Você está na página 1de 86

Keep Up With the Speed of

Electric Vehicle Technologies

www.intertek.com
Introductions

Larry Todd – Safety Certifications


Tom O’Hara – Battery Performance
Mike Koffink – Automotive EMC
Alex Porter - MC

We will have question and answer


sessions after each presentation
www.intertek.com
Larry Todd – Safety
Certifications

www.intertek.com
Electrical Product Safety Testing
and Certification

www.intertek.com
Agenda

• Product safety certifications


- What requires them and who enforces them
- What Are NRTL’s and who is acceptable to list products
• Additional rules for car manufacturers
- What is the NEC?
- Who are the AHJ’s and all these local inspectors?
• What does the NEC require (Article 625)?
• What Standards are used for evaluation and
certification of products for the US?
• What about Canadian requirements?
• What about the rest of the world?

www.intertek.com
Product Safety Certifications

• Product Safety Certifications in the U.S. are called Listings


• Listings are typically required for three reasons:
1. In the workplace, OSHA regulations require that all equipment
covered by a listing standard be listed if an employee is going to
use it.
2. For most other installations, the National Electrical Code (NFPA
70) requires either listing or approval by the AHJ (Authority Having
Jurisdiction)
3. Many companies want their products listed to help meet liability
insurance requirements

www.intertek.com
Product Safety Certifications

• Listings provide the following:

1. An evaluation to a nationally recognized product safety standard by


a third party organization trained in looking at equipment for reduction
of fire, shock and personal injury hazards.
2. Manufacturer is audited at least 4 times a year to insure the product
being labeled is the same as the tested and evaluated sample.
3. Listing Labs provide support when there are questions in the field.

www.intertek.com
Product Safety Certifications

• Because of OSHA, there is a national accreditation for Product


Safety Certification Labs, called NRTL (Nationally Recognized
Test Lab)
• Where the NEC calls out a recognized lab, AHJ’s and States
accept NRTL’s by OSHA, in addition to others in some cases
• There are 16 NRTL’s, some of which have accreditation in
only a few standards, companies like Intertek (ETL Mark), UL,
CSA, TUV have a large set of standards recognized by OSHA

www.intertek.com
Additional Rules for Car Makers

• Now that automobiles are being connected to the electrical


system, additional requirements need to be considered for the
OEM, customer and manufacturers of electrical support
equipment
• The NEC is the code or law that the U.S. uses to determine
the proper way of installing and using electrical equipment and
wiring in the U.S.
• The AHJ (local building official or electrical inspector) has the
final say in the acceptance of equipment and electrical
installations
• The NEC tells the electrical inspector that one way of knowing
a piece of equipment is ok is to look for the listing mark of an
approved lab (think NRTL)

www.intertek.com
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

www.intertek.com
Additional Rules for Car Makers

• A coordinated effort is needed to make sure the equipment


used in the charging of the vehicle and the supply to this
equipment complies with certification requirements and
also the proper wiring methods for installation
• Electrical Inspectors make sure that electrical installations
are put in properly and in accordance with the NEC and
any local laws and protect users and properly owners from
mistakes that could cause fires or shocks for the users.

www.intertek.com
Article 625 of NEC

• Article 625 is Electric Vehicle Charging Systems


- 625.1 Scope – The provisions of this article cover the electrical
conductors and equipment external to an electric vehicle that
connect an electric vehicle to a supply of electricity by conductive
or inductive means, and the installation of equipment and devices
relate to electric vehicle charging
- 625.2 Electric Vehicle - …On Road use, such as passenger
automobiles, buses, trucks, vans, neighborhood electrical vehicles
and the like, primarily powered by an electric motor that draws
current from a rechargeable storage battery, fuel cell, photovoltaic
array or other source of electric current
- UL Standard UL 2202 further includes hybrid electric vehicles
and plug in versions of these vehicles

www.intertek.com
Article 625 of NEC

Article 625 is Electric Vehicle Charging Systems


- 625.4 Voltages – Nominal AC voltages used to supply the
equipment covered by this section are 120, 120/240, 208Y/120,
240, 480Y/277, 480, 600Y/347 and 600V
- 625.5 Listed or Labeled –All electrical materials, devices,
fittings, and associated equipment shall be listed or labeled.
- 625.9 – Electric Vehicle Coupler has several requirements.
Compliance and listing to UL 2251 will meet all these code
requirements
- 625.13-625.19 Covers the Construction of the Equipment.
Listing to UL 2202 covers all these requirements

www.intertek.com
Article 625 of NEC

• Article 625 is Electric Vehicle Charging Systems


- 625.21-625.25 – Cover the Control and Protection of the
equipment and people using the equipment. Again listing of the
equipment to UL 2202 will cover these requirements with the
additional consideration of UL 2231-1 and UL 2231-2 which
covers the Personnel Protection Systems required to be in the
Charging System
- 625.28 – 625.30 Covers the locations the equipment can be
located and any ventilation required in the locations.
Indoor and Outdoor rules (which are covered by the standards)
but also mounting height requirements and specific ventilation
requirement and several ways to meet those are indicated.

www.intertek.com
Article 625 of NEC

• Article 625 is Electric Vehicle Charging Systems


- This Article of the NEC identifies that the equipment must be
listed and gives the general requirements for minimum equipment
requirements and installation requirements
- Even without the listing requirement, it would be difficult for a
manufacturer or an AHJ to know if something complies with these
requirements without a standard to design the equipment to and
for a third party to verify compliance
• Next we will take a look at the Standards used to certify
equipment

www.intertek.com
Safety Certification Standards

• Basic Standard for the Charging System Equipment is UL 2202


- Covers the charging systems that are either inductive or conductive
and supplied by 600V or less. Equipment may be on-board the vehicle or
off-board.
- Includes:
- Electrical construction
- Mechanical construction
- Protection of users against injury
- Normal performance
- Abnormal operations
- Optional ratings such as harmonic distortion

www.intertek.com
Safety Certification Standards

• In conjunction with UL 2202, UL 2231-1 and UL 2231-2


are used to evaluate the Personnel Protection Systems
for Electric Vehicles
- These standards look at the systems and devices that are
intended to reduce the risk of electric shock to the used from
accessible parts, in grounded or isolated circuits for charging
electric vehicles
- Evaluated with the charging circuits to make sure they work
with the particular system being designed

www.intertek.com
Safety Certification Standards

• For the plugs, receptacle and couplers for Electric


Vehicles, the standard is UL 2251.
- These requirements cover plugs, receptacles, vehicle inlets
and connectors rated up to 800 Amperes and up to 600V ac
or dc and intended for conductive connection systems for EVs
- This standard does not cover normal cords, cord sets,
(extension cords) and other types of normal cords covered by
other standards
- The couplers described and evaluated in this standard are in
the configurations from SAE J1772

www.intertek.com
Safety Certification Standards

• Special cases might need special combinations of


standards. These standard should cover most of the
equipment that will go with the chargers needed when
simple plug in the wall is not sufficient.
• Cables used as part of the system need to be type EV,
EVJ, EVE, EVJE, EVT, EVJT
- All suitable for wet locations; Listed to UL 62 Flexible Cords
and Cables)
• Power pedestals that just supply normal power (as in
parking lots, etc) are covered by UL 231 Power Outlets

www.intertek.com
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.

www.intertek.com
Safety Certification Standards

• Canadian listings are different than U.S. Accreditation is


by SCC (Standard Council of Canada). Most of the same
companies are also accredited by SCC for Canada.
• Listing marks will indicate Canadian approval.
• CSA Standard for the Charging Equipment is CSA C22.2
#107.1, which is the standard for General Use Power
Supplies

www.intertek.com
Safety Certification Standards

• European Requirements for Safety are based on


appropriate Directives and when the product is
determined to comply, can be marked with the “CE”
Mark which allows entry in the EU and free movement
between European countries
• A full program of necessary testing and evaluation can
be provided based on a combination of directives and
appropriate European norms.
• Note that this Mark is for Europe and does not cover
US requirements.

www.intertek.com
Special Circumstances

• If you find yourself in a special circumstance with a new


product or one not yet listed and need to install…..
• The same labs that do the listing can do Field Labeling. It is
possible in limited situations where the installation site is
known to quickly determine basic compliance with the rules
and working with the AHJ get acceptance for an installation
using the Labeled requirement rather than the “listing”
requirement.

www.intertek.com
Summary

• For EV, listing of all equipment going to attach to the


building wiring is needed
• Listing also provides the manufacturer with help in
meeting the requirements so that when you sell your
product you can be assured of acceptance in the field
• This electrical safety evaluation is one part of the
overall testing needed
• Listing to the appropriate UL and CSA standards will
allow installation of the charging equipment in
accordance with the National Electrical Code

www.intertek.com
Questions?
Next up – Battery Performance

www.intertek.com
Tom O’Hara – Battery
Performance

www.intertek.com
Automotive Testing Expo:
Performance, Durability and Abuse Testing of Batteries

www.intertek.com
Agenda

Introduction
• DOE Goals
• Automotive Applications
Battery Chemistries
Performance / Durability / Safety

www.intertek.com
DOE FreedomCAR Goals

2010 FreedomCAR Goal:


• 25 kW Power-Assist (18 second pulse)
• $20 per kW
• Battery Cost $500

Reference:
Toyota Prius has 25kW, 1.2 kWh NiMH, est. cost $900 to $1500

www.intertek.com
DOE FreedomCAR Goals

2014 DOE PHEV Goal:


• 10, 40 mile Capable PHEV Battery
• Cost $500 per kWh
•  PHEV 10 = $1,700
•  PHEV 40 = $3,400

Reference:
Chevy Volt, 16 kWh battery (8 kWh used), est. cost $8000

Note: EV at 20 kWh cost = $10,000

www.intertek.com
Automotive Applications

www.intertek.com
Automotive Applications

SLI: Starting / Lighting / Ignition


HEV: Hybrid Electric Vehicle (Micro, Mild, Strong)
PHEV: Plug-In Hybrid Electric Vehicle
EREV: Extended Range Electric Vehicle
EV: Electric Vehicle

www.intertek.com
Automotive Applications

US Justification?
 Cost and payback

European Justification?
 Reduced CO2 emissions

www.intertek.com
Battery Chemistries

www.intertek.com
Battery Chemistries

Pb/Ac NiMH

Nominal Voltage V 2 1.2

Specific energy Wh/kg 35 (80) 75

Energy density Wh/l 70 (115) 240 (300)

Specific Power W/kg 200 850


Cycle life
(100% DOD) cycles 250 (800) 450

Calendar life yrs 2-15 4-10

Self discharge
(% per month at 20C) 2-8 10-30

www.intertek.com
Battery Chemistries

Pb/Ac NiMH Li-Ion

Nominal Voltage V 2 1.2 2-4

Specific energy Wh/kg 35 (80) 75 150 (240)

Energy density Wh/l 70 (115) 240 (300) 400 (450)

Specific Power W/kg 200 850 1500


Cycle life
(100% DOD) cycles 250 (800) 450 1000

Calendar life yrs 2-15 4-10 2-5, (10?)

Self discharge
(% per month at 20C) 2-8 10-30 2-10

www.intertek.com
Battery Chemistries

Pb/Ac NiMH Li-Ion Ni/Zn Ag/Zn

Nominal Voltage V 2 1.2 2-4 1.65 1.5

Specific energy Wh/kg 35 (80) 75 150 (240) 60 200

Energy density Wh/l 70 (115) 240 (300) 400 (450) 170 460

Specific Power W/kg 200 850 1500 300 500


Cycle life
(100% DOD) cycles 250 (800) 450 1000 200 100 (300)

Calendar life yrs 2-15 4-10 2-5, (10?) ?? ??

Self discharge
(% per month at 20C) 2-8 10-30 2-10 <20 5

www.intertek.com
Battery Chemistries - Applications

Lead Acid
• SLI, micro HEV
• Global Market Leader ($ Sales)
• Still active Research and Development

www.intertek.com
Battery Chemistries - Applications

Nickel Metal Hydride (NiMH)


• Dominates HEV (Panasonic 80% market share)
• May move into PHEV
• HEV application utilizes only 30% of NiMH capacity (Charge Sustaining)
• 300,000 cycles expected

www.intertek.com
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

www.intertek.com
Performance

www.intertek.com
Performance - General

From a Performance perspective, DOE Goals are met.


 Issue now is Cost, Durability (Reliability), and Safety.

The remainder of this presentation will focus on Li-Ion Battery Chemistry

www.intertek.com
Performance - General

TRUE or FALSE:
All Li-Ion batteries are alike?

www.intertek.com
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…

www.intertek.com
Performance - General

Li-Ion comes in a variety of chemistries

Significant distinctions
• Anode Chemistries
• Cathode Chemistries
• Construction (Form Factor)
• Other Construction (electrolyte, separator, etc.)
• Manufacturing Expertise (relates to battery capacity and safety)

www.intertek.com
Performance - Anode Chemistry

LTO Anode Si/Sn Anode


Voltage ▼ ▼)
(▼
Specific energy ◊ ◊)
(◊
Energy density ◊ ◊)
(◊
Max discharge rate ▲▲ ?
Cyclelife (100% DoD) ▲ ?
Low temp operation ▲ ?
Charge time ▲▲ ?
Recycleability ▲▲ ?
Safety ▲ ▲
Cost (bare cell) ▼▼ ▼)
(▼

www.intertek.com
Performance – Cathode Chemistry

LiFePO4, LiMn2O4 NCA, NCM, LVP


Voltage ▼ ▲)
(▲
Specific energy ▼ ▲▲
Energy density ▼ ▲▲
Max discharge rate ◊ ▲
Cyclelife (100% DoD) ◊ ▲
Low temp operation ◊ ◊
Charge time ◊ ◊
Recycleability ◊ ▲
Safety ▲▲ ▲
Cost (bare cell) ▲▲ ▼▼

www.intertek.com
Performance – Construction

Form Factor:
Advantage / Disadvantages of various Li-Ion Form Factors
• Cylindrical
• Prismatic
• Layered

www.intertek.com
Performance – Construction

Cylindrical Can:
• Spiral wound electrodes
• High volume production
• Strong track record, commercial history

www.intertek.com
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

www.intertek.com
Performance – Construction

Layered (soft package):


• Stacked layers, laminated construction
• Further improved thermal management
• Flexible

www.intertek.com
Performance – Other Construction

Electrolyte:
• Non-flammable
• Anode reactivity (SEI concerns)
• High Voltage stability

Separator:
• Thermal shutdown (watch for shrinkage)
• Puncture resistance (internal shorting)

www.intertek.com
Performance – Manufacturing

Manufacturing Expertise:
• Manufacturer A vs B
• Manufacturer A, Lot to Lot Variation

 Manufacturing Controls

www.intertek.com
Durability (Reliability)

www.intertek.com
Durability – General Concerns

Performance Variables:
• DOD (Depth of Discharge on cycling)
• C Rate
• Temperature (Thermal Management)

Mercedes S 400 HYBRID


(battery is cooled by the A/C coolant)
(maintains operating temperature at 10C to 30C)
(50C max, 40C practical max)

Parking Lot in Phoenix

www.intertek.com
Durability – End of Life

Li-Ion End of Life Causes:


• Lithium plating reduces anode charge reserve
• Impedance rise at cathode
• Soft shorts
• Capacity loss (Li consumption at SEI)

www.intertek.com
Durability – Requirements

Cycle Life
Calendar Life
 Temperature Effects

www.intertek.com
Durability – Temperature Effect

www.intertek.com
Safety

www.intertek.com
Safety – General Test Requirements

• Controlled Crush • Elevated Temperature Storage


• Penetration • Rapid Charge/Discharge
• Drop • Thermal Shock Cycling
• Immersion • Overcharge / Overvoltage
• Roll-over Simulation • Short Circuit
• Mechanical Shock • Overdischarge / Voltage
• Thermal Stability • Partial Short Circuit
• Simulated Fuel Fires • Altitude simulation

www.intertek.com
Safety – General Test Requirements

Laptop and Cell Phone versus Automotive (Distinctions)


• Drop, Shock,
• Vibration, Crush

 Industry need for improved, meaningful Safety Tests

www.intertek.com
Safety – Laptop Perspective (18650)

Spiral Wound, Cylindrical (Large Volume Commercial cells):


 Incident rate is one in 5 to 10 million

Layered Constructions (Large Format Automotive):


 Incident rate is unknown

www.intertek.com
Safety – Failure Mechanism

Mechanism for 18650 field failures:


• Mechanical grinding (charge/discharge volume changes)
• Internal Short Circuit

 Failures occur either early in life (first few cycles)


or late in life (>50 cycles)

www.intertek.com
Safety – Failure Mechanism

For 18650…

 Nearly all field incidents have been caused by internal short circuits!!!

www.intertek.com
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

www.intertek.com
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

 Here, cathode chemistry is not the prime factor!

www.intertek.com
Safety – Failure Mechanism

Still, much safety related cathode research continues…

www.intertek.com
Safety – Cathode Comparisons

www.intertek.com
Safety – Failure Mechanism

What are the failure mechanisms for Large Format Automotive???

www.intertek.com
Summary

 DOE’s Performance based Goals for PHEV have been reached


 Battery / System Cost must be reduced
 Cycle Life and Calendar Life remain uncertain
 Thermal Management is critical to long term performance and durability
 The industry needs improved, meaningful safety tests

www.intertek.com
Questions?
Next Up – Automotive EMC

www.intertek.com
Michael Koffink – Automotive
EMC

www.intertek.com
Automotive Testing Expo:
EMC testing and Electric Vehicles

www.intertek.com
Agenda

Introduction
• The current state of standards
• New technologies bringing about change?
• What does this mean to the test lab?

www.intertek.com
What is EMC testing?

• Electro magnetic Compatibility testing is necessary to


ensure that all vehicle components do not generate high
levels of RF interference and are in turn immune to it as
well.
• Radiated and Conducted Emissions
• Transients
• ESD
• Very important in the automotive realm-Performance and
Safety demands it

www.intertek.com
Automotive EMC Regulations- US

• Most OEM’s have their own test standards


• USA- FCC has automotive devices on their exemption list for
unintentional radiators.
• Intentional radiators must meet CFR 47 Part 15C.
• FCC leaves it to the OEMs to enforce EMC through their own
standards
• SAE standards exist as guidance for non-OE devices

www.intertek.com
Automotive EMC Regulations- EU

• OEMs have own standards


• E and e Mark scheme-Automotive EMC Directive-
2004/104/ec
• “Old Approach Directive” Requires Type approval
• Also ECE 324 Regulation 10 03 governed by UN

www.intertek.com
Current Standards

• These automotive EMC standards were developed over the


years based on historical experiences with internal
combustion engine vehicles and the electronics sub
assemblies that are associated with them.
• For the most part OEM’s and government regulators have
done a good job trying to keep up with technical changes in
component and accessory technology and addressing it with
standard updates and careful test planning.
• Some methodology standardization…CISPR 25 for radiated
emissions as example
• But…. The development of electric vehicles is rapidly evolving.
A surge of technical changes could be inevitable

www.intertek.com
EV and HEV- hurdles

• Higher buss voltages up to 900V


• Motor drives
• Unique battery monitoring and charging circuitry
• Hi efficiency low power concepts for lighting
• Weight a factor
• Filtering techniques
• More shielding
• Conducted emissions issues
• Upgrade buss communication
• New private players in the industry
• Some manufacturers of sought after technology new to the
demand of automotive industry

www.intertek.com
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

www.intertek.com
EV and HEV- industry awareness

• Test Labs need to stay tuned for changes in rules as well as


test methodology
• Become more involved than ever in helping trouble shoot
problems. Expect more diagnostics and engineering
evaluation
• Clients want answers
• Full vehicle testing may become more common
• Expect cross over work from Military sector

www.intertek.com
Questions?

www.intertek.com
Additional Automotive Testing Capabilities

•Accelerated Stress Testing (AST) •Live Fuel Materials Testing


•Airbag Deployment •Materials Testing
•Analytical (Chem Lab) Testing •Performance Testing
•Audio Testing •Product Evaluation and
•Buzz Squeak & Rattle (BSR) •Durability Testing
•Dynamometer-based Engine Testing •Road Simulation Testing
•Electronics Testing •SHED Testing
•EMC Testing •Systems Certification
•Environmental Conditioning •Validation Engineering
•Failure Analysis •Training/Consulting
•Field Evaluation Services •Vehicle Testing
•Fuels & Lubricants Testing •Vehicle Fuel System Testing
•Laboratory Management •Vibration (Single & Multi-Axis)
•Lighting/Photometrics •VOC Testing

www.intertek.com
Global Network: Intertek Group
Countries Locations Staff

110 1030 24,000

Floated May 2002 – LSE: ITRK


FTSE 100, Support Services Sector

www.intertek.com
Your premier certification and testing
partner

www.intertek.com
Thank You

www.intertek.com

Você também pode gostar