cycle. It can be concluded that only applying the regulation UN-ECE R100 would not be sufficient as a guide for safe high voltage design. Using the UN-ECE R100 in combination with the ISO (2011) more appropriately addresses the requirements for protection against electric shock, however still considered to be not sufficient. Requirements for protection against other, not less important, electrically caused hazards are missing. These standards only consider electric shock as a hazard, but high power/high voltage electric systems also constitute other types of hazards such as fire and explosion related hazards. For design guidelines for safe high voltage (HV) systems, alternative methods may be applied to come to a good practice. If examination of the HV system of the vehicle shows that hazards might arise which are not (fully) addressed by the UN-ECE R100, ISO or other applied standards within the automotive domain, alternative methods using dedicated hazard analysis techniques should be applied to come to safe HV systems (see also chapter 7 "Hazard analysis techniques for designing safe high-voltage systems.") HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 18 of 88

19 If safety is achieved by electric/electronic and/or programmable electronic systems (E/E systems) whose loss of function or degradation beyond specified limits would result in an unacceptable risk, the term functional safety applies and for such systems the appropriate standards shall apply (see chapter 6 "Functional safety"). Vehicle safety and person protection with respect to the high voltage system is, as explained above, only limitedly addressed in the UN-ECE R100 and ISO To come to design guidelines for a safe high voltage system both basic safety and functional safety would apply to an extent beyond the requirements given in these standards HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 19 of 88

20 4. Guidelines for safe electrical energy storage and charging lithium-ion batteries At present many standards, studies and on-going standards committee work are available for the safety and performance of batteries. Lithium-ion based technologies have become the dominant rechargeable battery for electric vehicle propulsion and energy storage, mainly because of their high energy density. From a safety point of view new challenges are created with respect to a safe design, handling and fire related hazards. Technologies are developing fast, which poses extra challenges for standardization committees. Performance, reliability and safety during charging should also be addressed by those standards that consider battery systems for use in electric vehicle propulsion. Specific requirements for external charging stations can be found in IEC/EN series of standards (see ANNE 1 standards overview). Since it is external to the vehicle and part of the premises electric installation, it falls under the scope of the low voltage directive and not under the automotive directive. It is beyond the scope of this document to analyse and describe the IEC/EN series of standards. 4.1 Standards to be considered Requirements for lithium-ion based battery systems for use as a power source for the propulsion of electric road vehicles are significantly different from those for batteries used for consumer electronics or stationary usage. With this in mind, for the selection of one or two most appropriate standards for batteries in electric and hybrid-electric trucks, focus was given to available standards for the propulsion of electric road vehicles. Furthermore it was considered, since the aim of this task is the development of hybrid commercial and not of battery cells or battery pack/system, to select standards which focus on the overall battery pack/system as a component or built in the vehicle. Standards with specific requirements for battery cells were therefore not considered. Two recently issued standards, considered to be appropriate for the purpose are: 1. ISO SAE J2929 For both ISO and SAE J2929 an overview table is included in this chapter with the main requirements/tests of the standard. For the particular requirements/tests, it has been indicated whether they most likely (would) apply to the component or to the component built in a vehicle and whether they reflect normal use, a crash situation or a maintenance situation ISO ISO specifies test procedures for lithium-ion battery packs and systems for use in electrically propelled road vehicles. The specified test procedures enable the determination of the essential characteristics of performance, reliability and abuse of lithium-ion battery packs and systems. They assist the user to compare the test results achieved for different battery packs or systems. Therefore, ISO specifies standard test procedures for basic characteristics of HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 20 of 88

21 performance, reliability and abuse of lithium-ion battery packs and systems ISO enables the setting up of a dedicated test plan for an individual battery pack or system subject to agreement between the customer and supplier. If required, the relevant test procedures and/or test conditions of lithium-ion battery packs and systems can be selected from the standard tests provided in ISO to configure a dedicated test plan as can be seen in Table 3 below. Overview table3: ISO Cl. ISO : Description of test/requirement Applicable to 6 General tests 6.1 Preconditioning cycles: Purpose: Pre-conditioning by performing some electrical cycles before starting the real testing sequence, in order to ensure an adequate stabilization of the battery pack or system performance. 6.2 Standard cycle: Purpose: to ensure the same initial condition for each test of a battery pack or system Standard discharge: specific discharge according to the specifications given by the supplier Standard charge: specific charge according to the specifications given by the supplier 7 Performance tests 7.1 Energy and capacity at room temperature: Purpose: To determine the capacity at 1 C, 10 C and the maximum C rate as permitted by the supplier Requirements for Co Ve No Cr Ma Fc 7.2 Energy and capacity at different temperatures and discharge rates: Purpose: This test determines the capacity atdifferent temperatures (40 o C, 0 o C and -18 o C) at three different constant current discharge rates (1C, 10C and the maximum rated discharge current). HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 21 of 88

22 Cl. ISO : Description of test/requirement Applicable to Requirements for Co Ve No Cr Ma Fc 7.3 Power and Internal resistance: Purpose: The power and internal resistance test is intended to determine: - the dynamic power capability (discharge pulse power and regenerative charge pulse power) - the Ohmic resistance for discharge and charge conditions - The open circuit voltage as a function of state of charge and temperatures according to a realistic load profile derived from vehicle driving operation 7.4 No load SOC (state of charge) loss: Purpose: The purpose of this test is to measure the SOC loss of a battery system if it is not used for an extended period of time. This test refers to a scenario in which a vehicle is not driven for a long time period and, therefore, the battery system could not be placed on charge. The noload SOC loss, if it occurs, may be due to selfdischarge, which is normally temporary, or to other mechanisms that can produce permanent or semi-permanent loss of SOC. 7.5 SOC loss at storage: Purpose: The purpose of this test is to measure the SOC loss at storage of a battery system if it is stored for an extended period of time. This test refers to a scenario in which the battery system is shipped from a supplier to a customer. This SOC loss at storage, if it occurs, may be due to selfdischarge, which is normally temporary, or to other mechanisms which can produce permanent or semi-permanent loss of the SOC. 7.6 Cranking power at low temperature: Purpose: The cranking power test at low temperatures is intended to measure the power capability at low temperatures. The relevant temperatures shall be 18 C and, if agreed between the supplier and customer, also 30 C. The aim is to generate a database of timedependent power output at low temperatures. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 22 of 88

23 Cl. ISO : Description of test/requirement Applicable to Requirements for Co Ve No Cr Ma Fc 7.7 Cranking power at high temperature: Purpose: The test for cranking power at high temperature is intended to measure power capabilities at a high temperature of 50 C or the maximum temperature specified by the supplier. The aim is to generate a database of timedependent power output at high temperatures 7.8 Energy efficiency: Purpose: The purpose of the energy efficiency test is to determine the battery system round-trip efficiency by calculation from a charge balanced pulse profile. For high-power application, the energy efficiency of the used battery system has a significant influence on the overall vehicle efficiency. It directly affects the fuel consumption and emission levels of a vehicle equipped with a battery system for high-power application. 7.9 Cycle life: Purpose: To determine the lifetime of a battery by choosing a relevant ageing profile relating to the energy throughput. Real driving conditions shall be considered. 8 Reliability tests 8.1 Dewing Temperature change: Purpose: This test simulates the use of the system/component under high ambient humidity 8.2 Thermal shock cycling: Purpose: Thermal shock cycling is performed to determine the resistance of the battery pack and system to sudden changes in temperature 8.3 Vibration: Purpose: To test the battery pack and system for malfunctions and breakage caused by vibration. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 23 of 88

24 Cl. ISO : Description of test/requirement Applicable to Requirements for Co Ve No Cr Ma Fc 8.4 Mechanical shock: Purpose: This test is applicable to packs and systems intended to be mounted at rigid points of the body or on the frame of a vehicle (withstanding loads, for example when driving over a curb stone at high speed) Author note: crash situations are not defined, severity levels are less than standards which define crash situations 9 Abuse tests 9.2 Short circuit protection: Purpose: To check the functionality of the overcurrent protection device 9.3 Overcharge protection: Purpose: To check the functionality of the overcharge protection function. 9.4 Overdischarge protection: Purpose: to check the functionality of the overdischarge protection function Notes to table: Cl. Indicates the applicable clause number of the standard Co : applicable to the component, test/evaluation on component level Ve : applicable to the vehicle, test/evaluation on vehicle level No : requirements for normal operation Cr : requirements for crash situation Ma: requirements for maintenance Fc: (simulated) single fault condition/single point of failure SAE J2929 This SAE Standard defines a minimum set of acceptable safety criteria for a lithiumbased rechargeable battery system to be considered for use in a vehicle propulsion application as an energy storage system connected to a high voltage power train as can be seen in table 4. While the objective is a safe battery system when installed into a vehicle application, this standard is primarily focused, wherever possible, on conditions which can be evaluated utilizing the battery system alone. As this is a minimum set of criteria, it is recognized that battery system and vehicle manufacturers may have additional requirements for cells, modules, packs and systems in order to assure a safe HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 24 of 88

25 battery system for a given application. A battery system in the context of this standard is a completely functional energy storage system consisting of the pack(s) and necessary ancillary subsystems for physical support and enclosure, thermal management, and electronic control. Overview table4: SAE J2929 Cl. SAE J2929: Description of test/requirement Applicable to Vibration tests: Purpose: To simulate a vibration environment which a battery system will likely experience during its life. Requirements for Co Ve No Cr Ma Fc Thermal shock: Purpose: To simulate a rapid temperature change environment which a battery system will likely experience during its life Humidity/moisture exposure: Purpose: To simulate a temperature/humidity environment which a battery system will likely experience during its life 4.3 Drop test: Purpose: To simulate a service condition where the battery system is removed (or being removed) from the vehicle and is dropped while separated from the vehicle. 4.4 Immersion tests: Purpose: To simulate a situation in which a vehicle is flooded. 4.5 Mechanical shock: Purpose: To simulate inertial loads which may occur during a vehicle crash situation. Two evaluation/test alternatives: 1) Battery system level 2) Vehicle level HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 25 of 88

26 Cl. SAE J2929: Description of test/requirement Applicable to 4.6 Battery enclosure integrity: Purpose: To simulate contact loads which may occur during a vehicle crash situation. Three evaluation/test alternatives: 1) Battery system level - application specific Requirements for Co Ve No Cr Ma Fc 2) Battery system level - generic 3) Vehicle level 4.7 Exposure to simulated vehicle fire: Purpose: To simulate exposure to a vehicle fire condition to verify that the battery system does not pose additional risk due to explosion 4.8 Electrical short circuit: Purpose: To simulate a short circuit condition across the battery terminals. 4.9 Single point overcharge protection system failure: Purpose: To simulate a condition where the battery systems charge device is no longer being controlled and the failure may allow the battery system to be overcharged Single point over discharge protection system failure: Purpose: To simulate a condition where the battery systems discharge load is no longer being controlled and the failure may allow the battery system to be over discharged Single point thermal control system failure: Purpose: To simulate a condition where the battery system temperature control is no longer operating and the failure may lead to a battery system over temperature condition. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 26 of 88

27 Cl. SAE J2929: Description of test/requirement Applicable to 4.12 Fault analysis: Purpose: To verify through fault analysis of the system design (e.g. using FMEA per SAE J1739) that plausible single point faults will not result in fire, explosion, battery enclosure rupture or high voltage hazards. Requirements for Co Ve No Cr Ma Fc 4.13 Protection against high voltage exposure: Purpose: requirements for protection against direct contact and by automatic disconnection of the source. Notes to table: Cl. Indicates the applicable clause number of the standard Co : applicable to the component, test/evaluation on component level Ve : applicable to the vehicle, test/evaluation on vehicle level No : requirements for normal operation Cr : requirements for crash situation Ma: requirements for maintenance Fc: (simulated) single fault condition/single point of failure HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 27 of 88

28 4.2 Observations The ISO and SAE J2929 standards have been recently issued. Considering the current pressure on standardization (see chapter 2) it therefore could be questioned if they are already mature enough. These standards when focussed on safety include a lot of the requirements which are derived from battery standards for electronic appliances and standards for the transportation of dangerous goods (e.g. UN safety of lithium-based batteries during transport), which already exists for some years now, but are not adopted to automotive requirements. Both standards somewhat recognize this. For example in the scope of ISO it notes that "relevant test procedures and test conditions may be selected from this standard", which leaves it very open to the manufacturer in determining what testing to conduct and which criteria to apply. SAE J2929 includes in its clause 1.2 "future considerations", acknowledging that certain essential safety requirements are not or not fully included in the standard. The following is a list of observations applicable to ISO : ISO only includes test requirements and does not include specific compliance (pass/fail) criteria. Includes abnormal operating conditions, but no crash conditions Includes functionality check of protective devices but no real simulated fault conditions or failure analysis. All tests are on component level, not vehicle. Does not include maintenance requirements/tests. Does not include requirements for the integrity of battery enclosures. Does not consider flammability/explosion hazards. Does not consider propagation of fire and hazards related to thermal propagation. Does not consider potential toxicity of vented gasses/materials. Does not include Electro Magnetic Compatibility EMC immunity requirements or references to specific EMC standards for e.g. the battery management system electronics and protective electronic circuitry/devices. Does not include requirements or considerations concerning risks associated with latent mechanical damage. It is known that after an impact/shock, lithiumion batteries may seem to operate properly, but due to mild mechanical damage and after several times being discharged and recharged, internal short circuits and thermal runaway may occur. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 28 of 88

29 The following is a list of observations applicable to SAE J2929: SAE J2929 includes safety requirements and compliance criteria. Includes test options on (general) component/system level and alternative options for vehicle level evaluation. Includes minor requirements for maintenance. Includes crash requirements. For most of the testing and evaluation also reference is made to other SAE, ISO, IEC, UNECE publications and UL standards. Includes limited requirements for the integrity of battery enclosures. Includes limited considerations for flammability/explosion hazards. Includes limited considerations for the propagation of fire and hazards related to thermal propagation. Does not consider potential toxicity of vented gasses/materials. Does not include EMC immunity requirements or references to specific EMC standards for e.g. the battery management system electronics and protective electronic circuitry/devices. Does not include requirements or considerations concerning risks associated with latent mechanical damage. It is known that after an impact/shock, lithium-ion batteries may seem to operate properly, but due to mild mechanical damage and after several times being discharged and recharged, internal short circuits and thermal runaway may occur. Note: electric vehicles and its components are subjected to the same lawful constraints as the internal combustion engine vehicle. It may be that one or more of the above mentioned observations are covered by regulations or standards falling under the automotive directive 2007/46/EC. It is beyond the scope of this document to analyse these regulations and standards falling under the automotive directive. Using ISO in combination with SAE J2929 would be a recommended combination to define essential performance characteristics and a minimum set of safety criteria. Additional considerations however must be given to: Crush test force to be reconsidered for truck applications. (Expanded) Battery enclosure integrity requirements. (Expanded) Flammability requirements. (Expanded) Fire propagation requirements. (Expanded) Thermal (heat) propagation requirements. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 29 of 88

30 (Expanded) Explosion safety requirements. Toxicity of vented gasses/materials. EMC immunity requirements. Functional safety requirements of electric/electronic and/or programmable electronic systems (E/E systems). Latent mechanical damage. Determining a correct set of safety criteria would also enable to set up appropriate guidelines for emergency services with respect to eventual battery hazards caused by the use of electric and hybrid-electric vehicles. There are many different battery chemistries used in lithium-ion based batteries. Furthermore this is a very active area of research and new chemistries are developed constantly, which may require new safety requirements and/or test methods not covered by the currently available standards. It may be expected that ISO (see chapter 6 "functional safety") will also have its impact on the design criteria for energy storage systems. The hazard analysis techniques required by this standard fill the gap for new technologies, new insights and lack of requirements in existing standards and provide for state-off the-art design. Testing large format battery packs for use in electric and hybrid electric vehicles will pose increased challenges on test facilities and testing multiple packs may be very expensive. Vehicle manufacturers may seek for alternate methods to limit the number of packs to be tested. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 30 of 88

31 5. Crashworthiness of electrical energy storage systems To assess the crashworthiness of currently available electrical energy storage systems (more specific Li-Ion batteries and super capacitors) standards should include abuse testing requirements. Abuse testing is performed to characterize the response of an energy storage system to conditions or environmental situations which are not normal, i.e. beyond their normal operating situation. Such situations may be the result of a vehicle crash, but can also be the result of (internal) component failures, system failures, (electronic) control failures, transportation accidents, human errors etc. Safety standards for lithium-based batteries should include abuse testing and most of them do, but the majority of the currently available standards for the safety of lithiumbased batteries do not include abuse requirements simulating situations which may occur during a vehicle crash. E.g. the IEC ("safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications") includes a crushing of cells/battery requirement. But the test is to simulate a mechanical abuse, where the battery (cell) should be able to withstand a 13 kn flat plate crushing which could occur when the battery is thrown away (foreseeable misuse) and is crushed by a garbage container or similar. Such a test may not be representative to simulate a crash situation of a battery in an electric vehicle. Currently available standards for lithium-based energy storage systems for automotive applications which include requirement and tests to simulate situations which may occur during a vehicle crash are: SAE J2929 (see also chapter 4 of this report) SAE J2464 UL 2580 ISO and IEC SAE J2929 SAE J2929 defines a minimum set of acceptable safety criteria for a lithium-based rechargeable battery system to be considered for use in a vehicle propulsion application as an energy storage system connected to a high voltage power train. The standard includes acceptance criteria for the following requirements and tests to simulate situations which may occur during a vehicle crash: Immersion tests: To simulate a situation in which a vehicle is flooded. Mechanical shock test: To simulate inertial loads which may occur during a vehicle crash. Battery enclosure integrity test: To simulate contact loads which may occur during a vehicle crash. Exposure to simulated vehicle fire: To simulate exposure to a vehicle fire condition to verify that the battery system does not pose additional risk due to explosion. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 31 of 88

32 5.2 SAE J2464 SAE J2464 includes test descriptions for abuse testing; it however does not include acceptance criteria. The standard covers a broad range of vehicle applications as well as a broad range of electrical energy storage devices, including individual cells (both batteries and capacitors), modules and packs. Some of the tests described in the standard are referred to by SAE J2929. Tests described in SAE J2464 which can be applied to simulate situations which may occur during a vehicle crash are: Shock tests: To simulate inertial loads which may occur during a vehicle crash. Penetration test: To simulate a situation which may occur during a vehicle crash. where the energy storage (system) is penetrated by a nail or rod resulting in an internal short between the electrode layers causing potential thermal runaway. Roll-over test: To simulate an overturned vehicle. Immersion test: To simulate a situation in which a vehicle is flooded. Crush test: To determine the energy storage system's ability to withstand a crush that could occur during a vehicle accident. High temperature hazard test: To simulate exposure to a vehicle fire condition to verify that the battery system does not pose additional risk due to explosion. 5.3 UL 2580 UL 2580 includes requirements for electrical energy storage assembly/system and the ability of these assembly's/systems to safely withstand simulated abuse conditions and preventing any exposure of persons to hazards as a result of the abuse. As this last sentence implies, it is a safety standard with acceptance criteria and includes safety related testing and construction requirements. These requirements cover electrical energy storage assemblies such as battery packs and combination battery packelectrochemical capacitor assemblies for use in electric powered vehicles. The standard includes acceptance criteria for the following requirements and tests to simulate situations which may occur during a vehicle crash: Rotation test: To simulate an overturned vehicle. Shock tests: To simulate inertial loads which may occur during a vehicle crash. Crush test: To determine the energy storage system's ability to withstand a crush that could occur during a vehicle accident. Immersion test: To simulate a situation in which a vehicle is flooded. External fire exposure test: To simulate exposure to a vehicle fire condition to verify that the battery system does not pose additional risk due to explosion. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 32 of 88

33 5.4 ISO and IEC ISO and IEC are related. ISO provides specific test procedures for lithium-ion battery packs and systems and IEC specifies test procedures to observe the reliability and abuse behaviour of secondary lithium-ion cells used for propulsion of electric vehicles. These standards include test descriptions for abuse testing but do not include acceptance (pass/fail) criteria. The abuse test descriptions in the standards do not explicitly mention crash situations but the following was considered to be a test which could simulate situations which may occur during a vehicle crash: Crush test: To determine the ability of the cells to withstand external load forces that may cause deformation (such external forces may be expected due to an accident). The ISO and IEC do also include a mechanical shock test, but the severity levels are less than the levels defined in SAE J2929, SAE J2464 and UL 2580, furthermore the ISO standard indicates that it simulates a load which may occur, for example when driving over a curb stone at high speed, therefore it was considered that this test does not simulate inertial loads occurring during a vehicle crash. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 33 of 88

34 5.5 Observations These standards, which include abuse testing to simulate situations which may occur during a vehicle crash, all have been recently issued. Considering the current pressure on standardization (see chapter 2) it therefore could be questioned if they are already mature enough. These standards when compared, contain (more or less) similar safety test requirements and it appears that, besides some more severe (crash) requirements which obviously apply to the automotive environment, a lot of the requirements are derived from battery standards for electronic appliances (e.g. UL 1642) and standards for the transportation of dangerous goods (e.g. UN safety of lithium-based batteries during transport) which already exists for some years now, but are not adopted to automotive requirements. Both IEC and ISO in this case do not include tests, except perhaps for crush, to simulate vehicle crash situations. The European standard EN is derived from the IEC standard, so for Europe it can be concluded that at the moment there are no special standardisation requirements for the crashworthiness of electrical energy storage systems. None of the standards include requirements or considerations concerning risks associated with latent mechanical damage. It is known that after an impact/shock, lithiumion batteries may seem to operate properly, but due to mild mechanical damage and after several times being discharged and recharged, internal short circuits and thermal runaway may occur. There are many different battery chemistries used in lithium-ion based batteries. Furthermore this is a very active area of research and new chemistries are developed constantly, which may require new safety requirements and/or test methods not covered by the currently available standards. It may be expected that ISO (see chapter 6 "functional safety") will also have its impact on the design criteria for energy storage systems. The hazard analysis techniques required by this standard fill the gap for new technologies, new insights and lack of requirements in existing standards and provide for state-off the-art design. Another problem may be the fire behaviour of the battery packs. The US based standards include a test to simulate exposure to a vehicle fire condition to verify that the battery system does not pose additional risk due to explosion. The European standards do not include such a test. This in combination with the current situation that emergency services are hardly aware how to handle in case of eventual battery hazards, e.g. which fire suppressing methods to be used, how to deal with the high voltage and potential dangerous gasses/materials, leads to a conclusion that these hazards are not appropriately addressed at the moment. UN ECE regulations R94 and R95 (post crash requirements) have been amended to include specific requirements for electric vehicles, but mainly with respect to occupants protection against electric shock (in line with UN ECE R100 requirements), electrolyte spillage and the retention of the energy storage system during and post impact. Most of the concerns addressed in this chapter are not included in the regulatory requirements. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 34 of 88

35 6. Functional Safety Safety is one of the key issues of (future) automobile development. New functionality not only in the area of driver assistance but also in vehicle dynamics control and active and passive safety systems increasingly touches the domain of safety engineering. With the trend of increasing complexity, software content and electronics, there are increasing risks from systematic failures and random hardware failures. Functional safety is the keyword here and can be defined as performance other than that related to basic safety, whose loss of function or degradation beyond specified limits would result in an unacceptable risk. Functional safety for the past years has been applied in many technology areas, e.g. machinery, process industry and medical devices. It is also becoming more and more important in home use appliances, where the safety is increasingly relied on safety related controls and its software. One of the important standards for functional safety is the IEC series, which is intended as both a group safety publication for technical committees of product safety standards, but can also be used as a standalone standard for functional safety of E/E systems (Electrical and (programmable) Electronic systems). Recently the ISO series (part 1-10) have been published. This standard is adapted from IEC as the automotive standard for functional safety of E/E systems. It is expected that this standard will play an important role in future (EV/HEV) automobile development. 6.1 ISO ISO is intended to be applied to safety-related systems that include one or more E/E systems. It addresses possible hazards caused by malfunctioning behaviour of E/E safety-related systems including interaction of these systems. It does not address (basic safety) hazards as electric shock, fire, smoke, heat, radiation, toxicity, flammability, reactivity, corrosion, release of energy, and similar hazards unless directly caused by malfunctioning behaviour of E/E safety related systems. ISO consists of the following parts, under the general title Road vehicles- Functional safety: Part 1: Vocabulary Part 2: Management of functional safety Part 3: Concept phase Part 4: Product development: system level Part 5: Product development: hardware level Part 6: Product development: software level Part 7: Production and operation Part 8: Supporting processes Part 9: ASIL-oriented and safety-oriented analyses Part 10: Guideline on ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 35 of 88

36 Functional safety in the context of ISO is related to Electrical and/or (programmable) Electronic systems (E/E systems) such as: - Safety related controls - Software and linked hardware - Safety related communication busses More specific, ISO 26262: Is adapted from IEC which is a functional safety publication applied in many (technology) areas e.g. machinery, process industry but not specifically to automotive products. Is a lifecycle standard, including the following lifecycle phases: management - concept phase - development - production - operation - service - decommissioning. It supports tailoring the necessary activities during these lifecycle phases. Addresses hazards caused by malfunctioning of E/E systems in road vehicles. Does not address basic safety such as electric shock/fire hazards/mechanical related hazards etc. unless directly caused by malfunctioning of the E/E safety related system. Is for series production passenger cars up to 3.5 ton and concerned with E/E systems. Can be used as a frame work for other technologies (mechanical, hydraulic, pneumatic) and other vehicle applications (e.g. trucks). Provides an automotive specific risk based approach for determining risk classes. Automotive Safety Integrity Levels (ASIL). ASIL classification is used for specifying the necessary safety requirements for achieving an acceptable (residual) risk and; provides requirements for validation and confirmation to assure an acceptable level of safety being achieved. The overall structure of ISO is based upon a V-Model as a reference process model for the different phases of product development (see annex 2). ISO is intended to be implemented at the concept phase of a project. The process requires an 'item' to be defined and described prior to undertaking a hazard analysis and risk assessment. An item is a system or an array of systems or a function to which ISO is applied. An item in turn comprises subsystems and components and its dependencies and interactions with the environment and other items. The item description will be used in the next phase, being the hazard analysis and risk assessment. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 36 of 88

37 The operational situations and operating modes in which an item's malfunctioning behaviour is able to trigger hazards shall be described, both for cases when the item is correctly used and when it is incorrectly used in a foreseeable way, taking into account the vehicle related activities e.g.: - Intended use - Reasonable foreseeable misuse - Fault conditions - Crash - Servicing - Cleaning The hazard analysis and risk assessment identifies hazards that need risk reduction. The hazards of the item shall be determined systematically. Techniques such as brainstorming, checklists, quality history, FMEA, field studies etc. can be used for the extraction of hazards at an item level. A safety goal is formulated for each hazardous event; this is a top-level safety requirement as a result of the hazard analysis and risk assessment related to prevention or mitigation of the hazards in order to avoid unreasonable/unacceptable risk (see also chapter 7 "Hazard analysis techniques for safe high-voltage systems). An Automotive Safety Integrity Level (ASIL) is associated with each safety goal. There are four ASIL classes (A, B, C and D) with D representing the most stringent and A the least stringent level. ASIL classification is used for specifying the necessary safety requirements for achieving an acceptable (residual) risk and for providing the requirements for validation and confirmation to assure an acceptable level of safety being achieved. The functional safety concept is a statement of the functionality to achieve safety goals. This is stated in the functional safety requirements. The technical safety concept is a statement of how this functionality is implemented in hardware or software. This is stated in the technical safety requirements. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 37 of 88

38 Figure 2: Example of a functional safety concept The hazard and risk analysis considers the failure of unintended deployment of the airbag. This malfunction might be hazardous in an operational situation where no crash occurs, resulting in a higher 'probability of exposure' classification. The driver or passenger might be seriously injured if such an occasion occurs, resulting in a higher 'severity of potential harm' classification. If this failure occurs, harm cannot easily be avoided which results in a classification 'difficult to control or uncontrollable The combination of potential severity, probability of exposure during an operational situation and controllability in this example will result in a more stringent ASIL classification see figure Observations Safety is one of the key issues of (future) automobile development. New functionality not only in the area of driver assistance but also in vehicle dynamics control and active and passive safety systems increasingly touches the domain of safety engineering. With the trend of increasing complexity, software content and electronics, there are increasing risks from systematic failures and random hardware failures. ISO series covers the functional safety of road vehicles, in particular the safety of the vehicle's Electric and Electronic (E/E) systems. It also provides a framework within which safety-related systems based on other technologies can be considered. Though excluded from its scope, the framework of the standard therefore is considered to be suitable for EV/HEV truck applications as well. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 38 of 88

39 ISO is designed to be state-of-the-art and therefore considered to be best practice. In automotive the application of electronics and safety achieved by electrical and (programmable) electronic systems is growing fast. The ISO fills a gap in this area providing the framework for designers and integrators of functional safety related systems. The standard however is a very complex standard, it is quite voluminous and difficult to read and interpret. Furthermore one should be aware the standard only addresses functional safety, basic safety such as electric shock and fire hazards are not addressed. There can be no compliance with safety if only ISO is applied, however it is expected that ISO will also have its impact on the design criteria of other technologies such as the energy storage (batteries, super capacitors, fuel cells) of EV and (P)HEV. The hazard analysis techniques fill the gap for new technologies, new insights and lack of requirements in existing standards and provide for state-off the-art design. The standard includes the whole life cycle of the product and the necessary activities during these lifecycle phases. Its implementation therefore tends to be very expensive, especially for the smaller and medium sized companies not already working with risk management based activities. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 39 of 88

40 7. Hazard analysis techniques for designing safe High Voltage systems If examination of the vehicle shows that hazards might arise which are not (fully) addressed by the applied standards, alternative methods should be applied to come to safe high voltage systems. In the next clauses two methods are described which have proven their effectiveness in a broad range of applications. 7.1 Hazard analysis and Risk Assessment Where required, hazard analysis and risk assessment should be carried out and documented to achieve a tolerable risk (i.e. a risk which is accepted in a given context based on the current values of society). The tolerable risk will depend on many factors i.e. the severity of injury, the damage to property, the number of people exposed to danger, the frequency at which a person or people are exposed to danger and the duration of the exposure. For vehicles the operational situations and operating modes in which a malfunctioning behaviour is able to trigger hazards shall be described, taking e.g. into account: - intended use (correct use) - reasonable foreseeable misuse (incorrect use) - fault conditions - crash - servicing - cleaning etc. A tolerable risk shall be achieved by an iterative process (see fig. 3) covering the following: Risk analysis: Risk analysis is the process to identify hazards and to estimate the risk based on the use of available information. Risk evaluation: Each risk analysis requires a plan to evaluate the estimated severity and likelihood of a risk, and to judge the acceptability of the resulting risk level. Risk reduction: If the initial risk level is not acceptable, steps shall be taken to reduce the risk. The process of risk analysis and risk evaluation shall then be repeated, including checking that no new risks have been introduced. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 40 of 88

41 Figure 3: Flowchart of Iterative process of risk assessment and risk reduction (source: IEC 1032/10) HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 41 of 88

42 The hazards need to be determined systematically. Techniques such as brainstorming, checklists, quality history, FMEA, product metrics, and field studies can be used for the extraction of hazards. A technique frequently used and recommended practice in the automotive sector is Failure Mode and Effect Analysis (FMEA). An FMEA is an analytical technique to recognize and evaluate the potential failure of a product/process and the effects of that failure. The FMEA must be started as early as possible during product development, and should regularly be kept up to date. The FMEA aims at identifying possible failures for every product function. For every failure mode it is analysed what are the causes, effect (severity) and the occurrence of the fault. Finally, every failure mode ends up with a calculated score, to help sorting out high risks and low risks. This will give support in defining the correct and most urgent actions. Suitable standards which can be used are: - IEC 60812: Analysis Techniques for System Reliability Procedure for Failure Mode and Effects Analysis (FMEA). - SAE J1739: Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA). Other established procedures/standards which implement similar steps can also be used. In selecting the most appropriate methods of risk reduction, the manufacturer shall apply the following principles of safety integration (see also fig. 4), in the order given: 1) Eliminate or reduce risks as far as possible (an inherently safe design and construction). 2) Take the necessary protective measures in relation to risks that cannot be eliminated by step 1. 3) Inform users of the residual risks due to any shortcomings of the protective measures adopted. 4) Indicate whether any particular training is required, and specify any need to provide personal protective equipment (PPE). Risks remaining after a risk assessment shall be identified by giving adequate information about how to mitigate these risks in the instructions of the user. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 42 of 88

43 Figure 4: Principles of safety integration (source: ISO/IEC guide 51 'modified') Risk assessment procedures are contained in several standards such as IEC and ISO (see also ANNE 1 standards overview). Other established procedures/standards which implement similar steps can also be used. 7.2 Hazard based safety engineering Hazard based safety engineering (HBSE) can be described as a process for designers and engineers, to help them to integrate safety compliance early in the design cycle of a product. Most of the existing safety standards are product-based and prescriptive, i.e. describing specific constructions to comply with. Furthermore they have a more or less reactive approach, meaning it provides requirements for reactions to safety incidents or nearincidents. In contrary, applying HBSE is a proactive approach to prevent future incidents. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 43 of 88

44 The HBSE process is schematically drawn in the flowchart of figure 5 and hereafter described more in detail. Energy sources within the 'product' are identified and classified. To determine whether an energy source is hazardous or not, the limit values from available safety publications (e.g. IEC/EN/ISO basic and group safety publications) and other (international) standards should be used. A hazardous energy source becomes a hazard once there are means by which it can be transferred to a (human) body part or the surroundings of the 'product'. These means shall be identified in order to be able to design safeguards which will prevent energy transfer to a body part and/or the surroundings of a product. The safeguard requirements (test and parameters) are based on available safety publications (e.g. IEC/EN/ISO basic and group safety publications) and other (international) standards (e.g. SAE, UL, ANSI etc.). Energy sources which (may) exist in the electric system of an EV/HEV are: Electrical energy (causing electric shock, skin burn and/or internal organ burn) Thermal energy (causing ignition and fire leading to injury, burns by touching hot parts and damage to surroundings and property) Chemical energy (chemical substances causing skin injuries, damage to eyes or damage to organs in case of inhalation) Kinetic energy (injury caused by contact with moving parts like motors or expelled parts due to explosion, crush etc.) Radiation energy (electromagnetic and/or optical radiation in e.g. optical communication/transmission systems capable of causing injuries) A safeguard can be defined as a device or scheme or system that is: Interposed between an energy source capable of causing injury to a body part or damage to surroundings and property and Reduces the likelihood of transfer of the energy by: 1) attenuating (reducing the value), or; 2) impeding (slowing the rate), or; 3) diverting (changing the direction) or; 4) disconnecting, interrupting, disabling, or; 5) otherwise preventing the energy transfer Safeguards can be divided in: Product safeguards: These are physical part of the HV system within the vehicle. Examples are provision of safety insulation (creepage and clearance distances and solid insulation), equipotential bonding/earthing of accessible conductive parts, high integrity safety components, disconnect devices, enclosures and functional safety of E/E systems. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 44 of 88

45 Installation safeguards: Part of the installation, examples are overcurrent protection and continuity of earthing when connected to external chargers, safe charging protocols, charging plugs, cables and socket in/outlets. Personal safeguards: In case product safeguards are absent, e.g. during maintenance or service, personal protective equipment can be used such as insulating floor mats, gloves, tools and glasses. Instructional safeguards: A visual indicator (symbols or words or both) or an audible message, describing the existence and location of an energy source capable of causing injury and which is intended to invoke a specific behaviour on a person. An example is indicating the disconnect device for disconnecting the high voltage (battery) from the system during maintenance, service or in case of emergency services. The principles of HBSE are used in the IEC This standard includes within its framework a lot of product and specific application based requirements, established by applying the HBSE principles. Furthermore the process can be used for (new) 'state of the art' technologies and to keep up with convergence of technologies. The principles of HBSE, using the IEC and its requirements as a guide, are considered as a useful guideline and tool for both designing safe HV systems for (hybrid) electric vehicles and assessing compliance. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 45 of 88

46 Figure 5: Flowchart of HBSE (Source: IEC TC108: Hazard Based Standard Development Team) HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 46 of 88

47 8. Safe electric and hybrid-electric vehicle operation in traffic related to the noise level At the moment DEKRA Certification B.V. is not aware of any standards or regulations, which requires a minimum noise level for electric and hybrid electric vehicles. Except for some research reports from the US and Japan hardly any information is available about this new area of concern. Due to the quiet vehicles, there may be an increased safety risk to pedestrians, especially visually impaired and other vulnerable pedestrians in detecting the presence, direction, location, and operation of those vehicles. The UN World Forum for Harmonization of Vehicle Regulations (WP29) has setup an informal working group on Quiet Road Transport Vehicles, with the objective to develop harmonized pedestrian alert sound requirements for electric and hybrid-electric vehicles. Currently the WP 29 working group on noise (the GRB) is in the process of developing possible solutions based on acoustic measures. Japanese guidelines have been adopted by the UNECE and are used by the GRB for developing guidelines for amongst others: Electric and hybrid-electric vehicles to emit pedestrian alert sounds beginning when the vehicle starts moving and continuing until the speed of the vehicle reaches 20 km/h. There is no specification that a vehicle should emit an alert sound when the vehicle is stopped or when a hybrid-electric vehicles ICE (Internal Combustion Engine) is engaged and thus emitting sound. It may be allowed to have a pause switch, which enables the driver to stop the sound temporarily (this may be preferred e.g. in case of start/stop and slow speed driving in a traffic jam). Such a switch shall be located within easy reach of the driver and the driver shall be informed (e.g. by indication light) that the switch is enabled. The type(s) of sound to be generated and the volume level. It may be in future that such guidelines are turned into requirements and become part of regulation(s). HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 47 of 88

48 9. Dismantle (of the electric parts/electric storage systems) of the vehicle at the end of its life Electric and hybrid-electric vehicles are subjected to the same lawful constraints as the internal combustion engine vehicles. This includes regulations on recycling, the End of Life of Vehicles directive (2000/53/CE) and directive on waste battery and battery recycling (2006/66/CE). 9.1 Directive 2000/53/CE (End of Life of Vehicles) Directive 2000/53/CE (End of Life of Vehicles) currently does not apply to heavy goods vehicles or to electric and hybrid-electric vehicles, i.e. these vehicles are not included at the moment in the definition of 'what is a vehicle' in the directive. The objective of the directive is to prevent waste from vehicles and disposal of waste by reuse, recycling and other forms of recovery of end of life vehicles and their components. The main provisions of the directive include: It prohibits the use of hazardous substances (lead, mercury, cadmium, hexavalent chromium) above fixed threshold concentrations, in materials and components of vehicles. Exemptions apply for those heavy metals and applications where no appropriate alternatives exist, e.g. lead in batteries. It requires Member States to establish collection systems for waste arising from vehicles. Furthermore, they shall ensure suitable material coding systems and that end-of-life vehicles are transferred to authorized treatment facilities. Targets are set to increase the rate of reuse, recycling and recovery of vehicles and their components. Manufacturers, distributors and dismantlers are encouraged to publish information on - The design of the vehicles and their components (capacity for recovery and recycling). - The treatment of end-of-life vehicles (e.g. removal of fluids and dismantling). - The development and improvement of methods for reusing, recycling and recovering end-of-life vehicles and their components. - The progress made in the field of recovery and recycling. The End of Life of Vehicles is in some countries legislation for heavy goods vehicles and therefore enforces truck manufacturers to comply with the directive. Furthermore environmental conscious design and manufacturing should include proper end of life and disposal of waste which encourages truck manufacturer to comply with such requirements. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 48 of 88

49 For electric and hybrid-electric vehicles in addition considerations should be given to the following: The use of hazardous substances in energy storage systems like lithium-ion batteries and ultra-capacitors. Reusability and recycling of energy storage systems like lithium-ion batteries and ultra-capacitors. Safe dismantling of energy storage systems like lithium-ion batteries and ultracapacitors. Reusability and recycling of other electric vehicle components e.g. inverters, converters, connectors, cabling, electronic controllers and traction motors. 9.2 Directive 2006/66/CE (Waste Battery Directive) Directive 2006/66/CE applies to all type of batteries and accumulators sold in the European Union. The main provisions of the directive include: Industrial, automotive and portable batteries and accumulators. - Automotive batteries include the vehicle starting batteries. - Industrial batteries for industrial and professional use, includes batteries for the propulsion of electric vehicles. It prohibits the placing on the market of certain batteries and accumulators with a proportional mercury or cadmium content above a fixed threshold. It promotes a high rate of collection and recycling of waste batteries and accumulators and improvement in the environmental performance of all involved in the life-cycle of batteries and accumulators, including their recycling and disposal, e.g.: - Users of portable batteries and automotive starter batteries shall be able to return waste batteries to distributors or to designated collection points, free of charge - Producers and distributors of industrial batteries (including the automotive batteries for propulsion of EV) shall not refuse to take back waste industrial batteries from end-users. In addition independent parties may also collect these batteries. Member States also have to ensure that batteries and accumulators that have been collected are treated and recycled using the best available techniques. As a minimum, treatment must include removal of all fluids and acids. Batteries and accumulators must be treated and stored (even if only temporarily) in sites with impermeable surfaces and weatherproof covering, or in suitable containers. It prohibits disposal of industrial and automotive batteries and accumulators in landfill sites. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 49 of 88

50 It requires detailed arrangements to be made for a labelling system, which should provide end-users with transparent, reliable and clear information on batteries and accumulators and any heavy metals they contain. Directive 2006/66/EC confirms that automotive and industrial batteries and accumulators used in vehicles should meet the requirements of Directive 2000/53/EC (End of Life of Vehicles). For electric and hybrid-electric trucks the Directive 2006/66/EC does not impose any more onerous requirements than those already laid down by Directive 2000/53/EC. The same additional considerations as mentioned in clause 9.1 would apply. 9.3 Observations Lithium-ion batteries and ultra-capacitors normally do not contain significant quantities of the hazardous substances lead, mercury, cadmium and hexavalent chromium. Furthermore there might be a second life for these energy storage systems. They can be reused for other electro-mobility applications or industrial storage, grid applications etc. It therefore may be assumed that there will be no major difficulties to comply with the reuse targets and hazardous substances restrictions given in Directive 2000/53/CE (End of Life of Vehicles). For other electric vehicle components e.g. inverters, converters, connectors, cabling, electronic controllers and traction motors, difficulties at end of life for reuse and recycling are also not expected. A lot of these components may be developed by manufacturers and/or produced by factories which also manufacture other electric and electronic equipment which have to comply with Directive 2002/96/EC on waste electrical and electronic equipment (WEEE, Waste Electronic and Electrical Equipment) and Directive 2002/95/EC on the restriction of the use of certain hazardous substances (this e.g. includes the restriction on heavy metals and halogens) in electrical and electronic equipment (RoHS). With respect to person safety against electric shock, fire, explosion and chemical hazards clear dismantling instructions need to be provided by the manufacturer. For the high voltage (energy storage) system such instructions may have to include: Information on the vehicle HV system. Identification and location of (HV) components and a description of their operation to be included in the instructions. A more detailed description of the HV energy storage/battery pack, e.g.: - Nominal voltage and capacity of the pack system - Number of modules (or cells) in the pack and nominal voltage and capacity of the modules (cells) - Battery technology and information about chemistry used (cathode material, anode material, electrolyte). - Weight and dimensions of the pack and/or modules. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 50 of 88

51 - The included safety protection devices and precautions for not defeating them during handling. Information about safety such as: - Construction of the isolation measures for protection against direct contact to create awareness and enabling the dismantler to recognize possible hazardous situations. - Safety protection devices and precautions for not defeating them during handling. - Disconnection of the HV system from other circuitry - Preventing electrical discharge with fuels or gasses which might result in fire or explosion. Information on eventual tools to be used such as indicator circuitry and/or voltage metering or isolation resistance metering. Information on which tools to be used and a procedure for removal of the battery pack from the vehicle. Instructions for personal protective equipment (PPE), such as wearing protective clothing. How to handle in case of 'unwanted' situations which may occur during dismantling, e.g. electrolyte spillage and how to neutralize them and/or HV parts which have become accessible as a result of a crashed vehicle. Considerations should be given to the fact that the capacity of a lithium-ion battery pack is determined by the capacity of the weakest module/cell in a pack. This may result in situations where it seems that most of the capacity of a battery is lost, internal cells however may still have considerable electrical and chemical energy. Dismantlers should be aware of this. For environmental health and safety dismantling, instructions must also include Information about reuse, recycling and/or disposal of the battery pack or ultra-capacitors. Information should be provided, e.g. on the label of the energy storage system on whom to contact. Life cycle standards like ISO and IEC also include requirements on decommissioning. Besides requiring instructions to be provided, such standards also require a system to be in place enabling the manufacturer to collect and review field data to detect the presence of any safety issues and to take appropriate actions in case safety issues are found. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 51 of 88

52 10. Veolia operators point of view This chapter presents the recommendations on safety aspects from the operator point of view. These results are based on feedback collected from four maintenance teams in two different countries (France and Netherland) operating electric hybrid buses. Following the returns of the questionnaire created for collecting feedback of networks operating electric hybrid buses, the result is that no major troubles related to safety risks in operation, maintenance or crash situation, have been reported. Nowadays, a lot of networks have delegated the maintenance of hybrid systems to subcontractors (e.g.: manufacturers). That is why feedback on risks encountered in daily use of hybrid buses is so insignificant. Therefore, it is quite difficult to express advices and recommendations in design guidelines for next generation hybrid buses. Results and discussion However, what we can say, from the operator side, concerning electric hybrid components for next design guidelines is the following: Location: Avoid implementation of hybrid components on the bus roof (e.g: energy storage system, converters). It will increase maintenance works at heights that could present risky situations for workers (increased likelihood of serious injury by falling off the roof). Moreover, it will be necessary to invest on infrastructure (e.g. lifting devices) and personal training to maintain such parts. Next to the fact that it could slow down hybrids spreading, it will also increase risks toward loads handling. However, the accessibility of components should not suffer from transferring these away from the roof. If hybrid components have to be removed by hand, rules on workplace ergonomics should be taken into account in design and implementation. Otherwise, it must be done by ground handling devices. If work on roof is unavoidable, path and working areas signs have to be drawn on the roof to locate safe places. Identification: Risks related to proximity of hybrid components must be warned by use of bright colours or signs placed to alert workers of hazard when working nearby. Intervention on/nearby: As much as possible, avoid having heavy procedures or actions set for daily maintenance operations, due to the proximity of hybrid components. The level of risks for maintainers has to be equivalent as on a standard bus for this kind of work. Devices have to be integrated to shut down power in the working area and discharge procedures or systems have to be implemented to avoid electrical shocks due to the existence of energy storage devices on the vehicle (e.g: filtering capacitor, battery). Residual levels of energy and voltage of these have to be lowered to a state that does not cause risks to human health when intervening on or nearby. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 52 of 88

53 Connection: Usage of cables with connectors to link high voltage components (e.g: battery, converter, motor), instead of screwed connections, should reduce risks on electric safety issues by decreasing the probability of mistakes or bad connections during maintenance operations. Moreover, it will also ease the replacement of components by reducing reconnection time. Conclusions Independently of the subjects addressed above, one important issue in the design of a hybrid commercial vehicle is an energy storage system that allows the operator s maintenance team to safely disassemble modules in case of faulty elements replacement or removal at the end of service life. Today this issue does not show up yet due to the newness of this kind of vehicles, but can come in a short term for operators that intend to do the maintenance themselves instead of subcontracting it. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 53 of 88

54 11. Results and discussion Besides the already available standards as shown in the overview above from DEKRA there are still new standards in development. Some of the identified gaps in the published standards will be covered by some of the standards currently in development. For example: 1) ISO/WD : Electrically propelled road vehicles Safety specifications Part 4: Post crash electrical safety requirements Contents: Crash test procedures Electric safety requirements Protection against electric shock Voltage criterion Isolation resistance Protection against direct contact Electrical energy criterion Protection against short-circuit RESS safety requirements Electrolyte spillage RESS retention 2) ISO/DIS : Electrically propelled road vehicles Test specification for lithium- Ion traction battery systems Part 2: High energy applications 3) ISO/CD : Electrically propelled road vehicles Test specification for lithiumion battery packs and systems Part 3: Safety performance requirements Contents: General requirements General tests Mechanical tests Climatic tests Simulated vehicle accidents Electrical tests System failure tests 4) ISO 17409: Electrically propelled road vehicles - Connection to an external electric power supply - Safety requirements This standard is under development by ISO Technical Committee Road Vehicles 22 (TC22) in Sub Committee 21 electrically propelled road vehicles (SC21). DAF trucks NV is a member of the ISO TC22/SC21 and is closely watching this development. The identified gaps from this study will be used as input for these developments to close the identified gaps HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 54 of 88

55 Besides the ISO Road Vehicles there are multiple institutes that are developing new standards in the area of safety for Hybrid electrical vehicles. The IEC/TC64 is working on IEC Low voltage electrical installations Part 7-722: Requirements for special installations or locations - Supply of electric vehicle. Furthermore, the NEN institute is developing the NEN 3140 Operation of electrical installations - Low voltage. Even though the different institutes are working on closing the gaps there is no structural coordination between the institutes which results in a multitude of standards. Therefore it is important that an OEM closely watches the standard development and provides input where there is a demand for clarity and unity. The outcome of the study done within the Hybrid Commercial Vehicle FP7 project will be used to provide this input and come to a more complete set of standards for high voltage in commercial vehicles. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 55 of 88

56 12. Conclusions The study performed by DEKRA as shown in this report gives a useful overview of the standards to be used to develop a safe Hybrid Electric Commercial Vehicle. Even though the available standards are mostly redundant there are still gaps that have been identified. Fortunately new standards to close these gaps are already under development. Even though the different institutes are working on closing the gaps there is no structural coordination between the institutes which results in a multitude of standards. An update of the guidelines is recommended once these standards have become public. The recommended standards: Safe high voltage systems EC 661/2009 UN ECE R100 ISO Electrical energy storage ISO SAE J2929 Crashworthiness SAE J2929 (see also chapter 4 of this report) SAE J2464, UL 2580 ISO and IEC Functional safety ISO Combined with the hazard techniques to fill in the gaps mentioned in the observations for each standard in this report an OEM should be able to safely design, develop, built, operate, service, and dismantle a hybrid commercial vehicle. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 56 of 88

57 Bibliography CEN/CENELEC Focus Group on European Electro-Mobility, report on "Standardization for road vehicles and associated infrastructure" (version October 2011) DEKRA Certification BV, Consulted experts Dekra Report number PEP, IEC , Insulation coordination for equipment within low-voltage systems Part 1: Principles, requirements and tests IEC 60812, Analysis Techniques for System Reliability Procedure for Failure Mode and Effects Analysis (FMEA) IEC , Information technology equipment Safety Part 1: General requirements IEC , Safety requirements for electrical equipment for measurement, control, and laboratory use Part 1: General requirements IEC 61140, Protection against electrical shock Common aspects for installation and equipment IEC (all parts), Functional safety of electrical/electronic/programmable electronic safety-related systems IEC , Electric vehicle conductive charging system - Part 1: General requirements IEC 62133, Secondary cells and batteries containing alkaline or other non-acid electrolytes - Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications IEC 62281, Safety of primary and secondary lithium cells and batteries during transport IEC 62368, Audio/video, information and communication technology equipment Part 1: Safety requirements (Hazard Based safety Engineering) IEC , Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 1: Performance testing IEC , Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 2: Reliability and abuse testing ISO (all parts), Road vehicles Environmental conditions and testing for electrical and electronic equipment ISO (all parts), Road vehicles - Functional safety ISO : 2009, Electric road vehicles - Safety specifications - Part 1: On-board rechargeable energy storage system (RESS) ISO : 2009, Electric road vehicles - Safety specifications - Part 2: Vehicle operational safety means and protection against failures ISO :2011, Electric road vehicles - Safety specifications - Part 3: Protection of persons against electric hazards ISO , Electrically propelled road vehicles Test specification for lithium-ion traction battery packs and systems Part 1: High power applications SAE J1739, Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA SAE J2380, Vibration Testing of Electric Vehicle Batteries SAE J2464:1999, Electric Vehicle Battery Abuse Testing HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 57 of 88

58 SAE J2929, Electric and Hybrid vehicle propulsion battery system standard - Lithium based rechargeable cells Transport Research Laboratory, report on "Electric vehicles: Review of type-approval legislation and potential risks" (June 2010) UL 1642, Safety of Lithium-Ion Batteries Testing UL 2202: 2009, Electric vehicle Charging System Equipment (2nd edition) UL 2580:2011, Batteries for use in Electric Vehicles directives and articles vehicle regulations HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 58 of 88

59 ANNE 1: Standards overview Electric road vehicle Vocabulary Description Standard(s) Comments Electric road vehicles Vocabulary Electrically propelled road vehicles Terminology Graphical symbols for use on equipment Basic and safety principles for man-machine interface, marking and identification. Identification of conductors by colours or numerals Degrees of protection provided by enclosures (IP Code) Batteries ISO 8713:2005 EN 13447:2001; ISO 8713 IEC EN 60446, EN EN 60529, IEC under revision Description Standard(s) Comments General requirements for battery powered trucks Safety requirements for secondary batteries and battery installations Part 1: General safety information Safety requirements for secondary batteries and battery installations Part 2: Stationary batteries Safety requirements for secondary batteries and battery installations Part 3: Traction batteries Electric road vehicles - Safety specifications - Part 1: Onboard rechargeable energy storage system (RESS) EN EN EN EN ISO : 2009 Ed. 2 - Electrically propelled road vehicles Test specification for lithium-ion traction battery packs and systems Part 1: ISO For HEV applications HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 59 of 88

60 Batteries Description Standard(s) Comments High power applications Electrically propelled road vehicles Test specification for lithium-ion traction battery packs and systems Part 2: High energy applications Secondary cells and batteries containing alkaline or other non-acid electrolytes - Safety requirements for large format secondary lithium cells and batteries for use in industrial applications International Electrotechnical Vocabulary (IEV) - Part 482: Primary and secondary cells and batteries International Electrotechnical Vocabulary (IEV) - Chapter 486:Secondary cells and batteries Secondary cells and batteries containing alkaline or other non-acid electrolytes Sealed nickel-cadmium prismatic rechargeable single cells Secondary cells and batteries containing alkaline or other non-acid electrolytes Vented nickel-cadmium prismatic rechargeable single cells Secondary cells and batteries containing alkaline or other non-acid electrolytes Guide to the designation of current in alkaline secondary cell and battery standards ISO IEC IEC IEC EN 60622, IEC EN 60623, IEC EN 61434, IEC For EV applications Marking of secondary cells and batteries with the international recycling symbol ISO and indications regarding directives 93/86/EEC and EN 61429, IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 60 of 88

61 Batteries Description Standard(s) Comments 91/157/EEC Secondary cells and batteries containing alkaline or other non-acid electrolytes - Portable sealed rechargeable single cells Part 1: Nickelcadmium Secondary cells and batteries containing alkaline or other non-acid electrolytes - Portable sealed rechargeable single cells Part 2 :Nickelmetal hydride Secondary cells and batteries containing alkaline or other non-acid electrolytes Mechanical tests for sealed portable secondary cells and batteries Secondary cells and batteries containing alkaline or other non-acid electrolytes - Secondary lithium cells and batteries for portable applications Secondary batteries (except lithium) for the propulsion of electric road vehicles - Part 1: Performance and endurance tests Secondary batteries for the propulsion of electric road vehicles - Part 2: Dynamic discharge performance test and dynamic endurance test EN , IEC EN , IEC EN 61959, IEC EN 61960, IEC EN , IEC EN , IEC under revision Secondary batteries for the propulsion of electric road vehicles - Part 3: Performance and life testing (traffic compatible, urban use vehicles) Secondary batteries for the propulsion of electric road EN , IEC IEC Replaced by IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 61 of 88

62 Batteries Description Standard(s) Comments vehicles Part 1: Test parameters Secondary batteries for the propulsion of electric road vehicles Part 5: Safety testing for lithium-ion cells and batteries Secondary cells and batteries containing alkaline or other non-acid electrolytes - Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in portable applications Secondary cells and batteries containing alkaline or other non-acid electrolytes Design and manufacturing recommendations for portable batteries made from sealed secondary cells Secondary cells and batteries containing alkaline or other non-acid electrolytes Nickel cadmium prismatic secondary single cells with partial gas recombination Safety of primary and secondary lithium cells and batteries during transport Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 1: Performance testing Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 2: Reliability and abuse testing Electric double-layer capacitors for use in hybrid electric vehicles -Test methods for electrical char. Safety requirements for secondary batteries and IEC Replaced by IEC IEC IEC/TR EN 62259, IEC EN 62281, IEC EN , IEC EN , IEC EN 62576, IEC Under revision Related to UN 38.2 manual for transportation Li batteries IEC Related to EN HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 62 of 88

63 Batteries Description Standard(s) Comments battery installations Part 2: Stationary batteries Safety requirements for secondary batteries and battery installations Part 3: Traction batteries Safety requirements for secondary batteries and battery installations - Part 4: Batteries for use in portable appliances Possible safety and health hazards in the use of alkaline secondary cells and batteries - Guide to equipment manufacturers and users Life Test for Automotive Storage Batteries IEC Related to EN IEC IEC/TS SAE J240 - Storage Batteries SAE J537 - Test Procedure for Battery SAE J Flame Retardant Venting Systems Recommended Practice for SAE J Packaging of Electric Vehicle Battery Recommended Practice for SAE J Performance Rating of Electric Vehicle Battery Modules SAE J1766: Life Test for Heavy-Duty Storage Batteries Comprehensive Life Test for 12 V Automotive Storage Batteries Life Cycle Testing of Electric Vehicle Battery Modules Electric Driver Battery Pack System Functional Guidelines Electric Vehicle Battery Abuse Testing Vibration Testing of Electric Vehicle Batteries Electric and Hybrid vehicle propulsion battery system SAE J SAE J SAE J SAE J2289: SAE J2464: SAE J SAE J HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 63 of 88

64 Batteries Description Standard(s) Comments standard - Lithium based rechargeable cells Safety of Lithium-Ion Batteries Testing Batteries for use in Electric Vehicles Charging systems UL1642: UL 2580: Description Standard(s) Comments Low-voltage switchgear and controlgear assemblies Low-voltage switchgear and controlgear Part 1: General rules Low-voltage switchgear and controlgear Part 2 : Circuitbreakers Low-voltage switchgear and controlgear - Part 3: Switches, disconnectors, switch-disconnectors and fuse-combination units Electric vehicle conductive charging system - Part 1: General requirements Electric vehicle conductive charging system - Part 21: Electric vehicle requirements for conductive connection to an a.c./d.c. supply Electric vehicle conductive charging system - Part 22: AC electric vehicle charging station Electric vehicle conductive charging system - Part 23: d.c. electric vehicle charging station Electric vehicle conductive charging system - Part 24: Communication protocol between off-board charger and electric vehicle EN &EN series, IEC &IEC series EN , IEC EN , IEC EN , IEC EN , IEC EN , IEC EN , IEC IEC IEC being replaced by EMC requirements are currently included into this standard and part of them are safety requirements under revision. The safety related items of this part will be transferred to new work in ISO EMC related items remain in this part Under revision, EMC requirements are included into this standard and part of them are safety requirements New work (CD stage) New work (CD stage) Uninterruptible power EN , IEC Related to IEC/EN HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 64 of 88

65 Charging systems Description Standard(s) Comments systems (UPS) - Part 2: Electromagnetic compatibility (EMC) requirements Plugs, socket-outlets, vehicle couplers and vehicle inlets - Conductive charging of electric vehicles - Part 1: Charging of electric vehicles up to 250 A a.c. and 400 A d.c. Plugs, socket-outlets and vehicle couplers Conductive charging of electricity vehicles Part 2: Dimensional interchangeability requirements for a.c. pin and contact-tube accessories Plugs, socket-outlets, vehicle couplers and vehicle inlets - Conductive charging of electric vehicles - Part 3:Dimensional interchangeability requirements for d.c. pin and contact-tube vehicle couplers Conductive charging for electric vehicles - Part 1: D.C. charging station Conductive charging for electric vehicles - Part 2: Communication protocol between offboard charger and electric vehicle EN , IEC IEC IEC CLC/TS : CLC/TS : New work/under development Industrial battery chargers UL 1564: Electric vehicle Charging System Equipment (2nd edition) Outline of Investigation for Electric Vehicle Supply Circuit Vehicle On-Board Charging Power Quality UL 2202: UL 2594: SAE J HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 65 of 88

66 Charging systems Description Standard(s) Comments Electric Vehicle Inductively Coupled Charging Electric equipment for the supply of energy to electric road vehicles using an inductive coupling Part 1: General requirements Electric equipment for the supply of energy to electric road vehicles using an inductive coupling Part 2: Manual connection system using a paddle On board electric power equipment for electric road vehicles J IEC IEC IEC Wiring, connectors, controllers, rotating machines Description Standard(s) Comments Semiconductor converters General requirements and line commutated converters - Part 1-1: Specification of basic requirements Road vehicles 60 V and 600 V single-core cables Dimensions, test methods and requirements Multi-core connecting cables Part 1: Test methods and requirements for basic performance sheathed cables EN , IEC ISO ISO Multi-core connecting cables Part 2: Test methods and requirements for high performance sheathed cables Multi-core connecting cables Part 3: Construction, dimensions and marking of unscreened sheathed lowvoltage cables Multi-core connecting cables Part 4: Test methods and requirements for coiled cable ISO ISO ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 66 of 88

67 Wiring, connectors, controllers, rotating machines Description Standard(s) Comments assemblies Road vehicles Round, unscreened 60 V and 600 V multicore sheathed cables Test methods and requirements for basic and high performance cables Road vehicles Data cables Test methods and requirements Road vehicles Circuit breakers Part 1: Definitions and general test requirements Road vehicles Circuit breakers Part 4: Medium circuit breakers with tabs (blade type), Form CB15 Electric cables - Low voltage energy cables of rated voltages up to and including 450/750 V Halogen free, flame retardant EV charging cable for supplying power and communication for electrical vehicles (all parts) Plugs, socketoutlets and couplers for industrial purposes Plugs, socket-outlets and couplers for industrial purposes Part 1: General requirements Plugs, socket-outlets and couplers for industrial purposes Part 2: Dimensional interchangeability requirements for pin and contact-tube accessories Plugs, socket-outlets and couplers for industrial purposes Part 4: Switched socket-outlets and connectors with or without interlock ISO ISO/TS ISO ISO EN series K175 EN 60309, IEC EN , IEC EN , IEC EN , IEC Cables for general applications. Superseding HD21 and HD22 series which correspond to IEC and IEC series New work, under development. DEKRA standard based on EN series. HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 67 of 88

68 Wiring, connectors, controllers, rotating machines Description Standard(s) Comments Wiring and connectors for electric road Vehicles Wiring and connectors for electric road vehicles Instrumentation for electric road vehicles Rotating machines for electric road vehicles Common test methods for insulating and sheathing materials of electric cables and optical cables Plugs and socket-outlets for household and similar purposes Conductors of insulated cables Data for AWG and KCMIL sizes 60 V and 600 V Single Core Cables IEC/TR IEC/TR IEC/TR IEC/TR EN series, IEC series IEC IEC/TR SAE J2183: High Voltage Primary Cable SAE J1654: High Voltage Automotive Wiring Assembly Design Connections for High Voltage On-Board Road Vehicle Electrical Wiring SAE Electric Vehicle Conductive Charge Coupler SAE Electric Vehicle Inductively Coupled Charging 60 V and 600 V Single Core Cables Test Methods SAE J1673: SAE J1742: SAE J1772: SAE J1773: SAE J2183: Round, Screened and Unscreened, 60 V and 600 V Multi-Core Sheathed Cables Plugs, Receptacles and Couplers for EVs Road vehicles - Intelligent power switches - Part 1: High-side intelligent power switch Road vehicles Intelligent power switches Part 2: Low-side intelligent power SAE J2501: UL 2251: ISO ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 68 of 88

69 Wiring, connectors, controllers, rotating machines Description Standard(s) Comments switch Controllers for electric road vehicles IEC/TR Rotating electrical machines EN series, IEC series Electric road vehicles : Communication Description Standard(s) Comments Road vehicles - Vehicle to grid communication interface - Part 1: General information and use-case definition Road vehicles -- Vehicle to grid Communication Interface -- Part 2: Technical protocol description and open systems interconnections (OSI) requirements Information technology - Open Systems Interconnection - Basic Reference Model - Part 1: The Basic Model Information processing systems Open Systems Interconnection -Basic Reference Model - Part 2: Security Architecture Information technology - Open Systems Interconnection Basic Reference Model - Part 3: Naming and addressing Information technology Telecommunication and information exchange between systems Power line communication (PLC) High speed PLC medium access & control (MAC) and physical layer (PHY) Part 1: General requirements ISO/IEC ISO ISO/IEC , ISO/IEC ISO ISO/IEC , ISO/IEC ISO/IEC , ISO/IEC Road vehicles Extended ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 69 of 88

70 Electric road vehicles : Communication Description Standard(s) Comments data link security Coupling devices for power line carrier systems Communication networks and systems in substations IntelliGrid methodology for developing requirements for energy systems Energy Transfer System for Electric Vehicles Part 1: Functional Requirements and System Architectures Energy Transfer System for Electric Vehicles Part 2: Communication Requirements and Network Architecture Power Line Carrier Communications for Commercial Vehicles Use Cases for Communication between Plug-in Vehicles and the Utility Grid Use Cases for Communication between Plug-in Vehicles and the Supply Equipment (EVSE) Use Cases for Communication between Plug-in Vehicles and the Utility Grid for Reverse Power Flow Communication between Plug-in Vehicles and the Utility Grid Communication between Plug-in Vehicles and the Supply Equipment (EVSE) Communication between Plug-in Vehicles and the Utility Grid for Reverse Power Flow Vehicle safety & person protection IEC EN series, IEC series IEC SAE J SAE J SAEJ SAE J2836/1 - SAE J2836/2 - SAE J2836/3 - SAE J2847/1 - SAE J2847/2 - SAE J2847/3 - - Publicly available specification Description Standard(s) Comments HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 70 of 88

71 Vehicle safety & person protection Description Standard(s) Comments Electrically propelled road vehicles Specific requirements for safety - Part 1: On board energy storage Electrically propelled road vehicles Specific requirements for safety - Part 2:Functional safety means and protection against failures Electrically propelled road vehicles Specific requirements for safety - Part 3: Protection of users against electrical hazards Proposals for the braking of electrical vehicles Electrically propelled road vehicles Safety specifications -- Part 1: Onboard rechargeable energy storage system (RESS) Electric road vehicles - Safety specifications - Part 2: Vehicle operational safety means and protection against failures Electric road vehicles - Safety specifications - Part 3: Protection of persons against electric hazards Electric road vehicles - Safety specifications - Part 3: Protection of persons against electric hazards Road vehicles - Fuse-links - Part 1: Definitions and general test requirements Road vehicles - Fuse-links - Part 2: User's guide Road vehicles - Fuse-links - Part 3: Fuselinks with tabs (blade type) Type C (medium), Type E (high current) and Type F (miniature) EN :1997 EN : EN : CR 1955: ISO : ISO : ISO : ISO :2001/Cor1:2003 ISO (2011) ISO : ISO : ISO : Road vehicles - Fuse-links - ISO : Refer to ISO 6469 series edition HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 71 of 88

72 Vehicle safety & person protection Description Standard(s) Comments Part 4: Fuselinks with female contacts (type A) and boltin contacts (type B) and their test fixtures Road vehicles - Fuse-links - ISO : Part 5: Fuselinks with axial terminals (Strip fuse-links) Types SF 30 and SF 51 and test fixtures Road vehicles - Fuse-links - ISO : Part 6: Singlebolt fuse-links Road vehicles - Fuse-links - ISO : Part 7: Fuselinks with tabs (Type G) with rated voltage of 450 V IEC standard voltages IEC IEC standard current ratings IEC Basic and safety principles for man-machine interface, marking and identification Coding principles for indicators and actuators Protection against electrical shock Common aspects for installation and equipment Effects of current on human beings and livestock Low-voltage fuses Part 1 : General requirements Uninterruptible power systems (UPS) Part 1: General and safety requirements for UPS Uninterruptible power systems (UPS) - Part 2: Electromagnetic compatibility (EMC) requirements IEC EN 61140, IEC IEC/TS series - EN , IEC EN , IEC Related to IEC/EN EN , IEC Uninterruptible Power Systems (UPS) Part 3:Method of specifying the performance and test requirements Circuit breakers Switched protective earth portable residual current devices for EN , IEC IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 72 of 88

73 Vehicle safety & person protection Description Standard(s) Comments class I and battery powered vehicle applications General requirements for residual current operated protective devices Electrical accessories - Portable residual current devices without integral overcurrent protection for household and similar use (PRCDs) requirements for UPS used in operator access areas Personnel Protection Systems for EV Supply Circuits: Part 1: General Requirements Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: Particular Requirements for Protection Devices for Use in Charging Systems Safety of power transformers, power supplies, reactors and similar products Information technology equipment Safety Part 1: General requirements Safety requirements for electrical equipment for measurement, control, and laboratory use Part 1: General requirements Audio/video, information and communication technology equipment Part 1: Safety requirements IEC HD 639, IEC SAE J2344: UL : UL : EN series, IEC series EN :2006, IEC :2005 EN , IEC IEC Hazard based safety engineering standard Electronic equipment for use in power installations Electronic equipment for use in power installations Insulation coordination for equipment within low-voltage systems Part 1: Principles, requirements and tests EN IEC Related to EN EN , IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 73 of 88

74 Vehicle safety & person protection Description Standard(s) Comments Protection against electrical shock Common aspects for installation and equipment Effects of current on human beings and livestock Methods of measurement of touch current and protective conductor current EN 61140, IEC IEC/TS series - IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 74 of 88

75 Functional safety (Road vehicles) Description Standard(s) Comments Road vehicles - Functional safety - Part 1: Vocabulary Road vehicles Functional safety Part 2: Management of functional safety Road vehicles Functional safety Part 3: Concept phase Road vehicles Functional safety Part 4: Product development :system level Road vehicles Functional safety Part 5: Product development : hardware level Road vehicles Functional safety - Part 6: Product development : software level Road vehicles Functional safety - Part 7: Production and operation Road vehicles Functional safety - Part 8: Supporting processes ISO ISO ISO ISO ISO ISO ISO ISO Road vehicles Functional safety - Part 9: ASIL-oriented and safety-oriented analyses Road vehicles Functional safety - Part 10: Guideline ISO ISO EMC (Electro-magnetic compatibility) Description Standard(s) Comments Road vehicles - Test methods for electrical disturbances from electrostatic discharge Road vehicles - Vehicle test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 1: General principles and terminology Road vehicles - Vehicle test methods for electrical disturbances from ISO ISO ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 75 of 88

76 EMC (Electro-magnetic compatibility) Description Standard(s) Comments narrowband radiated electromagnetic energy Part 2: Off-vehicle radiation sources Road vehicles - Vehicle test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 3: On-board transmitter simulation Road vehicles - Vehicle test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 4: Bulk current injection (BCI) Road vehicles - Component test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 5: Stripline Road vehicles - Component test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 7: Direct radio frequency (RF) power injection Road vehicles - Component test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 8: Immunity to magnetic fields Road vehicles Component test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 9: Portable transmitters Road vehicles Component test methods for electrical disturbances from narrowband radiated ISO ISO ISO ISO ISO ISO ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 76 of 88

77 EMC (Electro-magnetic compatibility) Description Standard(s) Comments electromagnetic energy Part 10: Immunity to conducted disturbances in the extended audio frequency range Road vehicles Component test methods for electrical disturbances from narrowband radiated electromagnetic energy Part 11: Reverberation chamber Electromagnetic compatibility (EMC) Part 3-2: Limits Limits for harmonic current emissions (equipment input current < 16 A per phase) Electromagnetic compatibility (EMC) Part 3-3: Limits Limitation of voltage changes, voltage fluctuations and flicker in public lowvoltage systems for equipment with rated current 16 A per phase and not subjected to conditional connection Electromagnetic compatibility (EMC) - Part 3-4 Limits Limitation of emission of harmonic currents in lowvoltage power supply systems for equipment with rated current > 16 A Electromagnetic Compatibility (EMC) Part 3-11 Limits Limitation of voltage changes, voltage fluctuations and flicker in public lowvoltage systems - Equipment with rated current 75 A per phase and subjected to conditional connection Electromagnetic Compatibility (EMC) Part 3-12 Limits for harmonic current emissions produced by equipment connected to ISO EN : A1:2009+A2:2009, IEC EN : 2008, IEC EC/TS EN :2000, IEC EN : 2005, IEC TR is replaced by IEC for equipment 75 A - - HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 77 of 88

78 EMC (Electro-magnetic compatibility) Description Standard(s) Comments public low-voltage systems with input current > 16 A and 75 A per phase Electromagnetic compatibility EN , IEC (EMC) Part 4-1 Testing and measurement techniques Overview of IEC series Electromagnetic compatibility EN , IEC (EMC) Part 4-2 Testing and measurement techniques Electrostatic discharge immunity test Electromagnetic compatibility EN , IEC (EMC) Part 4-3 Testing and measurement techniques Radiated, radio-frequency, electromagnetic filed immunity test Electromagnetic Compatibility EN , IEC (EMC) Part 4-4 Testing and measurement techniques Electrical fast transients/burst immunity test Electromagnetic Compatibility EN , IEC (EMC) Part 4-5 Testing and measurement techniques Surge immunity test Electromagnetic Compatibility EN , IEC (EMC) Part 4-6 Testing and measurement techniques Immunity to conducted disturbances, induced by radio-frequency fields Testing and measurement EN , IEC techniques General guide on harmonics and interharmonics measurements and instrumentation, for power supply systems and equipment connected thereto Electromagnetic Compatibility (EMC) Part 4-8 Testing and measurement techniques Power frequency magnetic field immunity test EN , IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 78 of 88

79 EMC (Electro-magnetic compatibility) Description Standard(s) Comments Electromagnetic compatibility (EMC) Part 4-11: Testing and measurement techniques Voltage dips, short interruptions and voltage variations immunity tests Electromagnetic compatibility (EMC) - Part 4-13: Testing and measurement techniques - Harmonics and interharmonics including mains signalling at a.c. power port, low frequency immunity tests Electromagnetic compatibility (EMC) - Part 4-15: Testing and measurement techniques Flickermeter Functional and design specifications Electromagnetic compatibility (EMC) Part 4-21: Testing and measurement techniques Reverberation chamber test methods Electromagnetic Compatibility (EMC) Part 6-1 Generic standards Immunity for residential, commercial and light-industrial environments Electromagnetic Compatibility (EMC) Part 6-2 Generic standards Immunity for industrial environments Electromagnetic Compatibility (EMC) Part 6-3 Generic standards Emission standard for residential, commercial and light-industrial environments Electromagnetic Compatibility (EMC) Part 6-4 Generic standards Emission standard for industrial environments Signalling on low-voltage electrical installations in the frequency range 3 khz to 148,5 khz. General requirements, frequency EN , IEC EN , IEC EN , IEC EN , IEC EN : 2007, IEC :2005 EN : AC:2005, IEC EN : 2007, IEC :2006 EN :2007, IEC :2006 EN :2001+A1: HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 79 of 88

80 EMC (Electro-magnetic compatibility) Description Standard(s) Comments bands and electromagnetic disturbances Signalling on low-voltage electrical installations in the frequency range 3 khz to 148,5 khz - Part 2-1: Immunity requirements for mains communications equipment and systems operating in the range of frequencies 95 khz to 148,5 khz and intended for use in residential, commercial and light industrial environments Signalling on low-voltage electrical installations in the frequency range 3 khz to 148,5 khz - Part 2-2: Immunity requirements for mains communications equipment and systems operating in the range of frequencies equipment and systems operating in the range of frequencies 95 khz to 148,5 khz and intended for use in industrial environments Signalling on low-voltage electrical installations in the frequency range 3 khz to 148,5 khz - Part 2-3: Immunity requirements for mains communications equipment and systems operating in the range of frequencies 3 khz to 95 khz and intended for use by electricity suppliers and distributors Road vehicles - Electrical disturbances from conduction and coupling - Part 1: Definitions and general considerations EN : A1:2005+AC:2003 EN : A1:2005+ AC:2003 EN :2003+A1:2005+AC:2003 ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 80 of 88

81 EMC (Electro-magnetic compatibility) Description Standard(s) Comments Road vehicles - Electrical disturbances from conduction and coupling - Part 2: Electrical transient conduction along supply lines only Road vehicles - Electrical disturbances from conduction and coupling - Part 3: Electrical transient transmission by capacitive and inductive coupling via lines other than supply lines Information Technology Equipment Radio Disturbance Characteristics - Limits and Methods of Measurement. Industrial, Scientific and Medical (ISM) Radio- Frequency Equipment - Electromagnetic disturbance characteristics - Limits and methods of measurement. Specification for radio disturbance and immunity measuring apparatus and methods Vehicles, boats and internal combustion engine driven devices - Radio disturbance characteristics - Limits and methods of measurement for the protection of receivers except those installed in the vehicle/boat/device itself or in adjacent vehicles/boats/devices. Radio disturbance characteristics for the protection of receivers used on board vehicles, boats, and on devices - Limits and methods of measurement Low-Voltage Power Supplies, D.C. Output Part 3: Electromagnetic Compatibility (EMC) ISO ISO EN 55022, CISPR 22 - EN 55011, CISPR 11 - EN , CISPR 16-- EN 55012, CISPR 12 - EN 55025, CISPR 25 - IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 81 of 88

82 EMC (Electro-magnetic compatibility) Description Standard(s) Comments Uninterruptible power systems (UPS) Part 2: Electromagnetic compatibility (EMC) requirements International Electrotechnical Vocabulary (IEV) Chapter 161: Electromagnetic compatibility Telecontrol equipment and systems Part 2: Operating conditions Section 1: Power supply and electromagnetic compatibility GB/T : Limits and test methods of magnetic and electricc field strength from electric vehicle, broadband, 9 khz to 30 MHz. SAE J551-5 Performance Levels and Methods of Measurement of Magnetic and Electric Field Strength from Electric Vehicles, Broadband, 9 khz to 30 MHz Environmental conditions EN , IEC IEC (161) - EN , IEC SAE J1113-i - SAE J Description Standard(s) Comments Environmental conditions and testing for electrical and electronic equipment Part 1: General Road vehicles Environmental conditions and testing for electrical and electronic equipment Part 2: Electrical loads Road vehicles - Environmental conditions and testing for electrical and electronic equipment Part 3: Mechanical loads Road vehicles Environmental conditions and testing for electrical and electronic equipment Part 4: Climatic loads ISO ISO ISO ISO For EMC of socket, see IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 82 of 88

83 Environmental conditions Description Standard(s) Comments Road vehicles ISO Environmental conditions and testing for electrical and electronic equipment Part 5: Chemical loads Environmental testing EN series, IEC Classification of environmental conditions Electric and optical fibre cables Test methods for non-metallic materials series EN series, IEC series EN series, IEC series - Life cycle, mechanical properties of cables Measurements of electrical vehicle performance Description Standard(s) Comments Electric road vehicles - Road operating characteristics Electric road vehicles - Reference energy consumption and range - Test procedures for passenger cars and light commercial vehicles Electrically propelled road vehicles - Measurement of road operating ability - Part 1: Pure electric vehicles Electrically propelled road vehicles Measurement of road operating ability Part 2: Thermal electric hybrid vehicles Electrically propelled road vehicles - Measurement of energy performances - Part 1: Pure electric vehicles Electrically propelled road vehicles Measurement of energy performances Part 2: Thermal electric hybrid vehicles Electrically propelled road vehicles - Airborne acoustical noise of vehicle during charging with on-board ISO 8715: ISO 8714: EN :1996,ISO EN EN :1997, ISO EN EN 12736: HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 83 of 88

84 Measurements of electrical vehicle performance Description Standard(s) Comments chargers - Determination of sound power level Electrically propelled road EN vehicles Measurement of emissions of hybrid vehicles Part 1: Thermal electric hybrid vehicles Hybrid-electric road vehicles ISO Exhaust emissions and fuel consumption measurements Part 1: Non-externally chargeable vehicles Hybrid-electric road vehicles ISO Exhaust emissions and fuel consumption measurements Part 2: Externally chargeable vehicles Hybrid-electric road vehicles ISO Exhaust emissions and fuel consumption measurements Part 3: Forced charge mode Recommended Practice for SAE J Measuring the Exhaust Emissions and Fuel Economy of Hybrid-Electric Vehicles Electric road vehicles ISO Reference energy consumption and range Test procedures for passenger cars and light commercial vehicles Utility Factor Definitions for SAE J Plug-In Hybrid Electric Vehicles Using 2001 U.S. DOT National Household Travel Survey Data Hybrid-electric road vehicles - ISO/TR 11955: Guidelines for charge balance measurement Hybrid-electric road vehicles ISO 23274: Exhaust emissions and fuel consumption measurements - Non-externally chargeable vehicles Hybrid-electric road vehicles Exhaust emissions and fuel consumption measurements - ISO/DIS HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 84 of 88

85 Measurements of electrical vehicle performance Description Standard(s) Comments Part 2: Externally chargeable vehicles Electric double-layer EN 62576, IEC capacitors for use in hybrid electric vehicles - Test methods for electrical characteristics Electrically propelled road EN : vehicles - Measurement of emissions of hybrid vehicles - Part 1: Thermal electric hybrid vehicles Electrically propelled road EN : vehicles - Measurement of road operating ability - Part 2: Thermal electric hybrid vehicles Electrically propelled road EN : vehicles - Measurement of energy performances - Part 2: Thermal electric hybrid vehicles Hybrid Terminology SAE J Hybrid Electric Vehicle (HEV) & Electric Vehicle (EV) Terminology Recommended Practice for Measuring the Exhaust Emissions and Fuel Economy of Hybrid-Electric Vehicles Definition of the Utility Factor for Plug-In Hybrid Electric Vehicles Using NHTS Data SAE J SAE J SAE J HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 85 of 88

86 Standards containing Risk assessment procedures and/or hazard analysis techniques Description Standard(s) Comments Road vehicles - Functional ISO series - safety Functional safety of EN series, IEC electrical/electronic/ programmable electronic safety-related systems series Analysis Techniques for IEC System Reliability Procedure for Failure Mode and Effects Analysis (FMEA). Potential Failure Mode and SAE J Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA Fault Tree Analysis IEC Hazard and operability studies (HAZOP studies) Application guide IEC HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 86 of 88

87 ANNE2: Management of functional safety according ISO HCV Hybrid Commercial Vehicle D6300.1, Rev_5 page 87 of 88