SAE J2464

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SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 RECOMMENDED PRACTICE Submitted for recognition as an American National Standard J2464 ISSUED MAR1999 Issued 1999-03 Electric Vehicle Battery Abuse Testing TABLE OF CONTENTS 1. Scope ....................................................................................................................................................... 2 1.1 Purpose .................................................................................................................................................... 2 2. References ............................................................................................................................................... 2 2.1 Applicable Publications ............................................................................................................................ 2 2.2 Related Publications................................................................................................................................. 2 3. Definitions................................................................................................................................................. 3 4. Technical Requirements........................................................................................................................... 3 4.1 General Test Guidelines........................................................................................................................... 3 4.1.1 Hazardous Substance Monitoring ............................................................................................................ 3 4.1.2 Test Conditions and Measurement Accuracies........................................................................................ 4 4.1.3 Number, Condition and Size of Batteries To Be Tested........................................................................... 4 4.2 Mechanical Abuse Tests .......................................................................................................................... 5 4.2.1 Shock Tests.............................................................................................................................................. 5 4.2.2 Drop Test.................................................................................................................................................. 5 4.2.3 Penetration Test ....................................................................................................................................... 6 4.2.4 Roll-Over Test .......................................................................................................................................... 6 4.2.5 Immersion Test......................................................................................................................................... 7 4.2.6 Crush Test ................................................................................................................................................ 7 4.3 Thermal Abuse Tests ............................................................................................................................... 8 4.3.1 Radiant Heat Test .................................................................................................................................... 8 4.3.2 Thermal Stability Test............................................................................................................................... 9 4.3.3 Compromise of Thermal Insulation......................................................................................................... 10 4.3.4 Overheat / Thermal Runaway Test......................................................................................................... 10 4.3.5 Thermal Shock Cycling........................................................................................................................... 10 4.3.6 Elevated Temperature Storage Test ...................................................................................................... 11 4.4 Electrical Abuse Tests ............................................................................................................................ 11 4.4.1 Short Circuit Test.................................................................................................................................... 11 4.4.2 Partial Short Circuit Test......................................................................................................................... 11 4.4.3 Overcharge Test..................................................................................................................................... 12 4.4.4 Overdischarge Test ................................................................................................................................ 12 4.4.5 Extreme Cold Temperature Test ............................................................................................................ 13 SAE J2464 Issued MAR1999 -2- Table 1 Measurement Accuracies ......................................................................................................................... 4 Table 2 Shock Levels and Durations ..................................................................................................................... 5 Table 3 Penetration Characteristics.......................................................................................................................6 Table 4 Thermal Heatup Rates and Durations ...................................................................................................... 9 Table 5 Number and Type of Devices to be Shorted........................................................................................... 12 Table 6 Test Conditions Sequence and Required Actions .................................................................................. 13 1. Scope— This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. It describes a body of tests which may be used as needed for abuse testing of electric or hybrid electric vehicle batteries to determine the response of such batteries to conditions or events which are beyond their normal operating range. This document is derived from a similar document originally developed by the U.S. Advanced Battery Consortium. (See 2.2.1.) 1.1 Purpose— These tests are intended to simulate abuse conditions and potential internally initiated failures that may be experienced in electrochemical storage systems. These tests were derived from Failure Mode and Effect Analysis, user input and historical abuse testing. The outcome of testing shall be documented for use by potential users of the tested properties. It is not the intent of this procedure to apply acceptance criteria; each application has its own unique requirements and ancillary support systems. Users of these technologies shall make their own determination as to what measures to take to ensure a sound application of said technology. The tests are designed to provide a common framework for various Electrochemical Storage Systems (ECSS) technologies. The primary purpose of the tests is to gather response information to external/internal inputs. Some tests and/or measurements may not be required for some ECSS technologies and designs if it can be demonstrated that the test is not applicable and the measurement will yield no useful information. Note that the device to be tested using any of the procedures in this document is referred to as an Electrochemical Storage System (ECSS); this terminology may refer to an electrochemical cell, module or complete battery system, depending on the particular test. 2. References 2.1 Applicable Publications— The following publications form a part of this specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications shall apply. 2.1.1 SAE PUBLICATIONS— Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J1715— Electric Vehicle Terminology 2.2 Related Publications— The following publications are provided for information purposes only and are not a required part of this document. 2.2.1 USABC PUBLICATION— Available from NTIS, 5285 Port Royal Road, Springfield, VA 22161. Electrochemical Storage System Abuse Test Procedure Manual, February 1999 Version 1.0, T. Unkelhaeuser & D. Smallwood, published as Sandia Laboratories report SAND99-0497 2.2.2 AIHA PUBLICATION— Available from American Industrial Hygiene Association, 1997, AIHA Publications, Department #796, Alexandria, VA 22334-0796. Emergency Response Planning Guidelines, Level 2 SAE J2464 Issued MAR1999 -3- 3. Definitions 3.1 Electrochemical Storage Systems (ECSS)— A device for storing electrical energy in a reversible electrochemical form for use in mobile or stationary applications. In this document, the ‘device under test’ is always referred to as an ECSS whether it consists of a single cell, a multiple cell assembly or module, or a complete battery pack or system. 3.2 Emergency Response Planning Guidelines, Level 2 (ERPG-2)— ERPG-2 levels are defined as the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 h without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual’s ability to take protective action. This guideline is taken from the American Industrial Hygiene Association. Other world standards with like intent may be substituted, because use of these concentration levels is for comparison purposes only. 3.3 Fully Charged— 100% State of Charge. The state of an ECSS after a full charge cycle as specified by the ECSS manufacturer. For purposes of this document, an ECSS is considered fully charged up to 4 h after the completion of the charge cycle provided that the state of charge is not expected to fall below 95%. 4. Technical Requirements 4.1 General Test Guidelines— Subjecting batteries to conditions outside their intended operating range necessarily involves some risk of unintended failures. The responsible testing organization should consult the battery manufacturer for information regarding the possible consequences of such failures, including the potential release of hazardous substances, so that appropriate precautions can be taken for the safety of testing personnel. 4.1.1 HAZARDOUS SUBSTANCE MONITORING— The release of hazardous substances should be measured and referenced to the ERPG-2 levels. ERPG-2 refers to the Emergency Response Planning Guidelines, Level 2, from the American Industrial Hygiene Association. ERPG-2 levels are defined as the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 h without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual’s ability to take protective action. Use of these levels as a reference is done for comparison purposes only. Tests which require hazardous substance monitoring should be conducted in a closed volume of appropriate size to accommodate the test article and provide adequate air space to ensure a “normal” atmosphere. Any released gas concentration in that volume shall be normalized to a 1 m3 volume for quantitative analysis. If it is not practical to perform any test in a closed volume due to test article size, it is permissible to perform the test out of doors provided that wind speed is 3 mph or less. A minimum of three hazardous substances monitors, approximately equally spaced around the unit, should be placed as close as reasonable to the test and moved as close as practical to the ECSS after the test. (The rollover test is an exception to this.) Hazardous substance monitors shall be selected with respect to anticipated release products; manufacturer’s input will generally be required to determine this. If it is reasonable to expect that a specific technology will not vent during a particular test, or that gas collected will not be significantly different from that previously collected, gas collection and analysis are not required. The time resolution of such sampling is not specified because of the wide variability in test dynamics and release amounts/rates expected. The flammability of any expelled materials must be determined. The lower limit of flammability in air is used for flammable gases and liquids. For example, the lower limit of flammability in air for H2 is 4%. For substances not considered hazardous, the EPA reportable release limits are used as a reference for comparison purposes only. A release means any spilling, leaking, pumping, pouring, emitting, emptying, discharging, injecting, escaping, leaching, dumping, or disposing into the environment. SAE J2464 Issued MAR1999 -4- 4.1.2 TEST CONDITIONS AND MEASUREMENT ACCURACIES— All ECSS test articles shall be in a fully charged state, at normal operating temperature with any cooling media in place and thermal control systems running unless specifically stated otherwise. All test articles will be observed for a time period of at least 1 h or until such time that said test article is judged safe to handle after each test unless specifically stated otherwise. Except where specifically stated otherwise (e.g., temperature abuse tests), the ambient temperature for any tests defined in this document shall be 25 °C ± 3 °C, and the ECSS environment shall be stabilized at this temperature prior to the start of testing. Measured data shall be acquired at rates and with accuracies adequate to assure that the usefulness of the test data is not compromised. In the absence of more specific requirements by the test sponsor, the measurement accuracies in Table 1 shall be considered acceptable. Because of the wide variety of test dynamics, it is not possible to specify absolute data rates. However, the required data for a particular test shall be acquired at a rate such that errors due to test dynamics will not exceed the required measurement accuracies. For example, if the required accuracy for a given test is 10 °C, the temperature shall be measured sufficiently often that measurement delays will not contribute more than 10 °C error to the resulting data during the important parts of the test. 4.1.3 NUMBER, CONDITION, AND SIZE OF BATTERIES TO BE TESTED— Initial testing will probably be with a new ECSS, as systems or subsystems which have seen part of their useful life will not be available. Future efforts may include an ECSS well into, or near the end, of its useful life. Permutations of state of charge, system age, and temperature should be implemented at the test sponsor’s or manufacturer’s discretion based on the most susceptible condition of the technology. Note that information will generally be needed from the ECSS manufacturer to determine what types of hazardous substances (if any) may be expected to be released during a given test. Abuse testing is to be performed to characterize the ECSS response to undesirable conditions or environments associated with carelessness, poorly informed or trained users or mechanics, failure of specific ECSS control and support hardware, or transportation/handling incident or other accidents involving the ECSS. Some of these conditions can reasonably be expected to be encountered infrequently, but nevertheless represent conditions for which the ECSS was not designed or intended for use. Some of the tests are not applicable to all candidate ECSS technologies. Many of these tests may result in intentional destruction of the device under test. The required number of batteries to be subjected to testing will depend on actual performance (e.g., a single ECSS of some types may be capable of surviving all but the crush test, whereas for other technologies, as many as 3 to 4 batteries may be required). It is acceptable to use a new ECSS for each test. However, in many cases, it may be economically or technically desirable to subject a single device to multiple tests, either to reduce the number of test articles required or to study the interaction of multiple events (e.g., mechanical shocks followed by penetration, immersion, or high temperatures.) In general these tests should be conducted at the lowest level of assembly for which meaningful data can be gathered, i.e., cell, multi-cell module, or complete battery pack or system. The recommended lowest level of assembly to be used for each test is indicated on the title line for each test. Tests are grouped into three categories: mechanical, thermal, and electrical abuse. Some tests have been arbitrarily classified as they contain more than one of these elements. TABLE 1— MEASUREMENT ACCURACIES Parameter Accuracy Temperature ±2 °C ± 5% of reading Voltage, Current, Resistance 1% of reading Vibration, Deformation 4% of reading Hazardous Substance Concentration 10% of reading SAE J2464 Issued MAR1999 -5- 4.2 Mechanical Abuse Tests— The mounting and support of the ECSS shall be as similar as possible to the manufacturers recommended EV installation requirements for mechanical shock and vibration tests. If the support structure has any resonance below 50 Hz, the input will be determined by the average of the acceleration at each of the major support points. 4.2.1 SHOCK TESTS (MODULE LEVEL OR ABOVE) 4.2.1.1 Test Description— Subject the ECSS to shock events at one or more defined shock levels. The low level shock is a robustness test which an ECSS will generally survive without damage. The mid-level shocks are more severe and the ECSS may be inoperable after the test. Shock levels and durations are defined in Table 2. Each shock level is specified in terms of a velocity change and a corresponding maximum duration. (Shock duration is defined as the time between 10% and 90% of peak value.) Achieving this velocity change over this maximum duration is the goal of the test; however, the characteristics of the acceleration (deceleration) pulse are limited by the test equipment used. The maximum duration places lower limits on the peak acceleration which must be seen during the test. For example, for the low level test, the lowest possible acceleration meeting the requirements would be achieved if the acceleration was an ideal square wave of about 12.5 g. The minimum peak acceleration in Table 2 is specified at about twice this level, recognizing that an ideal square wave cannot be achieved in a real test. It is expected that a simple pulse shape (such as a half-sine) will be used for the test, but the pulse shape is not specified to allow as much flexibility as possible in the testing laboratory. Advanced techniques which more accurately simulate actual deceleration time histories are not excluded. It is generally in the interest of the ECSS manufacturer to keep the pulse duration as long as possible while meeting the specification. However, i