E-Mobility and Safety

E-Mobility Outlook and
Battery Safety
Bangkok, 2017 August 10
Volker Blandow
Global Head of e-Mobility, TÜV SÜD AG
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
800 Locations
64 Countries
2,2 Billion Revenue

150SÜD
TÜV Years
AG TÜV SÜD
Orientation:
UBER
Customer! Google
Apple
Faraday
Future
Toyota, ?
TESLA atieva
Honda,
Hyundai
Next
EV
Shareholder | Politics | Assets | Heads
TÜV SÜD AG
1.2 Billion vehicles are on the road globally
89 Million will be produced in 2016
this leads to additional
100 Million vehicles every 3 years

What if the whole world has the
same motorization rate
as Europe?
1,3
4,1 Billion 4,8 Billion
Billion
passenger cars passenger cars
cars
Today!
And what if the whole world had

the same motorization rate
as North Amercia?
Data source: International Organization of Motor Vehicle Manufacturers
TÜV SÜD AG
What if the entire world population
emitted the same amount of CO2
as an average European citizen?
63 x 109 32 x 109 115 x 109

t CO2 t CO2 t CO2
Today!
And what if the entire world population

emitted the same amount of CO2 as a
Data source: International Energy Agency North American?
TÜV SÜD AG
Historical CO² concentration
450 450
2030
430 critical co² concentration 400 to 450 ppm
410
Today
390
2005 380
370
350
co² concentration (parts per million ppm)
330
310 CO² concentration in the last 400.000 years
290
270
250 iceage
iceage iceage iceage
230
210
190
170
150
400.000 350.000 300.000 250.000 200.000 150.000 100.000 50.000 0
year
TÜV SÜD AG
World Population Growth
2025
8
2011
7
1999
6
Population (in billions)

1987
5
1974
4
1960
3
1930
2
1800
1
0
2-5 Million B.C. 7000B.C. 6000B.C. 5000B.C. 4000B.C. 3000B.C. 2000B.C. 1000B.C. 1000A.D. 2025 A.D.
Year
TÜV SÜD AG
1l
crude oil
25 tons of organic substances (mostly algae)
1.250 x
for 50 liters of gasoline
TÜV SÜD AG
TÜV SÜD AG
< 1.7°C UN agreed on stabilization of temperature rise
that means stabilization of CO2-concentration

< 450 ppm
anually we add another 2.5 ppm to
400 ppm existing concentration
that leaves us another

20 years to get to
0 ppm increase !
TÜV SÜD AG
But what does this really mean?
Real Estate Transport Power Supply Industry
0 CO² 0 CO² 0 CO² -90% CO²

by 2050 (industrialized countries!)
150SÜD
TÜV Years
AG TÜV SÜD
Real Estate: Plus Energy House (TU Vienna)
TÜV SÜD AG
Transport:
ELECTRIC Drive Train
Battery Electric Vehicles

Biofuels / Biogas
Fuel Cell Electric Vehicles
CNG / LNG (+Biogas)

Hybrids and Plug-in Hybrids
Hydrogen IC Engine
500 KG
TÜV SÜD AG
Electricity generation capacity investments 2015
5%
Investments 2015
Energy source
18% (in billion US$)
33%
PV 148
Wind 107
7%
Hydro 98
Gas 31
13%
Coal 78
24% Nuclear 21
PV Wind Hydroelectric Gas Coal Nuclear
• Global total energy investments 2015: 1,8 trillion US$

• Reduction of 8% compared to 2014
TÜV SÜD AG
Why is the transition to electric vehicles so important?
Different motivations to act!
• Global emissions, global warming
• Local emissions, air polution, threats to peoples health!
• Noise reduction, quality of life in our cities. Make them more liveable!
• Leadership in new technologies, an open race yet!
• Chances for new players (if boundary conditions are set wisely!)
• Any new technology needs certainty, investemts need security
• Entry for new technologies should be eased (tax credits, incentives, positive stimulation)
• While poluting technologies should be banned or penalized

Dynamic encounters:
German postal service became a vehicle manufacturer!
TÜV SÜD AG
e.GO
TÜV SÜD AG TÜV SÜD AG 17-08-10 Slide 18
Some reasons are very obvious!
Annual oil spending fot

Thailand @ 50$/barrel
18,25 Billion US$
2008 @ 100$ /barrel
29 Billion US$
TÜV SÜD AG
Additional electricity needed for 100% electrified Thailand!
TWh
No. of cars/SUV by end 2016:
Roughly 15.1 Mio
Travel km/a 14,000
Require 31,5 TWh
of additional power!
TÜV SÜD AG
Important side effects!
• Despite some naysayers (so called „Trumps“) – the transition already startet!
• Three megatrends (technology directions) will be overriding:
• Energy conservation – energy saving

• Renewable energies – solar, wind, biomass, hydro!
• Electrification of the transport system (battery or fuel cell)
This should be considered as an opportunity by ASEAN countries!
• Renewable energies create local jobs – distributed throughout the country

• Energy conservation measures especially stimulate local industries and investments
• New technologies are a playground also for new companies also from Thailand
TÜV SÜD AG
What do we need for a (market) success of e-Mobility?
Political / legal e-cars

Education framework that matter! Peace in mind!
Why do we go electric! e.g. emission regulations Cars with 300+ km Visible and accessible
like the current fleet emissions range charging spots
Are we responsible? regulations – + +
attractrive design and Easy home charging
Clear goal until 2030! features +
Clear goal until 2050! + Workplace charging
TCO cost parity
CONFIDENCE!
TÜV SÜD AG
TestingSafety
ServicesTesting for Energy
for Electrical EV Batteries
Storage Systems
New technologies – different risks
As with every energy source onboard a vehicle there is a risk in

case of system failure, abnormal environmental conditions or
external impacts like accident / crash... also with electric vehicles!
TÜV SÜD company mission since 150 years: Protect people by supporting industry to implement
the highest possible safety standards!
17-08-
TÜV SÜD AG Slide 24
Safety relevant battery trends 2017+
• No „relevant“ technology change in the next 2-3 years

• Batteries are getting bigger (300-500 km range, 40-90 kWh)=
• Batteries need to have fast charging (and HPC150/350) capabilities
• Reduced resistance of anode and cathode (e.g. Ni doting, nano coat)
• Higher capacity (bigger!) batteries require higher densed packaging

• HPC + Packaging = advanced cooling systems
• Challenge: homogenious cooling

• Homogenious cooling = homogenious aging of cells (safety behaivior)
TÜV SÜD AG 17-08-10 Slide 25

The battery challenge, six characteristics equilibrium
Capacity (Energy) Power (in/out)
Life Cycles Safety
Energy Density Costs

(volume/weight)

Charging times of a 80 kWh battery (typical from 10% to 95% SOC):
3 kW 26 h
11 kW 8h
22 kW 5h
HPC 150 30-40 min
HPC 350 15-30 min

Different areas for battery safety…
Product Safety Vehicle maintenance Rescue work Recycling / Decomissioning

Uncover the blind spot
Penetration of the battery

What happens if a metal
intrudes the battery?
source: mydailynews.com


Crash in an accident
How much can the battery
be deformed?


be deformed?
Mechanical shock
Does anything get lose?


be deformed?
Mechanical shock
Vibration
Does driving influence the
battery safety?
source: bgland24.de


be deformed?
Mechanical shock
source: NTSB
Vibration Propagation
Does driving influence the If a cell reacts, does it spread
battery safety? to other cells?

Examples for risks to be tested
Penetration of the battery Environmental influences

What happens if a metal How does the battery react to
intrudes the battery? temperature & humidity?
Crash in an accident:
be deformed?
Mechanical shock
source: wikipedia.en.org

Penetration of the battery Environmental influences High temperature

What happens if a metal How does the battery react to How does a defect cooling
intrudes the battery? temperature & humidity? affect the battery?
Crash in an accident: Immersion/Leakage

How much can the battery What does water in the battery
be deformed? generate?
Mechanical shock
source: topspeed.com

Full vehicle immersion and propagation test (forced thermal runaway)


Crash in an accident: Immersion/Leakage

Management failure
Mechanical shock
Has a defect of the controller
a negative effect?
source: bostonherald.com


Crash in an accident Immersion/Leakage

Management failure
Mechanical shock
Has a defect of the controller
a negative effect?
Vibration Propagation Validation

Does driving influence the If a cell reacts, does it spread Do my safety measures work
battery safety? to other cells? as intended?
source: ntsb.gov

Find out the risks to the battery

Crash in an accident Immersion/Leakage

How much can the battery Any risks What does water in the battery
specific to
the Management failure
Mechanical shock
Does anything get lose? application! Has a defect of the controller
a negative effect?
Vibration Propagation Validation

Does driving influence the If a cell reacts, does it spread Do my safety measures work
battery safety? to other cells? as intended?

Product safety
Vehicle manufacturer standards

Regulations Industry standards &
(e.g. type approval) (e.g. VDA) Product Liability
&
Quality Management

Sources for validation standards & regulations for xEVs
EU
Japan USA China
Germany
International Standardization Organisations (e.g. ISO, IEC)
Standardization
Japanese Industrial Deutsches Institut American National
JISC Standards Committee DIN 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

Mandatory Regulations
Japan & EU USA China
• UN ECE regulations • FMVSS (NHTSA) • CCC to GB standards

• Type approval • Self certification (AQSIQ, SAC)
• Conformity tested and • “It is the responsibility of a • Need to be performed by
confirmed by accredited manufacturer of vehicles specified execution bodies
service provider and/or items of motor vehicle (CATARC, SMVIC…)
• Accreditation by national equipment to certify that • Since July 2016: GB 31484,
authority, e.g. KBA in each motor vehicle and/or GB 31485 , GB 31486 are
Germany or NTSEL in Japan equipment item is in full mandatory
ECE R100 compliance with the • QC/T 743 will be replaced by
minimum performance new GB standards
requirements of all applicable • Some test items of GB
Federal Motor Vehicle Safety 31647.3 are requirements of
Standards (FMVSSs).” Beijing electric vehicle
FMVSS 305 admittance criterion
Tests defined in R100 and R136
UNECE R100 UNECE R136
Vibration Vibration
Thermal Shock Thermal Shock
Mechanical Shock Mechanical Drop
Mechanical Integrity Mechanical Shock
Fire Resistance Fire Resistance
External Short Circuit External Short Circuit
Overcharge Protection Overcharge Protection
Overdischarge Protection Overdischarge Protection
Overtemperature Protection Overtemperature Protection
Withstand Voltage and Water Resistance

TÜV SÜD Greater China 8/10/2017 Slide 43
Simplified type approval schedule…Focus: UN ECE R100 Rev2
Client: New electric vehicle!

(EV, PHEV or FCEV)
Need: Full vehicle type approval
Focus: UN ECE R100 / Rev. 2 (mandatory July 2016)
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
China: Overview of new GB standard system
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
But
Mandatory! Voluntary!
exceptions!
TÜV SÜD Japan 17-08-10 Slide 45
Propagation Test Specification
Producing a thermal runaway through misuse of one single cell in a battery.
Examples for applicable misuse tests:

• Overcharge
• Short Circuit
• Local heating
• Mechanical misuse e.g. nail penetration test
Assessment of thermal runaway propagation with focus on „infection“ of surrounding cells

Example for a test: Propagation Test – Results: Video

Example for a test: Propagation Test – Results: IR-Video

Propagation Test
Results - Measuring Data
T_01
Temperature
T_05
T_08
T_11
Voltage

Global TUV SUD Battery Testing Network
GERMANY
CANADA
U.S.A. Japan
CHINA SOUTH
KOREA
SINGAPORE
Toronto, Canada
Garching, Shenzhen, Suwon, Utsunomiya,
Auburn Hills, Germany *) Singapore *)
China Korea Japan
USA *)
Complete service Complete service Performance, Performance and Performance Environmental and
portfolio for cell, portfolio for cell, environmental and environmental testing on cell, abuse test on cell,
module and module and abuse testing on testing on cell, module and module and pack
system testing system testing cell and module module and system level, level
level – system Abuse test on cell
level in 2015 system level level
*) ISO/IEC 17025 accredited test lab or accreditation in 2015, Issuance of CB certificate / report possible
Experience is key in battery testing – testing for global customers!
TÜV SÜD has:

• 8 Years of experience in Battery Testing (system level)
• Specialized knowledge in safety and abuse testing
• Performed more than 6000 battery tests globally
• Full scope of automotive testing services,
• Certification and Homologation for global markets!

TÜV SÜD Battery Lab Germany: EV scale battery safety testing up to 800 kg
Safe,
Professional
&
Clean
Testing!
Batteries are getting larger – our machines as well!
Crush Machine 2 x 400 kW Battery Cyclers!

Mechanical Shock Test / Crash Test – High Risk Testing in Safe Hands!

TÜV SÜD e-Mobility Service Portfolio!
Testing/Certification
Charging Equipment
Type Approval for Battery Safety; Battery Testing
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 drive train testing

4-(8-) poster test rig

300 HP, V6
Diesel engine
380 HP electric
Motors 2x
Source: E-Force One AG
E-Motor: Maintenance free, oil free, no moving parts, minimum 10 Years, 95% efficiency!
TÜV SÜD AG
TÜV SÜD Group
One-stop testing, inspection, certification
and training.
For a Safer and Greener Future.
Thank you!
TÜV SÜD AG
Backup
Test items of GB/T 31467.3-2015
No. Test items Criteria

1 Vibration Battery pack or system: Deviation of minimum unit voltage no more than 0.15V;
battery or system in good connection, good structural integrity, no leakage, no
rupture, no fire or no explosion, isolation resistance no less than 100Ω/V;
Subsystem: Stay in good connection, good structural integrity, no installation loose,
BCU accuracy: Voltage≤2%FS, Temperature ≤±2oC, cell/module
voltage≤0.5%FS
2 Mechanical No leakage, no battery case rupture, no fire or no explosion, isolation resistance
shock no less than 100Ω/V
3 Drop No leakage, no fire or no explosion
4 Roll over No leakage, no battery case rupture, no fire or no explosion, isolation resistance
no less than 100Ω/V
5 Crash No leakage, no battery case rupture, no fire or no explosion, isolation resistance
6 Crush No fire or no explosion
7 Thermal shock No leakage, no battery case rupture, no fire or no explosion, isolation resistance
8 Heat damp No leakage, no battery case rupture, no fire or no explosion, isolation resistance
no less than 100Ω/V in 30min after test
Test items of GB/T 31467.2-2015
No. Test items DUT

9 Immersion No fire or no explosion
10 Fire stimulation No explosion, if flame occurs, flame should extinguish within
2 min after removal of fuel fire
11 Salt spray No leakage, no battery case rupture, no fire or no explosion
12 Altitude stimulation No obvious current change, no abnormal voltage change,
no leakage, no battery case rupture, no fire or no explosion,
after test the isolation resistance no less than 100Ω/V
13 Over heat protection BMS function in good condition, no venting, no battery case
rupture, no fire or no explosion, after test the isolation
resistance no less than 100Ω/V
14 External short circuit Safety protection act, no leakage, no battery case rupture,
protection no fire or no explosion, after test the isolation resistance no
15 Over charge protection less than 100Ω/V
16 Over discharge protection

The R100 is mandatory by regulation
9 Tests to be performed:
Mechanical shock
Very high risk for expensive test equipment!
(Crash facility / large Shaker)
Vibration test
Thermal shock cycling Fire protected chamber necessary!
External short circuit
Over-charge protection
Test should be performed in dedicated
Over-discharge protection
safety area
Over-temperature protection
Mechanical integrity (crush test)
Fire resistance (fuel fire test) High temperatures & Hazardous gases

Test items GB/T31467.3-2015
Mechanical shock
• Fully charged
• Mechanical shock : 25g 15ms half sine
• 3 times in Z-axis
• 2h observation
Drop test
• Fully charged
• Drop direction: the direction occurs during maintenance &
installation, if the direction is not specified drop in Z axis
• Height: 1m
• Floor: concrete floor
• 2h observation
Roll over
• Fully charged
• X-axis roll over at speed 6˚/s for 360˚, then keep at each
90˚ for 1h, roll over for 360˚
• Repeat in Y-axis
• 2h observation

Test items GB/T 31467.3-2015
Crush test Thermal shock

• Fully charged battery • Fully charged battery
• Crush plate: Radius 75mm, length is longer than • -40˚ ±2˚C ~ 85˚ ±2˚C change from low
DUT but less than 1m; temperature to high temperature in 30min, and
• Crush direction: X-axis and Y-axis keep at each limit temperature for 8h, 5 cycles
• Stop condition: Force reach 200kN or deformation
is more than 30% of initial dimension
• Keep at the position for 10min

Immersion test Fire resistance test

• Fully charged battery • Fully charged battery
• Immerse in 3.5% NaCl solution for 2h • After 60s preheat move DUT to the fire and expose
to the fire directly for 70s
• Then move a metal plate on the fire for additional
60s indirect fire
• Additional 2h observation

Altitude test Over heat protection

• Fully charged battery • Battery system with battery control unit in
• Stimulate the altitude of 4000m at RT operating
• Store in the low pressure environment for 5h and • Heat up to the up limited temperature and
then discharge at 1C (no more than 400A) until the discharge/charge at the maximum current until
cut-off condition BMS act or the following condition occurs
• 2h observation 1. Above maximum temperature 10oC;
2. Temperature change (Max ∆T) is less than 4oC/h
3. Other accidents happen

External short circuit test Over charge protection

• Fully charged battery with all BCU in operating • Battery system with battery control unit in
• External short circuit for 10min operating
• External short circuit resistor is no more than • Charge the battery at 1C or according to the client
20mΩ requirements until BMS act or one of the following
• 2h observation occurs
1. Voltage reach 1.2 maximum charging voltage;
2. SOC=130%
3. Battery temperature is above maximum
temperature for 5oC
4. Other accidents occur
• 2h observation
TÜV SÜD Japan 10/08/2017 17-08-10 Slide 68 Slide 68

Homologation in China
• GB 31484, GB 31485 and GB 31486 need to be tested in government labs for

rewarding the approval; the test in independent labs is not sufficient (although we
are working on this)
• To minimize the risk on IP-loss, we recommend to test in a 3rd party lab and
testing consultancy
• Based on our experience, these tests should be focused on:

– Nail-Penetration test of GB 31485
– Crush-Test of GB 31485
– Overcharge test of GB 31485
• All other abuse tests need also to be taken into account but are not so different
to other standards

But FCEV and BEV need different infrastructures with almost no synergies:
home charger workplace charger

Hydrogen Filling station
semi-public charger(shopping) semi-public charger(airport) public charger
fast charger HPC charger
Synergy: Both, Hydrogen Filling Stations and HPC chargers are lacking appropriate grid connections
on most remote locations e.g. on highway resting areas and on country roads.
H2-Production unit helps to better utilize grid utilization in off-peak times
TÜV SÜD AG
A very rough cost estimation: FCEV vs. BEV (Volkswirtschaftliche Kosten)
(Germany)
FCEV BEV
Cost per unit: 1.6 Million Euro
1000 units: 16 Billion Euro Assumption: 40 Mio vehicles

10.000 units: 15-16 Billion Euro Infrastructure Invest: 1000 Euro/vehicle
(400 Wallbox/ICCPD / 350 Installation / 250 Fast-Charging etc. + Grid)
(4.8 x 109 kg/a ; 13 x 106 kg/day; 12k km/a)
Redundancy factor ? (How many chargers per vehicle)
60 GW x 700 € = 42 Billion Euro (invest electrolyser)
40 Billion Euro + Grid x Redundancy factor (1.xx)
16 Billion + 42 Billion + Grid = 58 Billion + Grid
Source: FCH JU; LBST.de; Blandow, TÜV SÜD)
TÜV SÜD AG
Home Charging – everything set?
Example: Town house style, 28 Units, 32 underground parking lots, 15 overground parking lots, built 2016
50 m
TÜV SÜD AG
Mittelspannung
TÜV SÜD AG
Highway fast charging
TÜV SÜD AG
When do drivers refuel?
Medium to long distance travels…
Based on roughly 15.000 refuelings, California fuel cell partnership
TÜV SÜD AG
Refueling process with conventional fuel
TÜV SÜD AG
Fast charging at highways
World largest fast charging site (Norway, 20 x 120 kW (2.2 MW total) Holzkirchen near Munich
Peak demand resting area „Holzkirchen“
(16 refueling points, 6 Minutes processing time, 10h peak demand, 14 hours 50% of peak demand)
Total refuelings peak-day: 3264 Highway resting areas in Germany:

Charging power: 150 kW 380
Charging time 30 Min.
Requires roughly 38k chargers
 No charging points: 96 with 5.7 GW power
 Peak power demand 14,4 MW (calculations by Blandow, TÜV SÜD)
TÜV SÜD AG

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E-Mobility Outlook and

Bangkok, 2017 August 10

2,2 Billion Revenue

Shareholder | Politics | Assets | Heads

89 Million will be produced in 2016

this leads to additional

100 Million vehicles every 3 years

And what if the whole world had

63 x 109 32 x 109 115 x 109

And what if the entire world population

Population (in billions)

25 tons of organic substances (mostly algae)

that means stabilization of CO2-concentration

that leaves us another

Real Estate Transport Power Supply Industry

0 CO² 0 CO² 0 CO² -90% CO²

ELECTRIC Drive Train

Battery Electric Vehicles

Fuel Cell Electric Vehicles

CNG / LNG (+Biogas)

PV Wind Hydroelectric Gas Coal Nuclear

• Global total energy investments 2015: 1,8 trillion US$

Different motivations to act!

• Global emissions, global warming

• Local emissions, air polution, threats to peoples health!

• Leadership in new technologies, an open race yet!

• Any new technology needs certainty, investemts need security

• While poluting technologies should be banned or penalized

German postal service became a vehicle manufacturer!

Annual oil spending fot

18,25 Billion US$

2008 @ 100$ /barrel

Require 31,5 TWh

• Three megatrends (technology directions) will be overriding:

• Energy conservation – energy saving

This should be considered as an opportunity by ASEAN countries!

• Renewable energies create local jobs – distributed throughout the country

Political / legal e-cars

As with every energy source onboard a vehicle there is a risk in

• No „relevant“ technology change in the next 2-3 years

• Higher capacity (bigger!) batteries require higher densed packaging

• Challenge: homogenious cooling

TÜV SÜD AG 17-08-10 Slide 25

Capacity (Energy) Power (in/out)

Life Cycles Safety

Energy Density Costs

TÜV SÜD AG 17-08-10 Slide 26

HPC 150 30-40 min

HPC 350 15-30 min

TÜV SÜD AG 17-08-10 Slide 27

Product Safety Vehicle maintenance Rescue work Recycling / Decomissioning

TÜV SÜD AG 17-08-10 Slide 28

Penetration of the battery

TÜV SÜD AG 17-08-10 Slide 29

Penetration of the battery

TÜV SÜD AG 17-08-10 Slide 30

Penetration of the battery

TÜV SÜD AG 17-08-10 Slide 31

Penetration of the battery

TÜV SÜD AG 17-08-10 Slide 32

Penetration of the battery

TÜV SÜD AG 17-08-10 Slide 33

Penetration of the battery Environmental influences