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UN T1-T8 Tests
UN 38.3 Manual Of Tests
• 16 batteries
– 8 Fully charged
» 4 fresh and 4 with 50 cycles usage
– 8 Discharged
» 4 fresh and 4 with 50 cycles usage
• 3 hrs in each of 3 mutually perpendicular mounting positions
• Logarithmic sweep from 7Hz to 200Hz to 7Hz in 15 minutes
– 7Hz to 18Hz at 1gn; amplitude decreasing
– 18Hz to ~50Hz with 0.8mm amplitude; acceleration increasing to 8gn
– ~50Hz to 200Hz at 8gn; amplitude decreasing
– 200Hz to ~50Hz at 8gn; amplitude increasing
– ~50Hz to 18Hz with 0.8mm amplitude: acceleration decreasing to 1gn
– 18Hz to 7Hz at 1gn; amplitude increasing
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UN 38.3 Manual Of Tests
Current T4 Shock Testing Requirements
• 16 batteries
– 8 Fully charged
» 4 fresh and 4 with 50 cycles usage
– 8 Discharged
» 4 fresh and 4 with 50 cycles usage
• 18 shocks: 3 in negative and positive direction of 3 mutually
perpendicular mounting positions
• Shock parameters
– Normal batteries: Half-sine, 150 gn peak acceleration, 0.006 seconds pulse
duration
– Large batteries: Half-sine, 50 gn peak acceleration, 0.011 seconds pulse
duration
– Note: Large batteries have more than 500 grams ELC
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UN 38.3 Manual Of Tests
Pass Criteria for Both Tests
• No mass loss
• No leakage or venting
• No disassembly
• No rupture
• No fire
• OCV after test > 90% of OCV before test
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HEV Lithium-Ion Batteries
Mild and Full Hybrid Applications
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HEV Lithium-Ion Batteries
Mild and Full Hybrid Applications
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HEV Lithium-Ion Batteries
Typical Usage, Vibration and Shock OEM Vehicle Requirements
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HEV Lithium-ion Battery Transportation
• Prototype or Development Stage
– Air and vehicle modes utilized but mostly vehicle
– Domestic and international
– Multiple shipments possible for the same battery (some in the vehicle)
– Batteries have not passed UN 38.3 testing
– Competent Authority will be used to allow shipping
• Production
– Vessel and vehicle modes normally
– Domestic and international
– 5 or less shipments of battery before vehicle installation
– Starts in 2010
– Must pass UN 38.3 tests or obtain special approval
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UN 38.3 Vibration and Shock Testing
Issues and Impact
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UN 38.3 Vibration and Shock Testing
Test Analysis
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Vibration Test Analysis
• HEV battery systems are assemblies of electronic
controllers, sensors, air flow ducts, cabling, cell mounting
fixtures, cells, trays, covers and attachment brackets.
– They are not “solid” like cells and laptop batteries.
– They will have several resonant frequencies under 200 Hz.
– Estimated force exerted on mild HEV batteries due to damping and
resonance is approximately 27,000N.
– Full HEV battery force is approximately 94,000N.
• With the understanding that vibration test parameters are
based on air transportation of small lithium cells and
batteries, these parameters do not realistically apply to
larger batteries.
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Vibration Test Analysis
• UN T3 testing of HEV batteries at these frequencies and
8gn is unreasonable because:
– Vibration of the transportation mode is reduced due to the mass of the pack.
– Test requires vibration to be “faithfully” transmitted to device, yet vibration
would not directly pass from the transportation mode to the battery due to
the isolation provided by the skid or container and the package.
– Force levels can not be transmitted by the transportation mode
» Force required to vibrate a large notebook computer battery (0.5 kg) is
~1000N.
» 27,000N and 94,000N are very substantial forces
• 2750kg wrecking ball falling
• Or stopping a 550kg wrecking ball after falling 1 second (35kph/22mph) in 1 meter
• 9500kg wrecking ball falling
• Or stopping a 550kg wrecking ball after falling 1 second in 0.28 meters
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Vibration Test Analysis and Recommendation
• T3 Test Recommendation For batteries > 12kg:
– Reduce force level from 8gn to 2gn
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Shock Test Analysis and Recommendation
• T4 shock forces on mild HEV batteries would exceed 40,000N.
– Full HEV battery forces would be >140,000N.
• Again, with the understanding that these shock values are based on air
transportation of small lithium cells and batteries, these parameters do
not realistically apply to larger batteries.
• UN T4 testing of HEV battery packs at these forces is unreasonable
because:
– These force levels could not be transmitted by the transportation mode
» Force required to shock cell phone and notebook batteries at 150gn~1500N
» 1500N applied to shock a mild HEV battery (~500Wh, 12Kg) is ~6.5gn.
– There is no source for the additional 38,000N.
– Aviation specifications (RTCA) test for Crash Shock at 20g maximum.
• Recommend limiting acceleration to 50gn for all batteries > 12 kg
– Far exceeds realistic and expected levels
– 50gn already is used in UN 38.3 for large batteries.
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Summary
• Mild and full HEVs will have lithium-ion batteries that will
have to be tested according to UN 38.3 Manual of Tests
• UN 38.3 T3 vibration and T4 shock tests are unrealistic
when applied to large batteries
• If these tests remain as currently written, conversion of
the world vehicle fleet to hybrids will be delayed
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Back-up Material Follows
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Back-up
HEV Lithium-ion Battery Transportation Scenarios
• Prototype or Development Stage
1. Battery transported from manufacturer to airport by vehicle
2. Airport to airport
3. Airport to distribution center by vehicle
4. Distribution center to HEV system integrator by vehicle
5. HEV system from system integrator to OEM engineering by vehicle
6. HEV (car) from OEM engineering to test site by vehicle
7. HEV (car) back from test site to OEM engineering by vehicle
8. HEV system from OEM engineering back to integrator by vehicle
• Production Stage
1. Battery transported from manufacturer to marine port by vehicle
2. Marine port to marine port
3. Marine port to distribution center by vehicle
4. Distribution center to HEV system integrator by vehicle
5. HEV system from system integrator to OEM assembly plant by vehicle
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Back-up
Calculations
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Back-up
Vibration Isolation
Kp Stiffness of packaging
Kequivalent = 1
1 + 1 + 1
Kbattery Kpackaging Kcontainer
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Back-up
Calculations
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Back-up
Calculations
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Back-up
Calculations
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Back-up
Aviation Equipment Shock Requirements
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Back-up
RTCA Specification
• Shock
– “Saw Tooth” configuration pulses
– 11ms pulse for standard testing or 20ms for low frequency testing
– 18 shocks, 3 per orientation
– 6g
– Equipment operating
• Crash Safety
– Same as above except 1 shock/orientation at 20g
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