National Highway Traffic Safety Administration. Stranded Energy. Phil Gorney. Vehicle Safety Research Engineer November 30, 2016

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1 National Highway Traffic Safety Administration Stranded Energy Phil Gorney Vehicle Safety Research Engineer November 30, 2016

2 Stranded Energy Is Stranded Energy a problem? Can this Stranded Energy elevate safety risks in the handling of a used and potentially damaged Li-ion battery system? In the vehicle (potentially damaged) While being removed from the vehicle Storage Transport Reuse or Recycle Are there solutions? Technical Procedural Who is responsible for the solutions? Who, What, When, Where, Why, How, $

3 Stranded Energy During unforeseen or abnormal operation events, such as a vehicle crash, common vehicle safety systems generally will open electrical contactors isolating the battery from the rest of the vehicle providing safety from electrical shock and unintended propulsion.

4 Stranded Energy During unforeseen or abnormal operation events, such as a vehicle crash, common vehicle safety systems generally will open electrical contactors isolating the battery from the rest of the vehicle providing safety from electrical shock and unintended propulsion. The fundamental design principals governing the contactor safety device prevent the remaining energy in the pack from being assessed, accessed or removed.

5 Stranded Energy During unforeseen or abnormal operation events, such as a vehicle crash, common vehicle safety systems generally will open electrical contactors isolating the battery from the rest of the vehicle providing safety from electrical shock and unintended propulsion. The fundamental design principals governing the contactor safety device prevent the remaining energy in the pack from being assessed, accessed or removed. This stored electrical energy at the time of event is random as to it s use, and not likely to be in a safety optimal condition or state of charge determined for long term handling (repair, removal, or recycle).

6 Stranded Energy During unforeseen or abnormal operation events, such as a vehicle crash, common vehicle safety systems generally will open electrical contactors isolating the battery from the rest of the vehicle providing safety from electrical shock and unintended propulsion. The fundamental design principals governing the contactor safety device prevent the remaining energy in the pack from being assessed, accessed or removed. This stored electrical energy at the time of event is random as to it s use, and not likely to be in a safety optimal condition or state of charge determined for long term handling (repair, removal, or recycle). Additional safety risk can also be introduced to the system if, during an abusive event, physical damage has been introduced to the RESS. This damage may induce either immediate or latent failure modes and safety concerns within the pack which may result in exothermic release of the remaining RESS stored energy (venting or fire).

7 Stranded Energy History

8 Stranded Energy - History

9 Stranded Energy - History

10 Stranded Energy - History

11 Stranded Energy - History

12 Stranded Energy - History

13 Stranded Energy - History

14 Stranded Energy - History NHTSA surveyed 9 xev manufactures Post-Crash Safety Strategies The Process and documentation necessary to properly assess battery health or condition with respect to safe and normal operating conditions SOC requirements for removal, storage, and/or shipping The battery discharge process and special tools necessary to perform the function In vehicle Removed from the vehicle After known damage SAE J2990 and SAE J3009 were initiated

15 Stranded Energy History (ANL Project) This project is to identify, develop, and demonstrate methods for the safe management and handling of RESS in post-crash and non-operational environments. The procedures developed should be applicable to both damaged and fully functional RESS systems including non-operational environments such as: service repair, end of life disassembly, vehicle crash scene, vehicle tow, and vehicle storage. This research project has three objectives. 1) Develop a standard RESS assessment process used to qualify a RESS unit for discharge or safe handling. These assessment criteria are intended to be broadly applicable to a range of vehicle types and to support a common tool development. 2) Develop discharge procedure which can reduce the state of charge (SOC) to a safe level for handling in non-operational conditions. This discharge procedure shall be applicable for a wide range of existing and anticipated vehicle and RESS types. 3) Develop procedure(s), requirements, to remove/reduce the energy completely from a battery which cannot be safely discharged. This discharge procedure should standardized application to a wide range of vehicle and RESS designs. It is desirable to conduct this de-energization procedure or near a crash scene to permit safe transport of the damaged RESS.

16 Stranded Energy History (Sandia & Idaho N.L. Project) Battery State-of-health and Stability Diagnostic Tool Set Development The overall objective for this proposed research is to develop enhanced state of stability diagnostic assessment tools that are integrated into an advanced battery management system using novel metrics and demonstrated on a vehicle platform.

17 Stranded Energy Path Forward NHTSA has a history of successfully partnering together with industry to resolve complicated and significant safety issues De-powering Passenger Side Air Bags Automated Emergency Braking (AEB) Cyber Security Information Sharing and Analysis Center (ISAC) Vehicle Compatibility Frontal Crash of Compact Passenger Car with Light Truck Vehicles

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