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Research of the Electric Vehicle Safety

Zhang Henghai
Shandong Jiaotong University
Jinan, China
e-mail: zhh-80@163.com

Zhang Guirong
Shandong Jiaotong University
Jinan, China
e-mail: zgr6933@163.com

Abstract-Electric

vehicles

as

the

green

environmental

protection vehicles, they will occupy the important position


in the vehicle of the future market, to speed up the safety of
the electric vehicle research in promoting the promotion of
the electric vehicle plays a very important role. This essay
mainly analyses the power system of electric vehicles to crew
member of the damage caused by the explosion, the burning
of the battery, electrolyte leakage and the battery harmful
gas damage, release the collision of the electric vehicle
security hidden

danger.

Because of

our

country about

electric vehicle safety standards and laws and regulations is


not perfect, to speed up

the safety of the electric vehicle

research, continuously improve the safety performance of


the electric vehicle, promote the electric vehicle to use in our
country

and improve the electric vehicle safety standard

and related laws and regulations plays a positive role.

Keywords- Electric vehicles, Safety, Battery damage,


Experiment
I.

INTRODUCTION

Electric vehicles as the 21st century green vehicle, the


market prospects has become inevitable. To analysis and
research the safety of electric vehicles, establish the
electric vehicle safety standards will be imperative.
However, the electric vehicle power system is very
different from the traditional internal combustion engine
vehicle. The existence of security risks are also different
from the traditional internal combustion engine vehicles.
Thus, as the study of electric vehicles deeply and the
acceleration of the industrialization process increasing
quickly ,the performance of electric vehicles of the
security will be imperatived.
II.

THE ANALYSIS OF ELECTRIC VEHICLES SECURITY


HIDDEN DANGER

The safety hidden trouble of electric vehicles basically


has the following kinds:
a) The electricity damage: the electric vehicle voltage
is far higher than the human body can take safety voltage,
once produce leakage, the passenger will be harmed much
bigger. The collision between components in operation
process of vehicle, friction, extrusion etc may make
originally good insulation of wires failure, terminals and
metal lap around there will link. All of these may lead to
leakage and short circuit, make human body harm for
electrical shock. The electric spark of generation by Short
circuit may also lit undetermined around.
b) The pressure of the battery harmful: usually, the
battery in normal pressure and normal levels, but when the
battery is used undeserved or suffered by the battery

mechanical shock. Pressure may be more than batteries


could have limited and it will explose.
c) The combustion and explosion danger: electric
vehicle charging or in the process of moving for a variety
of reasons, it may trigger a burning explosion accident.
d) Electrolyte splash damage: electrolyte generally is
strong alkali substances, the electric vehicle battery
electrolyte won't appear big splash leakage in general
condition. But because the battery manufacturing defects
may make the battery shell when it in a violent oscillation
or collision accident occurred, it will lead to battery
electrolyte produce a big leakage, which will injure
passenger.
e) The heat damage of battery to the human body:
battery charging and working will generate heat, mainly
from three aspects: CDthe heat effect of electrochemical
reaction; the current through the battery in resistance;
current through the polarization resistance generated heat.
More batteries in your work, the highest temperature up to
500 degrees Celsius, decorate the position of the battery
reasonable and isolate the thermal between cabin and
passenger to prevent battery from injuring passengers.
III.

TEST AND METHODS OF ELECTRIC VEHICLE


BATTERIES SECURITY

According to the national safety regulation, the safety


performance of battery technology indicators are charging
resistance, discharge, short circuit, high temperature
resistant, drilling test, corrosion resistance test.
A

The overcharge, the over discharge test

Overcharge, over discharge cases, when gas


accumulate excessive inside the sealed battery, pressure
increasing beyond the limit of the design will burst, it will
endanger the personal safety, it is not allowed, to the
battery design, generally uses the negative excessive way
to avoid accumulating gas excessive in the internal battery.
Test battery of the overcharge, discharge ability,
general ofOB/Z18333-2001 recommended by the method.
If continue the test of charge. That is to say, in the (205)
C under the condition of constant pressure, control
starting current less than or equal to 11 (A) current, when
the battery charging maximum allowable voltage up to the
highest (4.2 V), the battery should be able to automatically
stop charging, continue the operation 5 times, charging
protection device could all action. And like again the
discharge or charging battery method. The first step in (20
5)Ccondition, the first 13 (A) current discharge, when the
battery to discharge termination voltage (2.52 V), use the
special charger, provide manufacturer in (205)C under

the condition of filling charging termination voltage to


charge (4.2 V). The second step in the (205)'C under the
conditions of use I3 (A) discharge current until the battery
voltage is zero, then the battery in (205)C under the
condition with I3(A) current discharge, until the battery up
to voltage 0.5 V. Through above two standard of test
battery, it do not allow appearing leakage, put gas,
explosion, fire and produce evident deformation anomaly.
Figure 1 is high power 8Ah core 50% next public
discharge performance SOC> 75% (DOD)
4.5

3.5

I ......
--

3
2.5

1.5

0.5
o
0.5

1.5

2.5

Figure 1 high power 8Ah core 50% next public discharge performance
SOC> 75% (DOD)
B

The short-circuit test

In short circuit test, circuit may appear spray and


discharging. Usually should have a good protective
measure. Common test conditions for the battery should
have enough electricity, should be short-circuited batteries
poles 1 h. Allow leaking in room temperature, but battery
don't allow appearing fire or explosion.

C High temperature resistant test


The battery is forbidden into the fire, and the battery
should have proper storage and temperature conditions.
General high temperature resistant temperature testing
temperature divided into high temperature and low
temperature. High temperature test is put it into the fire.
Low temperature zone for 100 200 C. Low temperature
area, there are two ways: one is to put the test into boiling
water (100 C), maintain two hours, battery should be no
explosion leak; it is will be full of electric batteries in a
150 C constant temperature box keep 10 min, battery
should be no explosion.

The provIsions of the vibration resistance battery


performance test of the development of electric road
vehicles classified into three steps:
CD Use the manufacturers provide special charger,
according to the rules of charging method fully charged
batteries;
@Put the full of electric batteries installed in vibration
test bed, the battery to I3(A) is current discharge;
Make the battery vibrated frequency from 30 to
50HZ, the vibration direction of battery maximum
acceleration of 30 m/s2 time and discharging voltage
abnormal variations, leakage.
1) Lead-acid battery track simulation vibration test
In the test, better road and rough road surface the
simulation are 40 Km speed/h, off-road for 20 Km/h, test
time all is 30 minutes. From the curve of test could see, in
good road the battery voltage almost not change. But on
the rough road surface the battery voltage all have 0.4 V
some higher change than better road surface frequency. In
the process of test to touch the battery can't feel
temperature rise significantly. Observation battery shell
surface, found no electrolyte leakage. Because when the
test for single cells and ventilation, considering the actual
use of simulation conditions complexer than some other
interference factors, lead-acid battery electric vehicle in the
rough road surface and cross-country road, battery voltage
will have a big fluctuations, ventilated condition is bad, the
temperature will inevitably rise, which will influence the
electric vehicle driving reliability and security.
2) lead-acid battery collision test
The test is testing power battery system appearance and
change voltage in simulation of the electric vehicle
collision, and referring to the J1766: 1998 electric vehicles
SAE of electric vehicles and mixed with battery system
overall impact test procedures and related national
standards recommend. The test is in Taiwan, the vehicle
battery tighten determine vehicle collision speed is 50
Kmlh.

D Drilling test
Intervened by the impact of the sharp objects, battery
may be punctured, if the thing is Pierce, it will be short
circuit, bring certain danger, we should do drilling test, the
drill bit should be the conductivity, test conditions should
be for: radial drilling, allowing the battery leakage, fever,
but not allow explosion. Because the test is destructive
testing, it should have the safety measures and equipment
to ensure safety.
E

Mechanical testing

There are impact test and vibration test in commonly


used mechanical testing. According to GB/T18333.1-by
2001. In the(20 5)'C under the condition of the battery,
from the height of 1.0 m on board, and fell into two drop
test a direction, the battery electrolyte observation have
leaks out, explosion, does not produce evident deformation
defects.

Corrosion test

Corrosion test generally have electrochemical test


method. the battery will expose to test cases, and the
atomization of the test solution should to gush into test
box, fine mist weight in under the action of the surface of
the sample in uneven subsidence, the solution for 5% of
the salt solution, among which, the solid content no more
than 20 milligrams, PH value of 6.5
7.2. Test
temperature of the salt fog in the cabinet should be kept
constant. The battery in the salt fog for 48 h, after test,
battery capacity should have significantly reduced, the
shell metal parts should not multiple, could not have rust
holes and obvious point corrosion, leakage, not allowed
explosing

IV.

BA TTERY MANAGEMENT SYSTEM

In the use of the power battery of electric vehicle, must


make battery work in reasonable voltage, current,
temperature range, so the the use of power battery of
electric vehicle require effective management. If manage
badly, not only may significantly shorten the life of the
battery, may cause serious accidents such as fire.
Battery Management System (BMS) is hot
Management and technology of SOC estimate application

platform. For the safety of the battery BMS, optimize the


use and vehicle management strategy execution is
necessary.
The safety of the battery management refers to the
battery management system in the battery voltage, current,
temperature and the unsafe state of appear is to give timely
alarm and emergency handling.
A

The battery thermal management

The battery thermal management from the user of


thermal management perspective. To ensure that the
battery in the temperature of the appropriate work within
the scope of the system, including battery box, blower,
heat transfer medium, monitoring equipment parts. The
thermal management of batterys main functions: the
temperature of the battery monitoring and accurate
measurement; High temperature of the battery when
effective heat and ventilation; Low temperature rapid
heating, the battery can work normally; Harmful gas
produced the effective ventilation; Ensure the battery of
temperature field distribution.
1) To determine the optimal battery work range
The battery thermal management is one of the main
functions of the system, the different vehicles running
condition, ensure the safety of the battery in the
temperature range, and will keeps the temperature of the
battery run in the highest working range as far as possible.
So design the battery should determine the optimal battery
of working temperature range.
2) Heat transfer medium of choice
Heat transfer medium choice to the thermal
management system has great effect on the performance of
the heat transfer medium, when design thermal
management system, according to the former determine
the heat transfer medium is different, thermal management
system can be divided into the air cold and liquid cooling
and cooling way. Air cooling is the most simple way, just
let the air through the cell surface. Liquid cooling is
divided into direct contact and the direct contact with the
two ways of mineral oil can be used as a direct contact heat
transfer material, water can be used as the typical without
direct contact heat transfer medium.
B

battery state detection

Battery management system in the following situation


of alarm and do some management:
(l)The total battery voltage: when the battery voltage
less than 200 V shows low pressure. When the battery
voltage total more than 280 V stops charging.
(2)The cell battery voltage: cell voltage judgment was
divided into two parts:
a) The normal work of the single cells voltage range is
[10, 9 V] if it beyond the scope will make corresponding
hints.
b) The battery voltage difference between cell battery.
If the voltage exceeds o.s V will tip, and points out that the
error of monomer voltage.
(3)Current judgment: discharge current is too big, and
the electric vehicle batteries are very dangerous. The size
of the discharge current by load decision, safety. The flow,
battery management system will trigger relays, cut off the
battery directly connected to vehicles to ensure security.

(4)Remaining power judgment: power battery is less


than 30% in time, SOC remind the driver of the battery is
low.
(S)Temperature judgment: Judge temperature is mainly
refers to single cells of the body surface temperature. The
operating temperatures of different battery are not the
same. Lead-acid battery work 40 C
temperature.
Temperature is too low to remind drivers, the battery can't
work. The battery is beyond the normal range of high
temperature usually indicate that the battery is broken.
State detection is pointing out in real time, accurate and
timely state detection directly affect the battery and the
electric vehicle security issues is very important.

V.
A

THE ELECTRIC VEHICLE COLLISION OF SAFETY

The electric vehicle crash safety of hidden trouble

When the electric vehicle in collision, the battery will


bear huge impact load, and may crush, puncture, etc, the
resulting damage safety accident modes include:
(1) Fires and explosions
For sealed battery such as the nickel-metal hydride
battery, lithium ion battery, fuel cell storage tank, when the
vehicle is collision, even if the batteries were not affected
by extrusion, puncture and batteries due to damage internal
pressure is too high, battery production defect, may also
cause power battery explosion, burning. As the vehicle
collision, the battery was damaged, piercing damage, it
will led to the battery explosion directly.
(2)The electrolyte splash damage
Because the electric vehicles use the strong acid
electrolyte of power battery, when the electric vehicle
collision damage, leading to electrolyte splash to the whole
vehicle, lead to splash of injury.
(3) Mechanical damage
The electric vehicle in the collision damage include
body produce deformation damage, the steering wheel, the
collision of damage, power battery part of the move into
the damage.
(4) Electricity damage
The electric vehicle in collision could cause short
circuit and make the body charged, to crew member
produce shock damage.
B The countermeasures of electric vehicle collision
safety

The electric vehicle collision security is when the


electric vehicle collision accident occurred the electric
vehicle could impose effective protection to reduce
damage ability.
(1) Electric damage protection
When the electric vehicle in collision it can be able to
automatically cut off the power supply reliable. Disconnect
the battery voltage of the system, reduce the connection to
prevent damage from the human body electricity. The
power system of electric vehicle under the dangerous
conditions, the safety current should be less than 30 mAo
Power battery in dangerous conditions may appear short
circuit, short circuit will make great current in the circuit
even if short circuit overheating, so that the insulating
layer combustion cause burning accident, and passengers
may also contact charged body, cause the damage. To

prevent the damage, the electric vehicle charged body


should take the necessary measures.
To ensure the safety of the passengers, the high
pressure parts of electric vehicle necessary to have low
voltage control. Shall set up sensor monitoring when there
is electricity for metal chassis, in an emergency situation,
should be cut off the current immediately. The electric
vehicle, the door open the hood and the airbag collision
sensor type open air condition to the vehicle collision
detection under the condition of high voltage circuit, the
electric vehicle should be cut off immediately. And should
guarantee good insulation, and get an electric shock. When
appear short circuit can automatically disconnect.
(2)Burning, explosion protection
To prevent electric vehicle in the collision happened as
burning explosion accident, the electric vehicle in the
development and design process to strictly prohibited old
and new batteries, different capacity of the battery USES a
mixture. But also for electric vehicle charging, in the
course of driving should meet the following protective
system:
CDThe place may not have any vehicles of the potential
danger when gas gathered;
Don't allow cab and containers of hydrogen
concentration in more than 2% of the volume;
@The biggest gathered to gases shall conform to the
state standards related safety;
@Battery process vehicle manufacturers to designated
areas of gas discharge in the combustible gas
concentration;
@When battery, measuring factory regulations should
be in the areas of concentration of hydrogen exhaust,
conventional charging operation, should be below the
volume of a gas hydrogen concentration of 1%; During
charging happens (the vehicle) ventilation device failure,
charger damage, power battery terminals loose, ventilation
pipe fall off when a fault, such as hydrogen concentration
in the volume of a gas should be less than 2%.
The electric vehicle in charge and the normal
operation of the process should take corresponding
measures to limit the pressure inside the battery to prevent
explosion.
(J) In the provision of exhaust area may not have
electricity contact spark source, fuse spark source, brake
facings formulations, contact the brush spark source.
electrostatic discharge spark source and cigarettes, develop
a flame of fire, and light source spark source.
(3)Electrolyte leakage protection
Battery in dangerous conditions, such as collision,
extrusion and other reasons, usually result in electrolyte
leakage. In protection of electrolyte leakage, SAE 11766electric vehicle and hybrid electric vehicle battery system
with the collision test recommended procedures, made a
regulation:
CD The dangerous conditions, control of the vehicle
passengers electrolyte leakage quantity does not exceed
5.0 L; General electrolyte leakage from the crash test
vehicle movement, stop 30 min vehicle and vehicle flip
during the trial period income measures; @The dangerous
conditions, storage battery electrolyte cabin passengers
should not be produce; @ The dangerous conditions
storage battery electrolyte can't throw from the vehicle.

(4) Mechanical damage protection


In order to reduce the electric vehicle collision occurs
can take the following measures:
CD The optimization of the structure of the electric
vehicle design, improve electric vehicle body stiffness and
strength; The safety body; @Using seat belts and seat
belts device is in advance; @Use airbag; @The special
safety glass; The steering device and absorb energy (J)
The reasonable design of electric vehicle batteries
installation position; @ Improve the electric vehicle
batteries installed frame of bull ability, in the vehicle to the
battery in a collision had some restriction ability, prevent
battery dislocation or fly out happened, so as not to
damage the passengers.
VI.

CONCLUSION

In order to improve the security of electric vehicles,


when electric vehicle batteries are installed, on the one
hand, we should consider the structure space utilization,
but also from the vehicle safety Angle consideration, the
arrangement of the battery will try to decorate the battery
to small parts collision by chance. Because when the
electric vehicle collision, rolling accident, battery electric
vehicle safety become different from traditional vehicle,
the design of the battery holder must be considered the
battery have sufficient strength to withstand the impact of
the inertial force. Ensure the system not from body, more
into the cabin crew will not, and must be resistant to bump
the assessment and optimize performance. Through the
electric vehicle safety research, it is important for
promoting the electric vehicle in our country and the
expansion of further development and improvement of
electric vehicle safety standard and related laws and
regulations.
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