Escolar Documentos
Profissional Documentos
Cultura Documentos
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Introductions
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Electrical Product Safety Testing
and Certification
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Agenda
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Product Safety Certifications
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Product Safety Certifications
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Product Safety Certifications
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Additional Rules for Car Makers
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Additional Rules for Car Makers
• The NEC also, in some cases tells the inspector that the only
way to accept a piece of equipment is to look for the listing Mark.
• In the case of Electric Vehicle Charging Systems Article 625.5
indicates that all electrical materials, devices, fittings and
associated equipment shall be listed or labeled.
• We will talk more about the specific requirements, but this means
that the charger and the wiring to it need to be installed in
accordance with the NEC and this includes the more powerful
recharging equipment that might even need a new branch circuit
to be installed in the user’s garage
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Additional Rules for Car Makers
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Article 625 of NEC
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Article 625 of NEC
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Article 625 of NEC
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Article 625 of NEC
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Safety Certification Standards
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Safety Certification Standards
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Safety Certification Standards
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Safety Certification Standards
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Safety Certification Standards
• Batteries
- Whether or not a battery is vented or not can effect how the system
is evaluated according to the NEC
- Classification of the batteries for this feature is also available
- Electric vehicle battery packs employing non-vented batteries or
batteries whose chemistry cannot produce hydrogen are investigated
by inspection of the manufacturer's product
- Electric vehicle battery packs employing batteries that can emit
hydrogen, such as valve regulated or vented lead-acid or nickel-metal
hydride batteries, are subjected to investigation in accordance with
SAE Recommended Practice J1718 (1994), "Measurement of
Hydrogen Gas Emission From Battery-Powered Cars and Light Trucks
During Battery Charging." Battery systems which do not produce
hydrogen concentrations in excess of 1% (25% of the lower
flammability limit) are considered in compliance with the requirements
of Article 625 of the NEC.
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Safety Certification Standards
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Safety Certification Standards
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Special Circumstances
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Summary
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Questions?
Next up – Battery Performance
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Tom O’Hara – Battery
Performance
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Automotive Testing Expo:
Performance, Durability and Abuse Testing of Batteries
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Agenda
Introduction
• DOE Goals
• Automotive Applications
Battery Chemistries
Performance / Durability / Safety
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DOE FreedomCAR Goals
Reference:
Toyota Prius has 25kW, 1.2 kWh NiMH, est. cost $900 to $1500
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DOE FreedomCAR Goals
Reference:
Chevy Volt, 16 kWh battery (8 kWh used), est. cost $8000
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Automotive Applications
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Automotive Applications
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Automotive Applications
US Justification?
Cost and payback
European Justification?
Reduced CO2 emissions
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Battery Chemistries
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Battery Chemistries
Pb/Ac NiMH
Self discharge
(% per month at 20C) 2-8 10-30
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Battery Chemistries
Self discharge
(% per month at 20C) 2-8 10-30 2-10
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Battery Chemistries
Energy density Wh/l 70 (115) 240 (300) 400 (450) 170 460
Self discharge
(% per month at 20C) 2-8 10-30 2-10 <20 5
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Battery Chemistries - Applications
Lead Acid
• SLI, micro HEV
• Global Market Leader ($ Sales)
• Still active Research and Development
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Battery Chemistries - Applications
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Battery Chemistries - Applications
Lithium Ion
• HEV, PHEV, EV
• For PHEV, utilizes 70% capacity
• In Charge Sustaining Mode: 300,000 cycles
• In Charge Depletion Mode: 5,000 deep discharge cycles
• For EV, near full 100% SOC
• Charge Depletion Mode: 1,000+ deep discharge cycles
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Performance
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Performance - General
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Performance - General
TRUE or FALSE:
All Li-Ion batteries are alike?
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Performance - General
Answer: FALSE
Some perspective…
Energizer/Duracell Zn/MnO2 (Alkaline Batteries)
-- $Millions are spent in Advertising
-- Distinctions are minor
-- But, each market share valued at over $20 Million, so…
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Performance - General
Significant distinctions
• Anode Chemistries
• Cathode Chemistries
• Construction (Form Factor)
• Other Construction (electrolyte, separator, etc.)
• Manufacturing Expertise (relates to battery capacity and safety)
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Performance - Anode Chemistry
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Performance – Cathode Chemistry
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Performance – Construction
Form Factor:
Advantage / Disadvantages of various Li-Ion Form Factors
• Cylindrical
• Prismatic
• Layered
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Performance – Construction
Cylindrical Can:
• Spiral wound electrodes
• High volume production
• Strong track record, commercial history
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Performance – Construction
Prismatic Can:
• Flattened spiral would or parallel plate electrodes
• Improved heat rejection from inner core
(Safety and Performance Advantage)
• Improved high power versus cylindrical
• Lower cost, modular Battery Design
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Performance – Construction
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Performance – Other Construction
Electrolyte:
• Non-flammable
• Anode reactivity (SEI concerns)
• High Voltage stability
Separator:
• Thermal shutdown (watch for shrinkage)
• Puncture resistance (internal shorting)
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Performance – Manufacturing
Manufacturing Expertise:
• Manufacturer A vs B
• Manufacturer A, Lot to Lot Variation
Manufacturing Controls
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Durability (Reliability)
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Durability – General Concerns
Performance Variables:
• DOD (Depth of Discharge on cycling)
• C Rate
• Temperature (Thermal Management)
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Durability – End of Life
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Durability – Requirements
Cycle Life
Calendar Life
Temperature Effects
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Durability – Temperature Effect
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Safety
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Safety – General Test Requirements
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Safety – General Test Requirements
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Safety – Laptop Perspective (18650)
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Safety – Failure Mechanism
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding:
Internal short must meet Energy & Power threshold levels for Thermal Runaway
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding:
Internal short must meet Energy & Power threshold levels for Thermal Runaway
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Safety – Failure Mechanism
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Safety – Cathode Comparisons
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Safety – Failure Mechanism
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Summary
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Questions?
Next Up – Automotive EMC
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Michael Koffink – Automotive
EMC
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Automotive Testing Expo:
EMC testing and Electric Vehicles
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Agenda
Introduction
• The current state of standards
• New technologies bringing about change?
• What does this mean to the test lab?
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What is EMC testing?
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Automotive EMC Regulations- US
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Automotive EMC Regulations- EU
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Current Standards
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EV and HEV- hurdles
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EV and HEV- more hurdles the PEV
• Plug- ins!!?
• Charging??
• What does this mean for power grid superstructure around the
globe?
• Cross over Standards from the household and industrial
sectors
• There are standards out there being developed but not yet
harmonized
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EV and HEV- industry awareness
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Questions?
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Additional Automotive Testing Capabilities
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Global Network: Intertek Group
Countries Locations Staff
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Your premier certification and testing
partner
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Thank You
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