1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSURFACEVEHICLERECOMMENDEDPRACTICEJ2464 NOV2009 Issued 1999-03Revised 2009-11 Superseding J2464 MAR1999 (R) Electric and Hybrid Electric Vehicle Rechargeable EnergyStorage System (RESS) Safety and Abuse Testing RATIONAL
5、EAbuse testing is performed to characterize the response of a Rechargeable Energy Storage System (RESS) to off-normal conditions or environments. The primary purpose of abuse testing is to gather response information to external/internal inputs that are designed to simulate actual use and abuse cond
6、itions. This response information is used to expose the hazards, if any, associated with a given RESS under a given set of use and abuse conditions and to help quantify the hazard mitigation efforts that should be taken for a particular RESS design. The revisions are intended to expand the scope of
7、SAE J2464 to include other types of electric energy storage devices and vehicular applications, make the test results more quantitative as well as incorporate improvements in test procedures and data analysis. TABLE OF CONTENTS 1. SCOPE 31.1 Purpose . 32. REFERENCES 42.1 Applicable Publications . 42
8、.1.1 SAE Publications . 42.2 Related Publications . 42.2.1 Electrochemical Society Publications . 42.2.2 Sandia National Laboratories Publications . 42.2.3 AIHA Publication . 52.2.4 EUCAR Publication . 52.2.5 United Nations Publication 53. DEFINITIONS . 53.1 Active Protection Device . 53.2 Ambient T
9、emperature . 53.3 Battery . 53.4 Capacitor . 53.5 Capacity 53.6 Cell 53.7 Combustible and Flammable Liquids 63.8 Device Under Test (DUT) . 63.9 Effluent 63.10 Emergency Response Planning Guidelines, Level 2 (ERPG-2) . 63.11 Explosion . 63.12 Fire or Flame . 6Copyright SAE International Provided by I
10、HS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2464 Revised NOV2009 Page 2 of 333.13 Flammable Gas . 63.14 Flammable Solid . 63.15 Flash Point 63.16 Fully Charged 73.17 Fully Discharged . 73.18 Integrator . 73.19 Leak 73.20 LFL 73.21
11、Overcharge . 73.22 Percent of Overcharge 73.23 OSHA 73.24 Over Current Protection Device 73.25 Overdischarge. 73.26 Pack 73.27 Passive Protection Device 73.28 Release . 83.29 Reversal 83.30 RESS. 83.31 RESS Cell . 83.32 RESS Module 83.33 RESS Pack . 83.34 Rupture . 83.35 State of Charge (SOC) 83.36
12、Test Article 83.37 Thermal Runaway . 83.38 Thermal Stability Limit . 83.39 UFL 83.40 Venting 94. TECHNICAL REQUIREMENTS 94.1 General Test Guidelines . 94.1.1 Number, Condition, and Size of Batteries to be Tested . 94.1.2 Types of Abuse Tests Addressed in this Document . 104.1.3 Test Conditions and M
13、easurement Accuracies 114.1.4 Hazardous Substance Monitoring . 114.1.5 Flammability Determination 124.1.6 Identification of Severity 124.1.7 Measured Data 134.1.8 Test Plans and Reporting . 134.2 Hazardous Substance Monitoring Tests (Cell Level and Above) . 134.2.1 Test Description 134.2.2 Measured
14、Data 144.3 Mechanical Abuse Tests . 154.3.1 Shock Tests (Cell Level or Above) . 154.3.2 Drop Test (Pack Level Only) . 164.3.3 Penetration Test (Cell Level or Above) . 164.3.4 Roll-over Test (Module and Pack Level) . 174.3.5 Immersion Test (Module or Pack Level) . 174.3.6 Crush Test (Cell Level or Ab
15、ove) 184.4 Thermal Abuse Tests 194.4.1 High Temperature Hazard Test (Pack Module Level and Above) 194.4.2 Thermal Stability Test (Cell Level) 214.4.3 Cycling without Thermal Management (Module and Pack Level) 224.4.4 Thermal Shock Cycling (Cell Level or Above) 224.4.5 Passive Propagation Resistance
16、Test (Module or Pack Level) 234.5 Electrical Abuse Tests 244.5.1 Short Circuit Tests (Cell and Module or Pack) 244.5.2 Overcharge Test (Cell and Module or Pack) 26Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license f
17、rom IHS-,-,-SAE J2464 Revised NOV2009 Page 3 of 334.5.3 Overdischarge (Forced Discharge) Test (Cell Level and Module) . 274.5.4 Separator Shutdown Integrity Test . 285. NOTES 285.1 Marginal Indicia . 28APPENDIX A 29APPENDIX B 31TABLE 1 RECOMMENDED AND OPTIONAL ABUSE TOLERANCE TESTS, INCLUDING THE NU
18、MBEROF RESS CELLS, MODULES AND PACKS FOR EACH TEST 10TABLE 2 MEASUREMENT ACCURACIES . 11TABLE 3 HAZARD SEVERITY LEVELS AND DESCRIPTIONS (ADAPTED FROM EUCAR ANDSAND2005-3123) 12TABLE 4 SHOCK LEVELS AND DURATIONS 15TABLE 5 PENETRATION CHARACTERISTICS . 16FIGURE 1 EXAMPLE OF A CRUSH TEST PLATEN FOR MOD
19、ULES AND PACKS . 18FIGURE 2 PHOTOGRAPH OF AN EXAMPLE OF A CYLINDRICAL CRUSH TEST FIXTURE FOR CELLS 18FIGURE 3 RADIANT HEATING FIXTURE TEST FIXTURE 20FIGURE 4 SCHEMATIC REPRESENTATION OF CELL LOCATIONS 1 THRU 5 AT WHICH CELLS ARE TRIGGERED INTO THERMAL RUNAWAY CONDITION IN PASSIVE PROPAGATION TEST .
20、241. SCOPE This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. It describes a body of tests which may be used as needed for abuse testing of electric or hybrid electric vehicle Rechargeable Energy
21、 Storage Systems (RESS) to determine the response of such electrical energy storage and control systems to conditions or events which are beyond their normal operating range.Abuse test procedures in this document are intended to cover a broad range of vehicle applications as well as a broad range of
22、 electrical energy storage devices, including individual RESS cells (batteries or capacitors), modules and packs. This document applies to vehicles with RESS voltages above 60 volts. This document does not apply to RESS that uses mechanical devices store energy (e.g., electro-mechanical flywheels).
23、1.1 Purpose This document is designed to provide a common framework of tests to evaluate the response of various RESS technologies to abusive conditions. These tests are intended to characterize the RESS response to undesirable abusive conditions also termed “off-normal” conditions or environments t
24、hat may arise as a result of operator negligence, vehicle accidents, device or system defects, poorly informed or trained users or mechanics, failure of specific RESS control and support hardware, or transportation/handling incidents or accidents.Tests in this document represent conditions for which
25、 the RESS was not designed or intended for use, but can reasonably be expected to be encountered infrequently during field use.This document is not intended to certify the RESS for shipping. These tests were derived from Failure Mode and Effect Analysis, user input and historical abuse testing. The
26、outcome of testing shall be documented for use by potential users of the tested RESS. It is not the intent of this procedure to establish acceptance criteria since each application has its own unique safety requirements. Moreover, cell safety is only one component of the safety approach that will em
27、ploy active and passive protection devices such as thermal and electronic controls, state of health monitoring, automatic disconnects as well as ancillary support systems. Users of these technologies shall make their own determination as to what measures to take to ensure a sound application of said
28、 technology. The test data from SAE J2464 may be used as input to “Battery Safety and Hazards Risk Mitigation” approach that has been developed (see “Analysis of Battery Safety and Hazards Risk Mitigation”, Cyrus Ashtiani, ECS Trans. 11 (19), 1 (2008). Copyright SAE International Provided by IHS und
29、er license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2464 Revised NOV2009 Page 4 of 33The scope of this document is to evaluate the response to abusive conditions at the cell, module and pack levels of RESS integration. While the abusive conditio
30、ns developed in this test are intended to be representative of potential hazardous conditions in the vehicle environment, not all types of vehicle level hazards are within the scope of this document. The tests described in this document should be supplemented with additional testing (performed at th
31、e test sponsors or manufacturers discretion) based on their need for data and their determination of the most susceptible condition of the technology. The primary purpose of the tests is to gather response information to external/internal inputs. Specific tests and/or measurements in this document m
32、ay not be appropriate for some RESS technologies and designs if it can be demonstrated by the RESS users (or system integrators) that the test is not applicable or the results will be duplicated by other tests. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this
33、specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside U
34、SA), www.sae.org.SAE J1715 Hybrid Electric Vehicle (HEV) and Electric Vehicle (EV) Terminology SAE J1739 Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) SAE J1950 Proving Ground Ve
35、hicle Corrosion Testing SAE J2344 Guidelines for Electric Vehicle Safety 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this document. 2.2.1 Electrochemical Society Publications Available from the Electrochemical Society,
36、 65 South Main Street, Building D, Pennington, NJ 08534-2839, Tel: 609-737-1902, http:/www.ecsdl.org/vsearch/servlet/VerityServlet?KEY=ECSTF8 a flammable liquid has a flash point that is below 100 F (38 C). 3.8 Device Under Test (DUT) A general term used to describe the device being tested. This ter
37、m includes all levels of integration of the test article and can refer to a single unit (cell), a multiple unit assembly (module or pack), or a complete system. 3.9 Effluent Liquid or gas released when a RESS cell leaks or vents. 3.10 Emergency Response Planning Guidelines, Level 2 (ERPG-2) ERPG-2 l
38、evels are defined as the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 h without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individuals ability to take protective actio
39、n. This guideline is taken from the American Industrial Hygiene Association (http:/www.aiha.org/Content).3.11 Explosion Very fast release of energy sufficient to cause pressure waves and/or projectiles that may cause considerable structural and/or bodily damage, depending on the size of the RESS. Th
40、e kinetic energy of flying debris from the RESS may be sufficient to cause damage as well. 3.12 Fire or Flame Ignition and sustained combustion of flammable gas or liquid (approximately more than one second). Sparks are not flames.3.13 Flammable Gas The OSHA Hazard Communication Standard (29 CFR 191
41、0 is available athttp:/www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards or forms a range of flammable mixtures with air wider than twelve (12) percent by volume.“ Thus, a gas can be categorized as flammable if the gas burns in air at a concentration of less than 13% by volume or the
42、difference between the lower flammability limit (LFL) and the upper flammability limit (UFL) is greater than12% by volume.3.14 Flammable Solid The OSHA Hazard Communication Standard (29 CFR 1910 is available athttp:/www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards manufacturers input
43、 or initial screening tests shall be required to determine this. Further calculations will be done by the manufacturer in order to determine if any gas component exceeds ERPG-2 levels or falls into the concentration range between upper and lower flammability limits when mixed with air. The time reso
44、lution of such sampling is not specified because of the wide variability in test dynamics and release amounts/rates expected.For substances not considered hazardous by ERPG-2, the EPA reportable release limits are used as a reference for comparison purposes only.4.1.5 Flammability Determination Flam
45、mability should be measured whenever the Hazard Severity Level is to be determined during any test which may result in the release of potentially flammable materials. Flammability determination and spark ignition sources are not required for tests that are performed for other purposes, such as failu
46、re mode (tear down) or gas species analysis according to 4.1.4 (HAZARDOUS SUBSTANCE). The determination of flammability requires the presence of an ignition source in combination with fuel and oxidizer in concentrations that will support combustion. A fire or flame will not be observed if any of the
47、se elements are absent. Credible abuse environments would likely include a spark source. For this reason, it is recommended that, when determining the Hazard Severity Level during any test described in this document (see Table 3), a continuous spark source (at least 2 sparks/sec with sufficient ener
48、gy to ignite natural gas) be used during tests that are likely to result in venting of the RESS. The flammability of any expelled materials will be determined using external ignition sources in at least two separate locations around the RESS to evaluate flammability of different fuel to air ratios.
49、Location of spark sources will be documented. 4.1.6 Identification of Severity RESS response to abusive tests will be determined. Severity level described in Table 3 will be reported for each test and this information can be used in the Battery Safety and Hazards Risk Mitigation approach.TABLE 3 - HAZARD SEVERITY LEVELS AND DESCRIPTIONS (ADAPTED
