E-mobility

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 Why is safety important for
Electric Vehicle (EV)?

Electric vehicle charging station

explodes while charging

Very dangerous if left

unchecked

Needs to be tested and certified before

being put into operation

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 Overview EV

Electric road vehicle (EV)

EV include, but are not limited to, road and rail cehicles,
surface and underwater vesels, electric aircraft and electric spacecraft.

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 Overview EV

Electric vehicle (EV)

EV include: Battery, Charger,Electric motor,other compoment,….

Each type of electric vehicle has a different structure but basically includes the
above parts

Charger and battery

very important for
safety before provide to
client

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 Charging Stations

In January 2022, the U.S. had almost 113,600 charging outlets

for plug-in electric vehicles (EVs). A considerable sum of these
chargers is found in California, with almost 41,300 public and
private power outlets. Plug-in power stations and charging
outlets are essential to increase
U.S. plug-in electric vehicle sales.

Outlets supporting the EV boom

Having a network of charging stations and outlets is absolutely

necessary for electric vehicles to be practical for most drivers.
Therefore, that China is among the
leading markets for electric vehicle sales is unsurprising. The
country has 800,000 or so electric vehicle chargers (EVSE).
Infrastructure issues will be one of the main hurdles for the
electric vehicle market, particularly when it comes to the
commercial vehicle segment. Forecasts project the
U.S. heavy truck charging infrastructure market to rapidly
increase until 2024 to offset this challenge.

With faster charging and cheaper, more efficient batteries, long

distance travel becomes possible with plug-in EVs. As a result,
the electric vehicle fleet size in California alone is expected to
grow to reach almost four million by 2030. California's EV
market share came to around eight percent in 2020.

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 Charging station

Wall mount type

AC charger Stand type
AC charger

DC Charger

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 Overview EV

Charger station

Plug,soket
Cable assembly
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 Charging standard

Safety for charging we have main standard:

ELECTRIC VEHICLE CONDUCTIVE CHARGING SYSTEM

1. Generral standard - IEC 61851-1:2017

2. Part 23 : DC electric vehicle charging station – IEC 61851-23:2014

3. Part 22 :AC electric vehicle charging station – IEC 61851-22:2014

4. Plugs, socket-outlets, vehicle connectors and vehicle inlets – IEC 62196

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 Overview EV

IEC 61851-1 scope IEC 62196-1 scope

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 Overview EV

Definition
Electric Vehicle Supply Equipment - Equipment or a combination of
equipment, providing dedicated functions to supply electric energy
EVSE
from a fixed electrical installation or supply network to an EV for
purpose of chargin
AC EV EVSE that supplies alternation current(AC) to an EV

DC EV EVSE that supplies direct current(DC) to an EV

Piece of equipment that is used establish the connection between the

Cable assembly
electroic vehicle and the electric vehicle supple equipment

Plug and socket

Means enabling the conection at will of a flexible cable to fixed wiring
-outlet

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 Overview EV

Charing mode

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 Overview EV

Connection

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 Touch current

• The test voltage shall be 1,1 times the maximum rated voltage
• IEC 60068-2-78, test Ca, at 40 °C± 2 °C and 93 % relative humidity for four
days
• The electric vehicle charging station connected to AC supply network

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 Protective earthing

If the DUT has any accessible metal part, it should conduct Ground
Bond test. Inject 25A A.C. current to measure the resistance between
accessible metal part and the earth is less than 0.1Ω.

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 Insulation resistance

• The test voltage measured with a 500 V DC voltage applied between all inputs/outputs
connected together (power source included) and the accessible parts
• IEC 60068-2-78, test Ca, at 40 °C± 2 °C and 93 % relative humidity for four days and
testing duration of 1min
• The electric vehicle charging station connected tothe accessible parts during the test
• Requiment :

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 IP degrees

Enclosures of the EV supply equipment shall have an IP degree:

1. Indoor use: at least IP21
2. Outdoor use: at least IP44

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 DC output

The tolerance between the output current of the d.c. EV charging station
compared to the required value sent by the electric vehicle shall be :
1. ± 2,5 A for the requirement below 50 A,
2. ± 5 % of the required value for 50 A or more

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BATTERY FOR EV
Currently, electric vehicles are increasingly popular such as electric cars,
electric motorcycles, electric bicycles, electric forklifts, etc.

Thereby, the electric vehicle battery (EV) is considered the most essential component of
an electric vehicle. Battery performance and reliability are important to ensure the
quality of the entire electric vehicle.
 Electric vehicle battery testing and certification services ensure that your
batteries, cells, chargers and electrical components for use in e-mobility,
comply with global safety requirements and operate reliable.
 POPULAR BATTERIES CURRENTLY

Lead Acid Battery Battery Nickel Metal Hydride (NiMH)

Battery lithium ion Battery Nickel – cadmium

 ADVANTAGES – DISADVANTAGES
OF DIFFERENT TYPES OF BATTERY

Criteria Lead Acid Battery Battery Nickel Metal Hydride Battery lithium ion Battery Nickel – cadmium

• Does not affect the • Do not pollute the • Small in size and weight, • There is a high current.
environment. environment. but holds a huge amount of • The anti-overcharge
• The price is cheaper than • Same size, lower capacity energy. property is also better than
other electric car batteries. than ion battery but higher • The battery weight is that of NiMH batteries. This
• Very good recyclability. than acid battery. relatively light, only about 3- is also an advantage
• Capable of recharging • Self-discharge is high. 4 kg. compared to other electric
multiple times. • The overall charging • Can be charged multiple vehicle batteries.
Advantages • Produced mainly in China capacity is large so there is times.
so the import process is no need to charge much. • Capable of holding power
simple. • Battery life is longer than for a long time, less prone to
acid battery. This is an self-discharge.
outstanding advantage • There is no need to
compared to other electric discharge the battery before
vehicle batteries. charging.
• Environmental friendliness.

• Mass and weight are large • Melting phenomenon occurs • The electrolyte solution that • Because it contains the
but the capacity to store easily. the battery uses is very second component,
energy is small. • If overloaded, it is easy to flammable, causing an cadmium, which is a very
• Have to charge many times. damage component parts. explosion. toxic type, Nicd batteries are
• Not suitable for fast • New batteries may have to • Battery life is only about 3-4 extremely harmful to users
Defect
charging and large go through several charging years. and pollute the environment.
discharge. or discharging processes • Prices are not stable. • This type of battery is
• Battery life is not great. before reaching the proper currently used less than the
• Regular maintenance and capacitance. electric vehicle batteries
replacement. above.
WHY IS THE BATTERY
TESTING IMPORTANT?
 Verification
03 Battery durability,
safety and reliability
during use
Batteries, sub-systems
and cooling system
Performance deteriorates
after a period of use
01 02 Battery
Available in various
sizes, shapes,
weights and
chemical
compositions
BATTERY TESTING
 BATTERY PERFORMANCE AND LIFECYCLE TESTING

Cycle testing under different climatic conditions (temperature,

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humidity)
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Parameter determination

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High performance cycling

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Lifecycle simulation

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Validation of cooling systems
 BATTERY PERFORMANCE AND LIFECYCLE TESTING

Example: Overview:
• Lifecycle simulation This Li-ion battery charge discharge testing equipment
• Continuous low-rate charging meets the requirements of lithium on battery and cell
(cells) pulse charge and discharge test, DC internal resistance
(DCIR) test, cycle life (Cycle Life) test, rate charge and
discharge test. It has two current range:
Range 1: 0.5mA~0.1A;
Range 2: 0.1A~6A, which can test the small capacity li-
ion batteries and the test result are more accuracy.

Test: (IEC62133-1:2017)
Fully charged cells are subjected for 28 days to a charge
as specified by the manufacturer.
Li-ion Batteies and Cells Life Analyzer
High Precision Dual Range Capacity
Test Equipment
 BATTERY ENVIRONMENT AND DURABILITY TESTING

Vibration and shock testing under different climatic conditions (temperature, humidity)
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2
Dust and salt fog testing

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Altitude simulation

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IPXX, immersion splash water testing

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Electromagnetic compatibility
testing

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Chemical influence analysis
 BATTERY ENVIRONMENT AND DURABILITY TESTING

Example: Vibration Vibration test system can simulate possible impact damage, it
Test can be used for early battery failure detection

Test: (IEC62133-1:2017)

Electro-dynamic Vibration Test System

 BATTERY ENVIRONMENT AND DURABILITY TESTING

Example: Altitude simulation Test: (IEC62133-1:2017)

Each fully charged cell or battery is dropped three times from a
height of 1,0 m onto a concrete floor. The cells or batteries are
dropped so as to obtain impacts in random orientations. After the
test, the sample shall be put on rest for a minimum of 1 h and
then a visual inspection shall be performed.

Drop Test Machine

 BATTERY SAFETY AND ABUSE TESTING

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Propagation
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Static and dynamic crush

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External short circuit 7
Roll-over

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Overcharge
8
Drop and impact

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Overdischarge
9
Water intrusion and
leakage
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Nail penetration 10
Fire resistance
 BATTERY SAFETY AND ABUSE
TESTING

Example: External short circuit Overview:

This battery external short circuit testing equipment is temperature
controlled type, it meets the requirement that the short circuit
device must conform to the range of internal resistance ≤5mΩ, to
obtain the maximum short-circuit current required by the test

Test: (IEC62133-1:2017)
Two sets of fully charged cells or batteries are stored in an ambient
temperature of 20 °C ± 5 °C and 55 °C ± 5 °C, respectively, when
the samples reach temperature balance with the ambient
temperature. The cell or battery is then short-circuited by
connecting the positive and negative terminals with a total external
resistance of 80 mΩ ± 20 mΩ.
The cells or batteries remain on test for 24 h or until the case
temperature declines by 20 % of the maximum temperature rise,
whichever is the sooner
External Short Circuit Testing
Equipment
 BATTERY SAFETY AND ABUSE TESTING

Example:
• Case stress at high ambient temperature Overview:
The battery thermal impact test equipment, also called
(batteries) the battery thermal abuse test chamber, adopts a hot air
• Thermal abuse (cells) circulation system by simulating a battery placed in a
forced-air high temperature chamber, raising the
temperature to a preset test temperature and maintaining
a certain time at a certain heating rate.
It can ensure even distribution of working temperature.

Test: (IEC62133-1:2017)
Each fully charged cell, stabilized in an ambient
temperature of 20 °C ± 5 °C, is placed in a gravity or
circulating air-convection oven. The oven temperature
is raised at a rate of 5 °C/min ± 2 °C/min to a
temperature of 130 °C ± 2 °C.
The cell remains at this temperature for 30 min
Air Circulating Oven Battery Testing before the test is terminated.
Equipment Battery Case Stress Thermal
Impact Test
 BATTERY SAFETY AND ABUSE TESTING

Example: Overview:
• Overcharge This explosion proof testing chamber is used to prevent
• Forced discharge (cells) unnecessary explosion or burning damage to the test personnel
during the battery overcharge and over discharge testing.

Test: (IEC62133-1:2017)
• A discharged cell or battery is
subjected to a high-rate charge of
2,5 times the recommended
Overcharge: charging current for a time that
produces a 250 % charge input
(250 % of rated capacity).

• . A discharged cell is
Forced discharge subjected to a reverse
(cells) charge at 1 It A for 90 min
Battery Explosion-Proof Test Chamber