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Volker Rothe GM Alternative Propulsion Center
EVS GTR Meeting, Washington D.C., April 2012
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Electric Vehicles Safety and the GTR
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Topics
• GM Alternative Propulsion Strategy
• Battery- and EV Testing
• Standards and Harmonization
• GTR Recommendations
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Advanced Propulsion Technology Strategy
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Improved
Vehicle Fuel
Economy &
Emissions
Displace
Petroleum
Hybrid Electric Vehicles (including
Plug-In HEV) Engine and
Transmission Improvements
Hydrogen Fuel Cell
Petroleum (Conventional & Alternative Sources)
Bio Fuels (Ethanol E85, Bio-diesel)
Hydrogen
Electricity (Conventional & Alternative Sources)
Battery Electric Vehicles
Time
Energy
Diversity
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Layers of Safety
• Driver Message
• Environment
• etc
Driver
Powertrain
• Electrical Protection
• Mechanical Protection
• etc
Battery /
Energy
Manager
• Charger Control
• Contactor Control
• Diagnostics
• etc
Charger
Vehicle
• Materials,
• Structure
• etc
Environment
Safety strategies at each level build from lower level designs
Cell Battery
Pack
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Battery Testing on Bench
Tests on cell level
Power and energy
Calendar life at various temperatures
Cycle life (USABC DST profile & Volt specific profile)
Fault tolerance (overcharge, short circuit, crush, over temperature, etc.)
Tests on pack level
Power
Energy
Efficiency
Thermal system
Controls
Cycle life
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Battery Validation
Validation
Crash
Mechanical: shock, vibration
Environmental: temperature, salt,
water
Electric: e.g. EMC
Customer use life cycle
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Battery Testing in Vehicle
Hot weather testing Winter testing
Mountain testing
Several hundred thousand kilometers
driven with the development fleet
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• Rigorous vehicle crash testing conducted
• Post crash evaluation includes the following items
• Short circuits
• Electrical arcing
• Bonding of High Voltage enclosures to the EV chassis
• Battery and component retention
• High Voltage disconnect and HV bus discharge
• High Voltage isolation from vehicle chassis
• Visible electrolyte spillage from RESS
• Cell venting behavior
Vehicle Crashworthiness
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EV and battery safety standards and research
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• Multiple existing industry and regulatory codes and standards related to EVs provide a rich framework for EVS GTR discussions • In addition, various countries are conducting research on EV safety, including lithium battery safety • Learnings from these sources should guide the content of the EVS GTR to assure that it represents state-of-the-art knowledge when published
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Global harmonization
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• Electrification of motor vehicle transportation is sweeping the world • Regulatory harmonization is an important enabler for this transition to succeed • Industry encourages contracting parties to adopt the EVS GTR into their national regulations when it is completed • Avoid to the extent possible conflicting, altered, or duplicative regulations • Electrification of auto transportation already faces significant cost challenges, non-harmonized regulations needlessly add burden to this
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GTR Recommendations
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• The EVS GTR should include in use and post crash electric safety requirements • Preference for performance-based safety requirements provides the necessary flexibility to accommodate future innovations
• Requirements should reflect the usage of batteries in electric vehicles • Sufficiently comprehensive requirements without options will avoid the need for country-specific regulations • The scope of the GTR should be limited to safety requirements for electric vehicles • Recommendations regarding charging infrastructure, first responders procedures or vehicle/components service, repair, maintenance and transportation issues could be given to the relevant organizations
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Thank you !
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