TÜV SÜD E-Mobility

Battery safety for e-mobility

applications
2019 July 8, Kick-off Event - Efficient Energy
Consumption in Germany: Traction Batteries
and Charging Infrastructure

Alexander Stadler
TÜV SÜD Battery Testing GmbH

TÜV SÜD AG | E-Mobility 19-07-08

TÜV SÜD Mission statement Since 150 years TÜV SÜD stays true to its
founding principles of protecting people,
environment and property against the adverse
effects of technology.

24.000+ Employees 2,4 Billion Revenue 57 Countries 1000+ Locations

TÜV SÜD AG | E-Mobility 19-07-08 2

 Testing/Certification Battery Safety; Battery Testing
Charging Equipment

TÜV SÜD e-Mobility Services

Type Approval for

Hydrogen Filling Stations,
Fuel Cell Testing

Pedelec/ e-bike Testing and Certification

Type Approval, Vehicle Safety,

Functional Safety, EMC-testing

High Voltage/ Battery Saftety Trainings

Fleet Management,
Carbon-Footprint, Periodic Inspection

TÜV SÜD AG | E-Mobility 19-07-08 3

The global automotive challenge:

>1.3 Billion vehicles are on the road globally

98 Million produced in 2018

this leads to additional

>100 Million vehicles every 3 years

TÜV SÜD AG | E-Mobility 19-07-08 4
The global automotive challenge:

@ current growth rate we end up @

2,4-2,9 Billion vehicles in 2050 !

(@ 10 Billion people in 2050 on our planet)

current transport emission reduction schemes are only looking
@ fleet emissions, not reflecting the total fleet growth!

TÜV SÜD AG | E-Mobility 19-07-08 5

New technologie with new risks

TÜV SÜD AG | E-Mobility 19-07-08 6

Know your risks

Know your risks

▪ Identify the safety level of your

cells, modules and battery packs

▪ Optimize safety level and

performance of your battery system

▪ TÜV SÜD supports from the early

development phase towards
certification and product evolution

TÜV SÜD AG | E-Mobility 19-07-08 7

Different steps that lead to high performing and safe EV batteries!

Homologation
Become ready for the market

Failure analysis & replication

Repeat failures in the lab and analyze failed
batteries
Pack validation
Test the battery pack to verify the safety and
performance
Module validation
Check the module design for safety and
performance, validate lifecycle data
Cell Assessment
Investigate the chosen cell to become sure
(safety, lifecycle, performance)

Cell Evaluation
Pick the right cell out of many manufacturers

TÜV SÜD AG | E-Mobility 19-07-08 8

Battery homologation / certification and how to create a safe battery!

Regulations Industry standards

(e.g. R100 type (e.g. national Vehicle manufacturer standards
approval) automotive standards &
like VDA) Product Liability
&
Quality Management

Custom tailored testing requirements

e.g. based on local road conditions!

Image: Porsche AG

TÜV SÜD AG | E-Mobility 19-07-08 9

Sources for validation standards & regulations for xEVs

▪ Japan ▪ EU ▪ USA ▪ China

Germany

International Standardization Organisations (e.g. ISO, IEC)

Standardization
Japanese Industrial Deutsches Institut American National
JISC Standards Committee ISO für Normung ANSI Standards Institute SAC Administration
of the P.R. of China

Mandatory Regulations Mandatory Mandatory

ECE Regulations Regulations
FMVSS GB

National / Industry National / Industry National / Industry National / Industry

standards standards standards standards

e.g. JIS,JAS e.g. DIN, VDI, e.g. ANSI, SAE, UL e.g. SAC, GB/T,
VDE, VDA QC/T

TÜV SÜD AG | E-Mobility 19-07-08 10

China: Overview of new GB standard scheme

Electric vehicle standards system

Electric vehicle Component Charging system interface

Electric motor Battery/Battery system Electric control system Ancillary apparatus

Battery cell & module Battery/Battery system

GB/T 31484 GB/T 31467.1
GB/T 31485 GB/T31467.2
GB/T 31486 GB/T31467.3

TÜV SÜD AG | E-Mobility 19-07-08 11

UN ECE Homologation R100

Need: Full vehicle type approval

Focus: UN ECE R100 / Rev. 2 (mandatory July 2016)

New EV, PHEV or FCEV

Two options:
Vehicle based testing Component Testing

All R100 related tests (e.g. electrical safety) and / or

Full vehicle R100 type approval R100 component

type approval (battery)
++ Full vehicle type approval
might be used for various vehicles
(but: every vehicle needs a sperate full vehicle R100!)
++ all 48 legal acts

TÜV SÜD AG | E-Mobility 19-07-08 12

 Homologation
UNECE R100

Mechanical shock Very high risk for expensive test

equipment!
Vibration test
▪ Necessary to pass the tests and get
(Crash facility / large Shaker)
an homologation by a registered
Thermal shock cycling Fire protected chamber necessary! technical service ( e.g. TÜV SÜD)
for access to UNECE area with >50
External short circuit countries
Overcharge protection
▪ For access to countries like US /
Test should be performed in dedicated
Over-discharge protection Canada and China TÜV SÜD can
safety area
assist as well
Over-temperature protection

Mechanical integrity (crush test)

Fire resistance (fuel fire test) High temperatures & Hazardous gases

TÜV SÜD AG | E-Mobility 19-07-08 13

TÜV SÜD EV Battery Testing

Safe, Professional & CleanTesting!

TÜV SÜD AG | E-Mobility 19-07-08 14

TÜV SÜD EV Battery Testing

TÜV SÜD AG | E-Mobility 19-07-08 15

TÜV SÜD EV Battery Testing – Mechanical Shock Test Facility

TÜV SÜD AG | E-Mobility 19-07-08 16

Battery testing goes beyond safety testing

Battery Testing goes beyond safety testing

TÜV SÜD performed already many other services around testing the
batteries:
▪ Gas analysis to investigate emissions during testing
▪ Dynamic Shock Testing of the battery with the car frame
▪ EMC Testing during cycling
▪ Functional Safety and Certification of the electronic components
▪ Cyber-Security & Interoperability with all the equipment around the battery
(BMS, Charger etc.)
▪ Advisory services for designing verification plans based on standards
▪ Post-Mortem-Analysis of damaged batteries

TÜV SÜD AG | E-Mobility 19-07-08 17

TÜV SÜD is a experienced partner in EV testing and certification

• TÜV SÜD soon operates 9 EV battery labs globbaly, 6 opearable, 3 labs are under construction, 2 more in planning stage

• TÜV SÜD started EV battery system testing 12 years ago (>6000 EV batteries tested so far)

• More than 50 UN ECE R100 rev2 certifications

• TÜV SÜD has a global network of experts (> 100 staff in battery testing)

• TÜV SÜD has a global customer base (EU, USA, Japan, Korea, China)

Expertise sharing is a key success factor for our labs!

TÜV SÜD AG | E-Mobility 19-07-08 18

Global Network of TÜV SÜD EV Battery Service Labs
TÜV SÜD Battery Lab Korea

Utsunomiya, Japan / Shenzhen, China New Market, Toronto, Canada Auburn Hills, Michigan, USA

TÜV SÜD AG | E-Mobility 19-07-08 19

New to come – the largest and most complete battery testlab in the ASEAN region
In partnership between Thai Automotive Institute and TÜV SÜD

TÜV SÜD AG | E-Mobility 19-07-08 20

New to come – First Automotive „grade“ EV battery lab für TÜV SÜD China in Changzhou!
Beginning of 2020 lab no. 2 will follow in Guangzhou (South China) + lab no.3 (north)?

TÜV SÜD AG | E-Mobility 19-07-08 21

Contact details
TÜV SÜD Global E-Mobility TÜV SÜD Battery Testing in Europe

Volker Blandow Alexander Stadler

Head of E-Mobility Sales & Project Management Europe

[email protected] [email protected]
www.tuv-sud.com/e-mobility www.tuv-sud.com/e-mobility

TÜV SÜD China Holding TÜV SÜD Battery Testing GmbH

3F WW, Lakeside 2, Science Park Drive Dailmerstr . 15
Hong Kong 85748 Garching bei München

Phone: +49 151 27786328 Phone: +49 157 58856593

Phone: +852 2788 5135 Phone: +49 89 32950 715

TÜV SÜD AG | E-Mobility 19-07-08 22

Discover the advantages of partnering with TÜV SÜD

Contact us:
www.tuv-sud.com/e-mobility

[email protected]

[email protected]

For a Safer and Greener Future!

Thank You!
@tuvsud
linkedin.com/company/tuvsud
youtube.com/tuvsud

TÜV SÜD AG | E-Mobility 19-07-08