Putting Science into Standards (PSIS) Workshop 2016

Transcription

1 Putting Science into Standards (PSIS) Workshop 2016 "Driving Towards Decarbonisation of Transport: Safety, Performance, Second life and Recycling of Automotive Batteries for e-vehicles" Session 1: Safety evaluation in E-mobility: abuse scenarios, testing and mitigation Standardisation: Elie DURCIK R&D Electrical Equipment Laboratory Batteries technologies and chemistry of electric materials EDF JRC Petten September 2016

2 INTEGRATION OF A TRACTION BATTERY SYSTEM IN A VEHICLE A traction battery embedded in a vehicle brings about some risks, specific or not How to avoid or be prepared to these hazards?

3 1 Risk analysis approach

4 RISK MANAGEMENT APPROACH Risk analysis Equipment identification Identification of the uses Risk assessment System failure analysis Security tests in labs (Full tests on vehicles) Risk reduction Improvement recommendations Safety action plan Risks shall be assessed at each level of integration

5 RISK ANALYSIS FOR A TRACTION BATTERY Materials Personnel Methods Thermal risk: burns Electrical risk: electrical shock (V>60V) Poisoning risk: Inhalation of toxic gases Mechanical risk: crushing Electrical risk: burns (short-circuit, metal melt projection) Injury accident due to the battery Mechanical risk: crash Thermal risk: burns Environment Machines Case of a lithium battery

6 CAUSES AND RISKS FACTORS Bad manipulation, inadequate qualification short-circuit, electrical shock Traffic accident crush, puncture, immersion Wrong use, system failure overcharge, internal or external short-circuit, over discharge Poor manufacturing quality, design unsuitable for the use, corrosion defective isolation, hot spots, thermal runaway Lifting crash, drop Other (vandalism, building fire, flooding, ) fire, water conductivity, immersion Case of a lithium battery

7 MACRO FAULT TREE ANALYSIS (EXAMPLE) Case of a vehicle with a lithium battery To be determined by testing

8 2 Safety Tests

9 SECURITY SAFETY TYPE TESTS IN LABS Security is handled by the overall system Redundancies could be necessary Tests shall be performed at different levels Battery Cell Battery Management System Battery Pack Vehicle Abuse tests Thermal Electrical Mechanical Safety Integrity Level (SIL) assessment or measurement EMC Test Dysfunctional (or abuse) tests Mechanical tests Crash test Fire test

10 BATTERY SAFETY TESTS PROCEDURES AND STANDARDS Cell tests IEC 62660* Secondary lithium-ion cells for the propulsion of electric road vehicles IEC Safety of primary and secondary lithium cells and batteries during transport ELLICERT (FR doc) Certification scheme for battery cells and packs for rechargeable electric and hybrid vehicles Freedom CAR (US doc) Electrical Energy Storage System Abuse Test Manual for Electric and Hybrid Electric Vehicle Application BMS tests IEC : Informations technology equipment Safety IEC/TS : Electromagnetic compatibility Battery packs ECE R Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train ISO Electrically propelled road vehicles Test specification for lithium-ion traction battery packs and systems E Vehicles ECE R Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train ISO 6469 : Electrically propelled road vehicles Safety specifications ISO : Road vehicles - Functional safety

11 OVERCHARGE CELL TEST 1/2 Example of an electrical abuse test : overcharge of a battery cell Objective is to reproduce the cell packaging in the module and in the pack The cell is placed between two plasterboards, which are put in between two metal plates handily bolted with a calibrated light pressure Unused Lithium-ion cell, 100%SOC 0 xx Time (min) 100 XXX SOC (%)

12 OVERCHARGE CELL TEST 2/2 Example of an electrical abuse test : overcharge of a battery cell To determine if the conditions are different at the end of life, the same test is performed with an aged battery cell Video, voltage, temperature are recorded all along the test and even after fire Aged Lithium-ion cell, 100%SOC, 20% capacity fade 0 xx Time (min) 100 Fumes and opening XXX SOC (%)

13 PENETRATION CELL TEST Example of an electrical abuse test : Perforation test The perforation is made with an drilling machine whose rotation and drop are automatic at a controlled speed Unused Lithium-ion cell, 100%SOC 0 xx Beginning of the fire Time (s) 100% SOC Compared to the use of a steel pointed rod, we noted that the use of a drilling machine improves the test reliability. This method could be proposed as an evolution of this test.

14 OTHER ABUSE TESTS Other abuse tests shall be conducted : over discharge short circuit immersion controlled crush mechanical shock thermal runaway Test results could be classified according to a hazard level scale (e.g. EUCAR), or an evaluation of test criteria (e.g. IEC 62660) : Hazard Level Description Classification Criteria and Effect 0 No Effect No loss of functionality, no effect 1 Passive Protection, Activated Cell reversibility reduced or protection device needs replacing, no leakage, no venting, explosion, fire or flames 2 Defect or Damage Cell irreversibly damaged, no leakage, no venting, explosion, fire or flame 3 Electrolyte Leakage Weight loss <50% of cell electrolyte, no venting, explosion, fire or flame 4a Venting Weight loss >50% of cell electrolyte, no explosion, fire or flame 4b Smoke Gray or black smoke Extract from IEC Fire or Flame No rupture or explosion (i.e., no flying parts) 6 Rupture No explosion, but some active mass is ejected 7 Explosion Disintegration of the cell (i.e., flying pieces of can and active mass)

15 OPERATING WINDOW OF A BMS Temperature BMS : Battery Management System Dangerous area Intermediate area working area permitted by the BMS Not dangerous degradation zone Voltage

16 Current (A) Flag (boolean) Pack Voltage (V) Flag (boolean) SOC (%) Cell coltage (V) Cell coltage (V) BMS OVERVOLTAGE FLAG TEST HV cell max & min cell voltage LV cell Example of a dysfunctional electric. test : raise of a safety BMS flag 00:00 01:00 02:00 03:00 04:00 05:00 06:00 ime (min) Objective is to control the proper functioning of the BMS concerning the overvoltage watch function A slow, limited and controlled overcharge is performed just after the end of charge condition is fulfilled on a battery pack SOC 0 00:00 01:00 02:00 03:00 04:00 05:00 06:00 Time (min) Pack Voltage 3 2 max & min cell voltage Cell over voltage level 1 flag HV cell LV cell 00:00 01:00 02:00 03:00 04:00 05:00 06:00 ime (min) 1 00:00 01:00 02:00 03:00 04:00 05:00 06: :00 01:00 02:00 03:00 04:00 05:00 06:00 Time (min) Pack Current Time (min) Pack over voltage level 1 flag The overcharge SOC can be calculated 00:00 01:00 02:00 03:00 04:00 05:00 06: :00 01:00 02:00 03:00 04:00 05:00 06:00 Time (min) Time (min)

17 OTHER DYSFUNCTIONNAL TESTS Other dysfunctional (or abuse) tests can be conducted, if necessary Under discharge watch function Over current/power watch function Over temperature watch function BMS power failure (short or long outage) Loss of communication In order to maintain the integrity of the system, the test conditions shall be defined or adapted with the manufacturer The different modes shall be tested (park, charge, drive)

18 3 Analysis

19 ANALYSIS AND CONCLUSION For existing batteries - first use in electromobility applications Safety risks are well covered by existing methods and procedures Evolutions or test improvements are carried out by relevant normative commissions (example : TC21X/WG01) This document proposes some evolution of the penetration cell test : use of a drill (instead of a nail) and use of clamping plates (e.g. plasterboards) to improve reliability In addition to these tests (not necessarily for the certification scheme) gas emission analysis could be useful, particularly for new technologies

20 FOLLOW-UP For aged batteries - second life applications Risk analysis is necessary in case of a new use or a new environment (different from the first use), to guarantee safety If necessary, additional tests could be performed (e.g. for stationary applications) If necessary, some existing tests could be performed again (e.g. in case of dismantling and assembling in a new pack)

21 Thank you