The New Battery Safety Standard EN for LEV s. Stephan Scheuer TÜV Rheinland

Transcription

1 The New Battery Safety Standard EN for LEV s Stephan Scheuer TÜV Rheinland

2 Content Intro TUV Rheinland The Need for Li-Ion- LEV Battery Standardization EN Scope, Application & Requirements Dates of Interest Battery Qualification & Certification 2

3 TÜV Rheinland. Milestones. Founded to ensure the safety of manufacturing plants First Vehicle Inspection First Product Certification First Foreign Subsidiary Merger with TÜV Berlin-Brandenburg One of the biggest independend ICT-Security service provider! We are an independent provider of technical services for testing, inspection, certification, consultation and training. 3

4 At Home on All Continents. Figures 2016 Employees Sales in million >2.000 Locations: more than 500 in 65 countries 4

5 ..and active with 3 battery testing & certifcation centers Nuremberg Shenzhen Battery Testing Laboratory & Battery Certification Body TUV Rheinland, Nuremberg, Germany Osaka 5

6 Safety Standardisation for LEV Batteries why? Typical (range) Electrical Voltage 2. 48V 800 V Electrical Current A Exhausting Materials Operating Conditions Electrolyt combustive C Flash point C Energy density (Lithium): Etherm > 10x EElectrical > Wh/kg Heat Fire Explosion Dangerous good 6

7 and possible implications Source: Battery Safety Organisation 7

8 Status in Electrical Standardization of LEV batteries GENERAL Electrical Telecomunication Consumer/ Industrial International EURPOEAN.. National CES 8

9 BATSO 01 Manual The LEV battery forerunner of EN and ISO Standardization < 25km/h Category: EPAC & S-Pedelec < 45km/h BATSO 01: Status: under Revision Manual for Evaluation of Energy Systems for Light Electric Vehicles (LEV) - Secondary Lithium Batteries 1. Overcharge 2. External short circuit 3. Vibration endurance test 4. Partial short circuit 5. Crush test 6. Shock test 7. Drop test 8. Low pressure test 9. Climate test 10. Factory inspection and Product surveillance will be adopted to EN

10 STATUS Quo

11 EN : Scope and Safety Objectives EN :2016 Status: Published August 2016 Secondary lithium batteries for LEV (Light Electric Vehicle) applications Part 1: General safety requirements and test methods Vehicle-Categories: Safety Objectives Categ. Battery mass > 50km/h < 50km/h < 25km/h L1 L7 E-Quadricycles E-Trycycle E-Bike/ E-Mopeds EPAC / Pedelec..0.25kW..15kW Mechanical Climate Simulated vehicle accidents Electrical System Functionality & UN 38.3 transport safety tests < 12kg 11

12 EN :2016 Safety Objectives and Tests Test category Clause Test item Mechanical Vibration Mechanical Shock Drop test Thermoplastic materials exposed to sunlight Climatic 7.1 Dewing (temperature change) 7.2 Thermal-shock cycling Simulated vehicle accidents Crush 8.3 Water immersion 8.4 Exposure to fire Over-temperature condition Under-temperature condition Electrical 9.1 Short circuit System functionality 10.1 Overcharge protection 10.3 Loss of thermal control 12

13 EN :2016

14 but. New Standards will not induce safe products automatically! 14

15 Type Testing, Type Approval, Certification! Single type testing acc. EN (incl. UN 38.3) is the first step for verification of a safe battery design for component type approval in vehicles (UN ECE Reg.) and consumer product compliance declarations with EU- Directives (CE-marking) To be on the safe side Battery Certification has to focus in addition to the production output and the products in the market 15

16 Qualification and certification THE 5 STEPS FOR A SAFE LEV-BATTERY MARKET 1. Battery type testing acc. EN on samples from pre-series or series in independent accredited test laboratory 2. Initial factory inspection 3. Certification by certification body Independent conformity assessment of type testing and factory inspection results 4. Repetitive factory inspection(s) 5. Product Market Surveillance 16

17 Qualification of manufacturing process 1 Initial factory inspection - CIG 022 / 023 factory quality audit regarding specific battery safety sensitive requirements and 2. Repetitive factory inspection(s) initial control and tests of battery components from suppliers Handling and storage of components and batteries Quality checks during manufacturing process of critical components and products (electrodes, cleaning processes, assembling..) Product shipment control & Packaging for air shipment Continuous product tests in a lab and check of documents 17

18 Certificate and Marking Independent accredited certification body issues Unique product identification for poduct verification (online) 24/7/365 18

19 Conclusions The new Standard EN addresses a mature safety level for the design and qualification of LEV batteries It covers a wide range of LEV applications (all) like the use in consumer products(like pedelecs) and vehicles (L category) In addition the independent inspected battery manufacturing process is a key factor for a safe battery mass production and for less risks in the market as well as prerequisite for a LEV battery product certification and for a safety type approval under QA aspects 19

20 Thank you. and always a safe and enjoyable e-drive! Stephan Scheuer 20