Ev Meeting Presentation 10-09 Final
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Keep Up With the Speed of Electric Vehicle Technologies
www.intertek.com
Introductions
Larry Todd – Safety Certifications Tom O’Hara – Battery Performance Mike Koffink – Automotive EMC Alex Porter - MC
We will have question and answer sessions after each presentation www.intertek.com
Larry Todd – Safety Certifications
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Electrical Product Safety Testing and Certification
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Agenda •
Product safety certifications - What requires them and who enforces them - What Are NRTL’s and who is acceptable to list products
•
Additional rules for car manufacturers - What is the NEC? - Who are the AHJ’s and all these local inspectors?
• •
What does the NEC require (Article 625)?
• •
What about Canadian requirements?
What Standards are used for evaluation and certification of products for the US?
What about the rest of the world? www.intertek.com
Product Safety Certifications • •
Product Safety Certifications in the U.S. are called Listings Listings are typically required for three reasons: 1. In the workplace, OSHA regulations require that all equipment covered by a listing standard be listed if an employee is going to use it. 2. For most other installations, the National Electrical Code (NFPA 70) requires either listing or approval by the AHJ (Authority Having Jurisdiction) 3. Many companies want their products listed to help meet liability insurance requirements
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Product Safety Certifications •
Listings provide the following:
1. An evaluation to a nationally recognized product safety standard by a third party organization trained in looking at equipment for reduction of fire, shock and personal injury hazards. 2. Manufacturer is audited at least 4 times a year to insure the product being labeled is the same as the tested and evaluated sample. 3. Listing Labs provide support when there are questions in the field.
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Product Safety Certifications •
Because of OSHA, there is a national accreditation for Product Safety Certification Labs, called NRTL (Nationally Recognized Test Lab)
•
Where the NEC calls out a recognized lab, AHJ’s and States accept NRTL’s by OSHA, in addition to others in some cases
•
There are 16 NRTL’s, some of which have accreditation in only a few standards, companies like Intertek (ETL Mark), UL, CSA, TUV have a large set of standards recognized by OSHA
www.intertek.com
Additional Rules for Car Makers •
Now that automobiles are being connected to the electrical system, additional requirements need to be considered for the OEM, customer and manufacturers of electrical support equipment
•
The NEC is the code or law that the U.S. uses to determine the proper way of installing and using electrical equipment and wiring in the U.S.
•
The AHJ (local building official or electrical inspector) has the final say in the acceptance of equipment and electrical installations
•
The NEC tells the electrical inspector that one way of knowing a piece of equipment is ok is to look for the listing mark of an approved lab (think NRTL)
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Additional Rules for Car Makers •
The NEC also, in some cases tells the inspector that the only way to accept a piece of equipment is to look for the listing Mark.
•
In the case of Electric Vehicle Charging Systems Article 625.5 indicates that all electrical materials, devices, fittings and associated equipment shall be listed or labeled.
•
We will talk more about the specific requirements, but this means that the charger and the wiring to it need to be installed in accordance with the NEC and this includes the more powerful recharging equipment that might even need a new branch circuit to be installed in the user’s garage
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Additional Rules for Car Makers •
A coordinated effort is needed to make sure the equipment used in the charging of the vehicle and the supply to this equipment complies with certification requirements and also the proper wiring methods for installation
•
Electrical Inspectors make sure that electrical installations are put in properly and in accordance with the NEC and any local laws and protect users and properly owners from mistakes that could cause fires or shocks for the users.
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Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - 625.1 Scope – The provisions of this article cover the electrical conductors and equipment external to an electric vehicle that connect an electric vehicle to a supply of electricity by conductive or inductive means, and the installation of equipment and devices relate to electric vehicle charging - 625.2 Electric Vehicle - …On Road use, such as passenger automobiles, buses, trucks, vans, neighborhood electrical vehicles and the like, primarily powered by an electric motor that draws current from a rechargeable storage battery, fuel cell, photovoltaic array or other source of electric current - UL Standard UL 2202 further includes hybrid electric vehicles and plug in versions of these vehicles
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Article 625 of NEC
Article 625 is Electric Vehicle Charging Systems - 625.4 Voltages – Nominal AC voltages used to supply the equipment covered by this section are 120, 120/240, 208Y/120, 240, 480Y/277, 480, 600Y/347 and 600V - 625.5 Listed or Labeled –All electrical materials, devices, fittings, and associated equipment shall be listed or labeled. - 625.9 – Electric Vehicle Coupler has several requirements. Compliance and listing to UL 2251 will meet all these code requirements - 625.13-625.19 Covers the Construction of the Equipment. Listing to UL 2202 covers all these requirements
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Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - 625.21-625.25 – Cover the Control and Protection of the equipment and people using the equipment. Again listing of the equipment to UL 2202 will cover these requirements with the additional consideration of UL 2231-1 and UL 2231-2 which covers the Personnel Protection Systems required to be in the Charging System - 625.28 – 625.30 Covers the locations the equipment can be located and any ventilation required in the locations. Indoor and Outdoor rules (which are covered by the standards) but also mounting height requirements and specific ventilation requirement and several ways to meet those are indicated.
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Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - This Article of the NEC identifies that the equipment must be listed and gives the general requirements for minimum equipment requirements and installation requirements - Even without the listing requirement, it would be difficult for a manufacturer or an AHJ to know if something complies with these requirements without a standard to design the equipment to and for a third party to verify compliance
•
Next we will take a look at the Standards used to certify equipment
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Safety Certification Standards •
Basic Standard for the Charging System Equipment is UL 2202 - Covers the charging systems that are either inductive or conductive and supplied by 600V or less. Equipment may be on-board the vehicle or off-board. - Includes: - Electrical construction - Mechanical construction - Protection of users against injury - Normal performance - Abnormal operations - Optional ratings such as harmonic distortion
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Safety Certification Standards •
In conjunction with UL 2202, UL 2231-1 and UL 2231-2 are used to evaluate the Personnel Protection Systems for Electric Vehicles - These standards look at the systems and devices that are intended to reduce the risk of electric shock to the used from accessible parts, in grounded or isolated circuits for charging electric vehicles - Evaluated with the charging circuits to make sure they work with the particular system being designed
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Safety Certification Standards •
For the plugs, receptacle and couplers for Electric Vehicles, the standard is UL 2251. - These requirements cover plugs, receptacles, vehicle inlets and connectors rated up to 800 Amperes and up to 600V ac or dc and intended for conductive connection systems for EVs - This standard does not cover normal cords, cord sets, (extension cords) and other types of normal cords covered by other standards - The couplers described and evaluated in this standard are in the configurations from SAE J1772
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Safety Certification Standards •
Special cases might need special combinations of standards. These standard should cover most of the equipment that will go with the chargers needed when simple plug in the wall is not sufficient.
•
Cables used as part of the system need to be type EV, EVJ, EVE, EVJE, EVT, EVJT - All suitable for wet locations; Listed to UL 62 Flexible Cords and Cables)
•
Power pedestals that just supply normal power (as in parking lots, etc) are covered by UL 231 Power Outlets
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Safety Certification Standards •
Batteries - Whether or not a battery is vented or not can effect how the system is evaluated according to the NEC - Classification of the batteries for this feature is also available - Electric vehicle battery packs employing non-vented batteries or batteries whose chemistry cannot produce hydrogen are investigated by inspection of the manufacturer's product - Electric vehicle battery packs employing batteries that can emit hydrogen, such as valve regulated or vented lead-acid or nickel-metal hydride batteries, are subjected to investigation in accordance with SAE Recommended Practice J1718 (1994), "Measurement of Hydrogen Gas Emission From Battery-Powered Cars and Light Trucks During Battery Charging." Battery systems which do not produce hydrogen concentrations in excess of 1% (25% of the lower flammability limit) are considered in compliance with the requirements of Article 625 of the NEC. www.intertek.com
Safety Certification Standards •
Canadian listings are different than U.S. Accreditation is by SCC (Standard Council of Canada). Most of the same companies are also accredited by SCC for Canada.
• •
Listing marks will indicate Canadian approval. CSA Standard for the Charging Equipment is CSA C22.2 #107.1, which is the standard for General Use Power Supplies
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Safety Certification Standards •
European Requirements for Safety are based on appropriate Directives and when the product is determined to comply, can be marked with the “CE” Mark which allows entry in the EU and free movement between European countries
•
A full program of necessary testing and evaluation can be provided based on a combination of directives and appropriate European norms.
•
Note that this Mark is for Europe and does not cover US requirements.
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Special Circumstances •
If you find yourself in a special circumstance with a new product or one not yet listed and need to install…..
•
The same labs that do the listing can do Field Labeling. It is possible in limited situations where the installation site is known to quickly determine basic compliance with the rules and working with the AHJ get acceptance for an installation using the Labeled requirement rather than the “listing” requirement.
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Summary •
For EV, listing of all equipment going to attach to the building wiring is needed
•
Listing also provides the manufacturer with help in meeting the requirements so that when you sell your product you can be assured of acceptance in the field
•
This electrical safety evaluation is one part of the overall testing needed
•
Listing to the appropriate UL and CSA standards will allow installation of the charging equipment in accordance with the National Electrical Code
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Questions? Next up – Battery Performance
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Tom O’Hara – Battery Performance
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Automotive Testing Expo: Performance, Durability and Abuse Testing of Batteries
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Agenda
Introduction
• •
DOE Goals Automotive Applications
Battery Chemistries Performance / Durability / Safety
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DOE FreedomCAR Goals
2010 FreedomCAR Goal:
• • •
25 kW Power-Assist (18 second pulse) $20 per kW Battery Cost $500
Reference: Toyota Prius has 25kW, 1.2 kWh NiMH, est. cost $900 to $1500
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DOE FreedomCAR Goals
2014 DOE PHEV Goal:
• • • •
10, 40 mile Capable PHEV Battery Cost $500 per kWh PHEV 10 = $1,700 PHEV 40 = $3,400
Reference: Chevy Volt, 16 kWh battery (8 kWh used), est. cost $8000
Note: EV at 20 kWh cost = $10,000
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Automotive Applications
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Automotive Applications
SLI: Starting / Lighting / Ignition HEV: Hybrid Electric Vehicle (Micro, Mild, Strong) PHEV: Plug-In Hybrid Electric Vehicle EREV: Extended Range Electric Vehicle EV: Electric Vehicle
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Automotive Applications
US Justification?
Cost and payback European Justification?
Reduced CO2 emissions
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Battery Chemistries
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH 2
1.2
35 (80)
75
Wh/l
70 (115)
240 (300)
Specific Power
W/kg
200
850
Cycle life (100% DOD)
cycles
250 (800)
450
Calendar life
yrs
2-15
4-10
2-8
10-30
Self discharge (% per month at 20C)
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH
Li-Ion
2
1.2
2-4
35 (80)
75
150 (240)
Wh/l
70 (115)
240 (300)
400 (450)
Specific Power
W/kg
200
850
1500
Cycle life (100% DOD)
cycles
250 (800)
450
1000
Calendar life
yrs
2-15
4-10
2-5, (10?)
2-8
10-30
2-10
Self discharge (% per month at 20C)
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH
Li-Ion
Ni/Zn
Ag/Zn
2
1.2
2-4
1.65
1.5
35 (80)
75
150 (240)
60
200
Wh/l
70 (115)
240 (300)
400 (450)
170
460
Specific Power
W/kg
200
850
1500
300
500
Cycle life (100% DOD)
cycles
250 (800)
450
1000
200
100 (300)
Calendar life
yrs
2-15
4-10
2-5, (10?)
??
??
2-8
10-30
2-10
<20
5
Self discharge (% per month at 20C)
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Battery Chemistries - Applications
Lead Acid
• • •
SLI, micro HEV Global Market Leader ($ Sales) Still active Research and Development
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Battery Chemistries - Applications
Nickel Metal Hydride (NiMH)
• • • •
Dominates HEV (Panasonic 80% market share) May move into PHEV HEV application utilizes only 30% of NiMH capacity (Charge Sustaining) 300,000 cycles expected
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Battery Chemistries - Applications
Lithium Ion
• •
HEV, PHEV, EV For PHEV, utilizes 70% capacity
• • •
In Charge Sustaining Mode: 300,000 cycles In Charge Depletion Mode: 5,000 deep discharge cycles
For EV, near full 100% SOC
•
Charge Depletion Mode: 1,000+ deep discharge cycles
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Performance
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Performance - General
From a Performance perspective, DOE Goals are met.
Issue now is Cost, Durability (Reliability), and Safety.
The remainder of this presentation will focus on Li-Ion Battery Chemistry
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Performance - General
TRUE or FALSE: All Li-Ion batteries are alike?
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Performance - General
Answer: FALSE
Some perspective… Energizer/Duracell Zn/MnO2 (Alkaline Batteries) -- $Millions are spent in Advertising -- Distinctions are minor -- But, each market share valued at over $20 Million, so…
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Performance - General
Li-Ion comes in a variety of chemistries
Significant distinctions
• • • • •
Anode Chemistries Cathode Chemistries Construction (Form Factor) Other Construction (electrolyte, separator, etc.) Manufacturing Expertise (relates to battery capacity and safety)
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Performance - Anode Chemistry
LTO Anode
Si/Sn Anode
Voltage
▼
(▼ ▼)
Specific energy
◊
(◊ ◊)
Energy density
◊
(◊ ◊)
▲▲
?
Cyclelife (100% DoD)
▲
?
Low temp operation
▲
?
Charge time
▲▲
?
Recycleability
▲▲
?
▲
▲
▼▼
(▼ ▼)
Max discharge rate
Safety Cost (bare cell)
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Performance – Cathode Chemistry
LiFePO4, LiMn2O4
NCA, NCM, LVP
Voltage
▼
(▲ ▲)
Specific energy
▼
▲▲
Energy density
▼
▲▲
Max discharge rate
◊
▲
Cyclelife (100% DoD)
◊
▲
Low temp operation
◊
◊
Charge time
◊
◊
Recycleability
◊
▲
Safety
▲▲
▲
Cost (bare cell)
▲▲
▼▼
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Performance – Construction
Form Factor: Advantage / Disadvantages of various Li-Ion Form Factors
• • •
Cylindrical Prismatic Layered
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Performance – Construction
Cylindrical Can:
• • •
Spiral wound electrodes High volume production Strong track record, commercial history
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Performance – Construction
Prismatic Can:
• •
Flattened spiral would or parallel plate electrodes Improved heat rejection from inner core (Safety and Performance Advantage)
• •
Improved high power versus cylindrical Lower cost, modular Battery Design
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Performance – Construction
Layered (soft package):
• • •
Stacked layers, laminated construction Further improved thermal management Flexible
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Performance – Other Construction
Electrolyte:
• • •
Non-flammable Anode reactivity (SEI concerns) High Voltage stability
Separator:
• •
Thermal shutdown (watch for shrinkage) Puncture resistance (internal shorting)
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Performance – Manufacturing
Manufacturing Expertise:
• •
Manufacturer A vs B Manufacturer A, Lot to Lot Variation
Manufacturing Controls
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Durability (Reliability)
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Durability – General Concerns
Performance Variables:
• • •
DOD (Depth of Discharge on cycling) C Rate Temperature (Thermal Management)
Mercedes S 400 HYBRID (battery is cooled by the A/C coolant) (maintains operating temperature at 10C to 30C) (50C max, 40C practical max)
Parking Lot in Phoenix www.intertek.com
Durability – End of Life
Li-Ion End of Life Causes:
• • • •
Lithium plating reduces anode charge reserve Impedance rise at cathode Soft shorts Capacity loss (Li consumption at SEI)
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Durability – Requirements
Cycle Life Calendar Life
Temperature Effects
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Durability – Temperature Effect
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Safety
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Safety – General Test Requirements • • • • • • • •
Controlled Crush Penetration Drop Immersion Roll-over Simulation Mechanical Shock Thermal Stability Simulated Fuel Fires
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• • • • • • • •
Elevated Temperature Storage Rapid Charge/Discharge Thermal Shock Cycling Overcharge / Overvoltage Short Circuit Overdischarge / Voltage Partial Short Circuit Altitude simulation
Safety – General Test Requirements
Laptop and Cell Phone versus Automotive (Distinctions)
• •
Drop, Shock, Vibration, Crush
Industry need for improved, meaningful Safety Tests
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Safety – Laptop Perspective (18650)
Spiral Wound, Cylindrical (Large Volume Commercial cells):
Incident rate is one in 5 to 10 million Layered Constructions (Large Format Automotive):
Incident rate is unknown
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Safety – Failure Mechanism
Mechanism for 18650 field failures:
• •
Mechanical grinding (charge/discharge volume changes) Internal Short Circuit
Failures occur either early in life (first few cycles) or late in life (>50 cycles)
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding: Internal short must meet Energy & Power threshold levels for Thermal Runaway
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding: Internal short must meet Energy & Power threshold levels for Thermal Runaway
Here, cathode chemistry is not the prime factor!
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Safety – Failure Mechanism
Still, much safety related cathode research continues…
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Safety – Cathode Comparisons
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Safety – Failure Mechanism
What are the failure mechanisms for Large Format Automotive???
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Summary
DOE’s Performance based Goals for PHEV have been reached Battery / System Cost must be reduced Cycle Life and Calendar Life remain uncertain Thermal Management is critical to long term performance and durability The industry needs improved, meaningful safety tests
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Questions? Next Up – Automotive EMC
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Michael Koffink – Automotive EMC
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Automotive Testing Expo: EMC testing and Electric Vehicles
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Agenda
Introduction
• • •
The current state of standards New technologies bringing about change? What does this mean to the test lab?
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What is EMC testing?
•
Electro magnetic Compatibility testing is necessary to ensure that all vehicle components do not generate high levels of RF interference and are in turn immune to it as well.
• • • •
Radiated and Conducted Emissions Transients ESD Very important in the automotive realm-Performance and Safety demands it
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Automotive EMC Regulations- US
• •
Most OEM’s have their own test standards
• •
Intentional radiators must meet CFR 47 Part 15C.
•
SAE standards exist as guidance for non-OE devices
USA- FCC has automotive devices on their exemption list for unintentional radiators.
FCC leaves it to the OEMs to enforce EMC through their own standards
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Automotive EMC Regulations- EU • •
OEMs have own standards
• •
“Old Approach Directive” Requires Type approval
E and e Mark scheme-Automotive EMC Directive2004/104/ec
Also ECE 324 Regulation 10 03 governed by UN
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Current Standards •
These automotive EMC standards were developed over the years based on historical experiences with internal combustion engine vehicles and the electronics sub assemblies that are associated with them.
•
For the most part OEM’s and government regulators have done a good job trying to keep up with technical changes in component and accessory technology and addressing it with standard updates and careful test planning.
•
Some methodology standardization…CISPR 25 for radiated emissions as example
•
But…. The development of electric vehicles is rapidly evolving. A surge of technical changes could be inevitable
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EV and HEV- hurdles • • • • • • • • • • •
Higher buss voltages up to 900V Motor drives Unique battery monitoring and charging circuitry Hi efficiency low power concepts for lighting Weight a factor Filtering techniques More shielding Conducted emissions issues Upgrade buss communication New private players in the industry Some manufacturers of sought after technology new to the demand of automotive industry
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EV and HEV- more hurdles the PEV • • •
Plug- ins!!?
•
Cross over Standards from the household and industrial sectors
•
There are standards out there being developed but not yet harmonized
Charging?? What does this mean for power grid superstructure around the globe?
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EV and HEV- industry awareness •
Test Labs need to stay tuned for changes in rules as well as test methodology
•
Become more involved than ever in helping trouble shoot problems. Expect more diagnostics and engineering evaluation
• • •
Clients want answers Full vehicle testing may become more common Expect cross over work from Military sector
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Questions?
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Additional Automotive Testing Capabilities
•Accelerated Stress Testing (AST) •Airbag Deployment •Analytical (Chem Lab) Testing •Audio Testing •Buzz Squeak & Rattle (BSR) •Dynamometer-based Engine Testing •Electronics Testing •EMC Testing •Environmental Conditioning •Failure Analysis •Field Evaluation Services •Fuels & Lubricants Testing •Laboratory Management •Lighting/Photometrics
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•Live Fuel Materials Testing •Materials Testing •Performance Testing •Product Evaluation and •Durability Testing •Road Simulation Testing •SHED Testing •Systems Certification •Validation Engineering •Training/Consulting •Vehicle Testing •Vehicle Fuel System Testing •Vibration (Single & Multi-Axis) •VOC Testing
Global Network: Intertek Group Countries
110
Locations
1030
24,000
Floated May 2002 – LSE: ITRK FTSE 100, Support Services Sector
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Staff
Your premier certification and testing partner
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Thank You
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Introductions
Larry Todd – Safety Certifications Tom O’Hara – Battery Performance Mike Koffink – Automotive EMC Alex Porter - MC
We will have question and answer sessions after each presentation www.intertek.com
Larry Todd – Safety Certifications
www.intertek.com
Electrical Product Safety Testing and Certification
www.intertek.com
Agenda •
Product safety certifications - What requires them and who enforces them - What Are NRTL’s and who is acceptable to list products
•
Additional rules for car manufacturers - What is the NEC? - Who are the AHJ’s and all these local inspectors?
• •
What does the NEC require (Article 625)?
• •
What about Canadian requirements?
What Standards are used for evaluation and certification of products for the US?
What about the rest of the world? www.intertek.com
Product Safety Certifications • •
Product Safety Certifications in the U.S. are called Listings Listings are typically required for three reasons: 1. In the workplace, OSHA regulations require that all equipment covered by a listing standard be listed if an employee is going to use it. 2. For most other installations, the National Electrical Code (NFPA 70) requires either listing or approval by the AHJ (Authority Having Jurisdiction) 3. Many companies want their products listed to help meet liability insurance requirements
www.intertek.com
Product Safety Certifications •
Listings provide the following:
1. An evaluation to a nationally recognized product safety standard by a third party organization trained in looking at equipment for reduction of fire, shock and personal injury hazards. 2. Manufacturer is audited at least 4 times a year to insure the product being labeled is the same as the tested and evaluated sample. 3. Listing Labs provide support when there are questions in the field.
www.intertek.com
Product Safety Certifications •
Because of OSHA, there is a national accreditation for Product Safety Certification Labs, called NRTL (Nationally Recognized Test Lab)
•
Where the NEC calls out a recognized lab, AHJ’s and States accept NRTL’s by OSHA, in addition to others in some cases
•
There are 16 NRTL’s, some of which have accreditation in only a few standards, companies like Intertek (ETL Mark), UL, CSA, TUV have a large set of standards recognized by OSHA
www.intertek.com
Additional Rules for Car Makers •
Now that automobiles are being connected to the electrical system, additional requirements need to be considered for the OEM, customer and manufacturers of electrical support equipment
•
The NEC is the code or law that the U.S. uses to determine the proper way of installing and using electrical equipment and wiring in the U.S.
•
The AHJ (local building official or electrical inspector) has the final say in the acceptance of equipment and electrical installations
•
The NEC tells the electrical inspector that one way of knowing a piece of equipment is ok is to look for the listing mark of an approved lab (think NRTL)
www.intertek.com
Additional Rules for Car Makers •
The NEC also, in some cases tells the inspector that the only way to accept a piece of equipment is to look for the listing Mark.
•
In the case of Electric Vehicle Charging Systems Article 625.5 indicates that all electrical materials, devices, fittings and associated equipment shall be listed or labeled.
•
We will talk more about the specific requirements, but this means that the charger and the wiring to it need to be installed in accordance with the NEC and this includes the more powerful recharging equipment that might even need a new branch circuit to be installed in the user’s garage
www.intertek.com
Additional Rules for Car Makers •
A coordinated effort is needed to make sure the equipment used in the charging of the vehicle and the supply to this equipment complies with certification requirements and also the proper wiring methods for installation
•
Electrical Inspectors make sure that electrical installations are put in properly and in accordance with the NEC and any local laws and protect users and properly owners from mistakes that could cause fires or shocks for the users.
www.intertek.com
Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - 625.1 Scope – The provisions of this article cover the electrical conductors and equipment external to an electric vehicle that connect an electric vehicle to a supply of electricity by conductive or inductive means, and the installation of equipment and devices relate to electric vehicle charging - 625.2 Electric Vehicle - …On Road use, such as passenger automobiles, buses, trucks, vans, neighborhood electrical vehicles and the like, primarily powered by an electric motor that draws current from a rechargeable storage battery, fuel cell, photovoltaic array or other source of electric current - UL Standard UL 2202 further includes hybrid electric vehicles and plug in versions of these vehicles
www.intertek.com
Article 625 of NEC
Article 625 is Electric Vehicle Charging Systems - 625.4 Voltages – Nominal AC voltages used to supply the equipment covered by this section are 120, 120/240, 208Y/120, 240, 480Y/277, 480, 600Y/347 and 600V - 625.5 Listed or Labeled –All electrical materials, devices, fittings, and associated equipment shall be listed or labeled. - 625.9 – Electric Vehicle Coupler has several requirements. Compliance and listing to UL 2251 will meet all these code requirements - 625.13-625.19 Covers the Construction of the Equipment. Listing to UL 2202 covers all these requirements
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Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - 625.21-625.25 – Cover the Control and Protection of the equipment and people using the equipment. Again listing of the equipment to UL 2202 will cover these requirements with the additional consideration of UL 2231-1 and UL 2231-2 which covers the Personnel Protection Systems required to be in the Charging System - 625.28 – 625.30 Covers the locations the equipment can be located and any ventilation required in the locations. Indoor and Outdoor rules (which are covered by the standards) but also mounting height requirements and specific ventilation requirement and several ways to meet those are indicated.
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Article 625 of NEC •
Article 625 is Electric Vehicle Charging Systems - This Article of the NEC identifies that the equipment must be listed and gives the general requirements for minimum equipment requirements and installation requirements - Even without the listing requirement, it would be difficult for a manufacturer or an AHJ to know if something complies with these requirements without a standard to design the equipment to and for a third party to verify compliance
•
Next we will take a look at the Standards used to certify equipment
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Safety Certification Standards •
Basic Standard for the Charging System Equipment is UL 2202 - Covers the charging systems that are either inductive or conductive and supplied by 600V or less. Equipment may be on-board the vehicle or off-board. - Includes: - Electrical construction - Mechanical construction - Protection of users against injury - Normal performance - Abnormal operations - Optional ratings such as harmonic distortion
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Safety Certification Standards •
In conjunction with UL 2202, UL 2231-1 and UL 2231-2 are used to evaluate the Personnel Protection Systems for Electric Vehicles - These standards look at the systems and devices that are intended to reduce the risk of electric shock to the used from accessible parts, in grounded or isolated circuits for charging electric vehicles - Evaluated with the charging circuits to make sure they work with the particular system being designed
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Safety Certification Standards •
For the plugs, receptacle and couplers for Electric Vehicles, the standard is UL 2251. - These requirements cover plugs, receptacles, vehicle inlets and connectors rated up to 800 Amperes and up to 600V ac or dc and intended for conductive connection systems for EVs - This standard does not cover normal cords, cord sets, (extension cords) and other types of normal cords covered by other standards - The couplers described and evaluated in this standard are in the configurations from SAE J1772
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Safety Certification Standards •
Special cases might need special combinations of standards. These standard should cover most of the equipment that will go with the chargers needed when simple plug in the wall is not sufficient.
•
Cables used as part of the system need to be type EV, EVJ, EVE, EVJE, EVT, EVJT - All suitable for wet locations; Listed to UL 62 Flexible Cords and Cables)
•
Power pedestals that just supply normal power (as in parking lots, etc) are covered by UL 231 Power Outlets
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Safety Certification Standards •
Batteries - Whether or not a battery is vented or not can effect how the system is evaluated according to the NEC - Classification of the batteries for this feature is also available - Electric vehicle battery packs employing non-vented batteries or batteries whose chemistry cannot produce hydrogen are investigated by inspection of the manufacturer's product - Electric vehicle battery packs employing batteries that can emit hydrogen, such as valve regulated or vented lead-acid or nickel-metal hydride batteries, are subjected to investigation in accordance with SAE Recommended Practice J1718 (1994), "Measurement of Hydrogen Gas Emission From Battery-Powered Cars and Light Trucks During Battery Charging." Battery systems which do not produce hydrogen concentrations in excess of 1% (25% of the lower flammability limit) are considered in compliance with the requirements of Article 625 of the NEC. www.intertek.com
Safety Certification Standards •
Canadian listings are different than U.S. Accreditation is by SCC (Standard Council of Canada). Most of the same companies are also accredited by SCC for Canada.
• •
Listing marks will indicate Canadian approval. CSA Standard for the Charging Equipment is CSA C22.2 #107.1, which is the standard for General Use Power Supplies
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Safety Certification Standards •
European Requirements for Safety are based on appropriate Directives and when the product is determined to comply, can be marked with the “CE” Mark which allows entry in the EU and free movement between European countries
•
A full program of necessary testing and evaluation can be provided based on a combination of directives and appropriate European norms.
•
Note that this Mark is for Europe and does not cover US requirements.
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Special Circumstances •
If you find yourself in a special circumstance with a new product or one not yet listed and need to install…..
•
The same labs that do the listing can do Field Labeling. It is possible in limited situations where the installation site is known to quickly determine basic compliance with the rules and working with the AHJ get acceptance for an installation using the Labeled requirement rather than the “listing” requirement.
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Summary •
For EV, listing of all equipment going to attach to the building wiring is needed
•
Listing also provides the manufacturer with help in meeting the requirements so that when you sell your product you can be assured of acceptance in the field
•
This electrical safety evaluation is one part of the overall testing needed
•
Listing to the appropriate UL and CSA standards will allow installation of the charging equipment in accordance with the National Electrical Code
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Questions? Next up – Battery Performance
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Tom O’Hara – Battery Performance
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Automotive Testing Expo: Performance, Durability and Abuse Testing of Batteries
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Agenda
Introduction
• •
DOE Goals Automotive Applications
Battery Chemistries Performance / Durability / Safety
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DOE FreedomCAR Goals
2010 FreedomCAR Goal:
• • •
25 kW Power-Assist (18 second pulse) $20 per kW Battery Cost $500
Reference: Toyota Prius has 25kW, 1.2 kWh NiMH, est. cost $900 to $1500
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DOE FreedomCAR Goals
2014 DOE PHEV Goal:
• • • •
10, 40 mile Capable PHEV Battery Cost $500 per kWh PHEV 10 = $1,700 PHEV 40 = $3,400
Reference: Chevy Volt, 16 kWh battery (8 kWh used), est. cost $8000
Note: EV at 20 kWh cost = $10,000
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Automotive Applications
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Automotive Applications
SLI: Starting / Lighting / Ignition HEV: Hybrid Electric Vehicle (Micro, Mild, Strong) PHEV: Plug-In Hybrid Electric Vehicle EREV: Extended Range Electric Vehicle EV: Electric Vehicle
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Automotive Applications
US Justification?
Cost and payback European Justification?
Reduced CO2 emissions
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Battery Chemistries
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH 2
1.2
35 (80)
75
Wh/l
70 (115)
240 (300)
Specific Power
W/kg
200
850
Cycle life (100% DOD)
cycles
250 (800)
450
Calendar life
yrs
2-15
4-10
2-8
10-30
Self discharge (% per month at 20C)
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH
Li-Ion
2
1.2
2-4
35 (80)
75
150 (240)
Wh/l
70 (115)
240 (300)
400 (450)
Specific Power
W/kg
200
850
1500
Cycle life (100% DOD)
cycles
250 (800)
450
1000
Calendar life
yrs
2-15
4-10
2-5, (10?)
2-8
10-30
2-10
Self discharge (% per month at 20C)
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Battery Chemistries
Pb/Ac Nominal Voltage
V
Specific energy
Wh/kg
Energy density
NiMH
Li-Ion
Ni/Zn
Ag/Zn
2
1.2
2-4
1.65
1.5
35 (80)
75
150 (240)
60
200
Wh/l
70 (115)
240 (300)
400 (450)
170
460
Specific Power
W/kg
200
850
1500
300
500
Cycle life (100% DOD)
cycles
250 (800)
450
1000
200
100 (300)
Calendar life
yrs
2-15
4-10
2-5, (10?)
??
??
2-8
10-30
2-10
<20
5
Self discharge (% per month at 20C)
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Battery Chemistries - Applications
Lead Acid
• • •
SLI, micro HEV Global Market Leader ($ Sales) Still active Research and Development
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Battery Chemistries - Applications
Nickel Metal Hydride (NiMH)
• • • •
Dominates HEV (Panasonic 80% market share) May move into PHEV HEV application utilizes only 30% of NiMH capacity (Charge Sustaining) 300,000 cycles expected
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Battery Chemistries - Applications
Lithium Ion
• •
HEV, PHEV, EV For PHEV, utilizes 70% capacity
• • •
In Charge Sustaining Mode: 300,000 cycles In Charge Depletion Mode: 5,000 deep discharge cycles
For EV, near full 100% SOC
•
Charge Depletion Mode: 1,000+ deep discharge cycles
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Performance
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Performance - General
From a Performance perspective, DOE Goals are met.
Issue now is Cost, Durability (Reliability), and Safety.
The remainder of this presentation will focus on Li-Ion Battery Chemistry
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Performance - General
TRUE or FALSE: All Li-Ion batteries are alike?
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Performance - General
Answer: FALSE
Some perspective… Energizer/Duracell Zn/MnO2 (Alkaline Batteries) -- $Millions are spent in Advertising -- Distinctions are minor -- But, each market share valued at over $20 Million, so…
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Performance - General
Li-Ion comes in a variety of chemistries
Significant distinctions
• • • • •
Anode Chemistries Cathode Chemistries Construction (Form Factor) Other Construction (electrolyte, separator, etc.) Manufacturing Expertise (relates to battery capacity and safety)
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Performance - Anode Chemistry
LTO Anode
Si/Sn Anode
Voltage
▼
(▼ ▼)
Specific energy
◊
(◊ ◊)
Energy density
◊
(◊ ◊)
▲▲
?
Cyclelife (100% DoD)
▲
?
Low temp operation
▲
?
Charge time
▲▲
?
Recycleability
▲▲
?
▲
▲
▼▼
(▼ ▼)
Max discharge rate
Safety Cost (bare cell)
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Performance – Cathode Chemistry
LiFePO4, LiMn2O4
NCA, NCM, LVP
Voltage
▼
(▲ ▲)
Specific energy
▼
▲▲
Energy density
▼
▲▲
Max discharge rate
◊
▲
Cyclelife (100% DoD)
◊
▲
Low temp operation
◊
◊
Charge time
◊
◊
Recycleability
◊
▲
Safety
▲▲
▲
Cost (bare cell)
▲▲
▼▼
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Performance – Construction
Form Factor: Advantage / Disadvantages of various Li-Ion Form Factors
• • •
Cylindrical Prismatic Layered
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Performance – Construction
Cylindrical Can:
• • •
Spiral wound electrodes High volume production Strong track record, commercial history
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Performance – Construction
Prismatic Can:
• •
Flattened spiral would or parallel plate electrodes Improved heat rejection from inner core (Safety and Performance Advantage)
• •
Improved high power versus cylindrical Lower cost, modular Battery Design
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Performance – Construction
Layered (soft package):
• • •
Stacked layers, laminated construction Further improved thermal management Flexible
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Performance – Other Construction
Electrolyte:
• • •
Non-flammable Anode reactivity (SEI concerns) High Voltage stability
Separator:
• •
Thermal shutdown (watch for shrinkage) Puncture resistance (internal shorting)
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Performance – Manufacturing
Manufacturing Expertise:
• •
Manufacturer A vs B Manufacturer A, Lot to Lot Variation
Manufacturing Controls
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Durability (Reliability)
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Durability – General Concerns
Performance Variables:
• • •
DOD (Depth of Discharge on cycling) C Rate Temperature (Thermal Management)
Mercedes S 400 HYBRID (battery is cooled by the A/C coolant) (maintains operating temperature at 10C to 30C) (50C max, 40C practical max)
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Durability – End of Life
Li-Ion End of Life Causes:
• • • •
Lithium plating reduces anode charge reserve Impedance rise at cathode Soft shorts Capacity loss (Li consumption at SEI)
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Durability – Requirements
Cycle Life Calendar Life
Temperature Effects
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Durability – Temperature Effect
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Safety
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Safety – General Test Requirements • • • • • • • •
Controlled Crush Penetration Drop Immersion Roll-over Simulation Mechanical Shock Thermal Stability Simulated Fuel Fires
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• • • • • • • •
Elevated Temperature Storage Rapid Charge/Discharge Thermal Shock Cycling Overcharge / Overvoltage Short Circuit Overdischarge / Voltage Partial Short Circuit Altitude simulation
Safety – General Test Requirements
Laptop and Cell Phone versus Automotive (Distinctions)
• •
Drop, Shock, Vibration, Crush
Industry need for improved, meaningful Safety Tests
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Safety – Laptop Perspective (18650)
Spiral Wound, Cylindrical (Large Volume Commercial cells):
Incident rate is one in 5 to 10 million Layered Constructions (Large Format Automotive):
Incident rate is unknown
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Safety – Failure Mechanism
Mechanism for 18650 field failures:
• •
Mechanical grinding (charge/discharge volume changes) Internal Short Circuit
Failures occur either early in life (first few cycles) or late in life (>50 cycles)
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding: Internal short must meet Energy & Power threshold levels for Thermal Runaway
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Safety – Failure Mechanism
For 18650…
Nearly all field incidents have been caused by internal short circuits!!!
Best Understanding: Internal short must meet Energy & Power threshold levels for Thermal Runaway
Here, cathode chemistry is not the prime factor!
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Safety – Failure Mechanism
Still, much safety related cathode research continues…
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Safety – Cathode Comparisons
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Safety – Failure Mechanism
What are the failure mechanisms for Large Format Automotive???
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Summary
DOE’s Performance based Goals for PHEV have been reached Battery / System Cost must be reduced Cycle Life and Calendar Life remain uncertain Thermal Management is critical to long term performance and durability The industry needs improved, meaningful safety tests
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Questions? Next Up – Automotive EMC
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Michael Koffink – Automotive EMC
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Automotive Testing Expo: EMC testing and Electric Vehicles
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Agenda
Introduction
• • •
The current state of standards New technologies bringing about change? What does this mean to the test lab?
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What is EMC testing?
•
Electro magnetic Compatibility testing is necessary to ensure that all vehicle components do not generate high levels of RF interference and are in turn immune to it as well.
• • • •
Radiated and Conducted Emissions Transients ESD Very important in the automotive realm-Performance and Safety demands it
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Automotive EMC Regulations- US
• •
Most OEM’s have their own test standards
• •
Intentional radiators must meet CFR 47 Part 15C.
•
SAE standards exist as guidance for non-OE devices
USA- FCC has automotive devices on their exemption list for unintentional radiators.
FCC leaves it to the OEMs to enforce EMC through their own standards
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Automotive EMC Regulations- EU • •
OEMs have own standards
• •
“Old Approach Directive” Requires Type approval
E and e Mark scheme-Automotive EMC Directive2004/104/ec
Also ECE 324 Regulation 10 03 governed by UN
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Current Standards •
These automotive EMC standards were developed over the years based on historical experiences with internal combustion engine vehicles and the electronics sub assemblies that are associated with them.
•
For the most part OEM’s and government regulators have done a good job trying to keep up with technical changes in component and accessory technology and addressing it with standard updates and careful test planning.
•
Some methodology standardization…CISPR 25 for radiated emissions as example
•
But…. The development of electric vehicles is rapidly evolving. A surge of technical changes could be inevitable
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EV and HEV- hurdles • • • • • • • • • • •
Higher buss voltages up to 900V Motor drives Unique battery monitoring and charging circuitry Hi efficiency low power concepts for lighting Weight a factor Filtering techniques More shielding Conducted emissions issues Upgrade buss communication New private players in the industry Some manufacturers of sought after technology new to the demand of automotive industry
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EV and HEV- more hurdles the PEV • • •
Plug- ins!!?
•
Cross over Standards from the household and industrial sectors
•
There are standards out there being developed but not yet harmonized
Charging?? What does this mean for power grid superstructure around the globe?
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EV and HEV- industry awareness •
Test Labs need to stay tuned for changes in rules as well as test methodology
•
Become more involved than ever in helping trouble shoot problems. Expect more diagnostics and engineering evaluation
• • •
Clients want answers Full vehicle testing may become more common Expect cross over work from Military sector
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Questions?
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Additional Automotive Testing Capabilities
•Accelerated Stress Testing (AST) •Airbag Deployment •Analytical (Chem Lab) Testing •Audio Testing •Buzz Squeak & Rattle (BSR) •Dynamometer-based Engine Testing •Electronics Testing •EMC Testing •Environmental Conditioning •Failure Analysis •Field Evaluation Services •Fuels & Lubricants Testing •Laboratory Management •Lighting/Photometrics
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•Live Fuel Materials Testing •Materials Testing •Performance Testing •Product Evaluation and •Durability Testing •Road Simulation Testing •SHED Testing •Systems Certification •Validation Engineering •Training/Consulting •Vehicle Testing •Vehicle Fuel System Testing •Vibration (Single & Multi-Axis) •VOC Testing
Global Network: Intertek Group Countries
110
Locations
1030
24,000
Floated May 2002 – LSE: ITRK FTSE 100, Support Services Sector
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Staff
Your premier certification and testing partner
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Thank You
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