trends in ev testing and certification michael deakin tÜv ... · future technology –batteries...
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Trends in EV testing and
certification
Michael Deakin
TÜV Rheinland Indonesia
Global wave of “Electrification“
2
Electrify
entire vehicle
lineup by
2022
EV+PHEV
more than 80
models by
2025
No engine
only models
by 2025
Half of the
models with
EV, PHEV,
FCV, HEV by
2030
All new
models
electified in
2019
Half of the
models with
EV, PHEV,
FCV, HEV by
2030
Ban sales of
gasoline and
diesel engine
cars by 2040
3
1888 2019?
Lohner Porsche Semper Vivus - first hybrid production vehicle. Series-hybrid petrol engine generating power for the wheel-mounted motors
1900~05
Ford Model T: Over 180,000 soldElectric cars: Total 6000. Mass Pro effectively kills EV development
1913
Toyota introduces the Prius and hybrids go mainstream
1997 >
Suzuki Burgmanfuel-cell Moped
2011
Tesla Roadster EV in 2008Nissan Leaf EV in 2010
2008
Arab Oil Embargo -renewed interest in energy efficient and electric vehicles
1973
Lithium battery firstdemonstrated
1979
Hybrid technology develops rapidly for marines, railway and bus applications.
Technology – A few milestones
Battery electric cars already under construction in UK, Germany & France
Technology – 2019 & Current Hybrid Drivetrains
▪ ‘Mild’ hybrid:
− Examples: Electric motor(s) used to supplement conventional drivetrain
− Or: regenerative energy used to charge the battery and reduce the burden on conventional charging
− Cannot propel the vehicle by electric motor alone.
▪ Full hybrid:
− Vehicle can be propelled either by ICE, the electric traction motor or a varying combination of both
− May have plug-in charging capability
▪ Range extender (series hybrid):
− Powertrain is essentially a full EV, but with an on-board engine driven generator for re-charging the
traction battery.
− Big advantage - the generator engine can be optimized to operate under constant speed/load conditions
− Alternative engines configurations can be adopted (Free piston engines, Sterling engines, gas turbines)
− May have plug-in capability
4
Technology - The hybrid of the future
5
▪ The range extender:
−A move away from conventional engines to optimised
generator engines made specifically for the application
−For light duty: free piston engines and linear generators
−For heavy duty: turbo-generators
▪ Full hybrids, Plug-ins and Mild hybrids:
−Harnessing waste energy from every possible source
−Turbo-compounding (already in use in motorsport)
−Solar charging
▪ Can give overall drivetrain efficiencies >50%
Technology – 2019 Pure Electric Vehicles
▪ Present day ‘normal’
−Lithium ion battery + power converter + AC traction
motor
▪ Limiting factors:
−Energy density of the battery (typically 100x less than
petrol)
−Access to recharging infrastructure & an abundant
electricity supply
−EV recharging time vs ICE refueling time
▪ Well suited to:
−Buses operating on pre-determined routes
−Motorcycles
6
Future Technology – Batteries & Charging
• Battery and charging technology will have more impact than any other aspect of xEV design
• Research focusing on evolving technology:
• Solid state lithium batteries
• Li-ion with inorganic electrolyte
• Specific energy of 1000Wh/kg (Tesla Model 3 is 250Wh/kg)
• Wireless charging, both stationary and on the move
• Vehicle battery as an emergency power bank
7
Technology - Fuel Cells
▪ Enormous potential, but….
− Hydrogen refueling infrastructure is limited
− Energy density is lower than liquid fuels - storage is not so convenient, but
refueling time is the same as ICE vehicles
− Require careful temperature control
− Require high purity gas
− Zero pollution – emit only water vapour
− Range limited only by fuel storage capacity
− Expensive
▪ Bikes and cars are on the market now
▪ Commercial vehicles are under development
8
Scope of existing regulations which incorporate requirements for EV’s
9
• Regardless of the regulatory system, the current focus for hybrid and EV is on 4 key areas:
• Electrical safety
• Energy consumption (fuel/electrical) and emissions
• Charging and regenerative braking
• Silent operation at low speed - (Acoustic Vehicle Alerting System)
• Even when there is no direct reference to hybrids or EV’s, implications exist within many system
and component regulations
• Example: If a vehicle is fitted with solar panels, do they require glazing approvals?
Existing UN Regulations which have specific requirements for EV & Hybrids
Regulation Topic Focal Points With Regards xEV
R10 Electromagnetic compatibility Charging systems
R12, 94, 95 Impacts/crash Post-crash electrical safety, battery leaks
R13, 13H, 78 Braking Regenerative braking, electrical control
R40, 83, 101 Emissions & fuel consumption Electric range
R41, 51, 63 Drive-by noise Different test modes
R68, 85 Power/maximum speed Motor power, sustainability
R100, 136 Electrical safety Contact with live parts, battery integrity
R134, 146 Hydrogen & FCV‘s Explosion risks, hydrogen system integrity
R138 Quiet vehicles Minimum sound levels, acoustic systems
EV’s in Other Regulatory systems – 2 Examples:
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• United States:
• Hybrids and EV’s must comply with all FMVSS standards which are mandatory for ICE
vehicles
• In addition:
• FMVSS 305 - Electric-Powered Vehicles, Electrolyte Spillage and Electrical Shock Protection.
• Content is largely the same as the original version of UN-R100, but also includes crash test specific
requirements
• FMVSS 141 (draft) - Minimum Sound for Hybrid and Electric Vehicles.
• Principle is the same as UN-R138, but content is different
• US Product Liability laws
• basically require a manufacturer to ensure products are as safe as possible, regardless of what the
regulatory situation is: “state-of-the-art” and “due care” to consider in addition to FMVSS.
• South Korea:
• Regulatory framework is based upon FMVSS and/or UN-R with some local difference
• But, ‘mild hybrid’ definition is not clear and does not correspond to either US or UN
Direction of Regulation – Where will it go in the next 5~10 years?
12
• Specifically regarding xEV technology, regulation is now well established in Europe, US and
North East Asia
• Regardless of region, global trend is in the same direction – positive for EV and hybrid
• Do not expect to see fully harmonised standards, although there will be many common elements
• Local differences exist because of varying traffic and environmental conditions
• Regulation tends to follow technology, but will need to move more quickly
• Already moving towards approval of ‘safety concepts’ where complex functions are concerned
• Expect to see more responsibility on manufacturers to adopt the US ‘state of the art’ approach
• Functional safety (ISO26262) will be a fundamental part of regulation
• Example: Wireless charging is not currently defined in the scope of applicable UN ECE Regulations.
Direction of Regulation – Integration with other emerging technologies
13
• EV progress will go hand in hand with greater dependence on autonomous driving functions
• Synergy of xEV and smart transport systems will optimise vehicle range
• UN Working Party on Automated/Autonomous and Connected Vehicles (GRVA) established in 2018
• Focus is on future regulations needed to encompass autonomy, cybersecurity, interconnectivity, artificial
intelligence networks, privacy and data protection.
• Disruptive players
• The next generation will not be traditional vehicle manufacturers (Examples: Tesla, Dyson) and will challenge the status quo
• Integration of technology platforms between industrial, domestic and automotive
• For most of the world, ICE’s will continue to play a significant role for the foreseeable future
Testing facilities
14
Test Type
Fail Criteria After Test
Electrolyte Leakage Rupture Fire ExplosionIsolation Resistance
>100 Ω/Volt
Vibration x x x x x
Thermal Shock & Cycling x x x x x
Drop Test x x x x x
Mechanical Shock x x x x x
Fire Resistance - - - x -
Short Circuit x x x x x
Overcharge Protection x x x x x
Over-discharge Protection x x x x x
Over-temperature Protection x x x x x
Summary of Battery Test Requirements in UN-R100 & R136
May become
irrelevant?
Testing facilities – Gearing up for change!
▪ Depending on your location and market, spending on ICE testing labs might be a short-lived
investment
▪ Electric motor test benches are already in big demand for regulatory, developmental and
production conformity tests.
▪ Motors are relatively simple machines, future emphasis will be on testing the software and
control systems
Testing facilities
16
• Complexity and interconnectivity of systems will require a more holistic
approach than is currently applied.
• Braking:
• Maximum possible energy recovery from regenerative braking without upsetting vehicle
stability and ABS performance.
• Move from hydraulic to electric control
• E-4WD and hub motors: Integrated E-steering and E-braking will enhance
the capabilities of vehicle dynamic control systems
• Will operate autonomously, perhaps in response to signals from other vehicles
• In the commercial sector, powered trailers may become the new normal
• Communication between tractor and trailer will need to be standardised and tested
Dynamic and Safety Tests
Testing next generation vehicles
• Change of mindset for test engineers:
▪ Mechanical engineering will no longer be the fundamental starting point of vehicle design and testing
▪ Experts needed with skills in functional safety, electrical and electronics, software engineering,
programming and cyber security.
• ‘Hacking‘ in particular presents a whole new dimension which must be tested in real-world
scenarios:
▪ Ability to over-ride and control individual vehicles and, through inter-vehicle connectivity, maybe entire
infrastructures
▪ Systems need to be robust, failsafe and compatible
▪ Test labs will need to incorporate a more software-based approach
▪ Co-operation with the manufacturers.
• Vehicles can no longer be tested in isolation if they are part of an integrated transport system
• More ‘real world‘ testing will be involved
To Summarise………
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• History already tells us that the future will most likely be determined by:
• Oil price
• Political motivation/willpower
• Availability of mains electricity without relying on fossil fuels
• Alternative battery technology
• Other considerations which will help or hinder wider use of xEV’s:
• Cost (financial and environmental) ---> availability of copper and rare-earth elements for motors
• Availability and harmonisation of charging infrastructure
• Battery safety – increasing energy density
• Car sharing platforms
Closing thought - EU Direction on Batteries:
1: https://ec.europa.eu/growth/industry/policy/european-battery-alliance_en19
• October 2017 - the European Commission launched the 'European Battery Alliance'
• Cooperation platform with industry stakeholders, EU Member States and the European Investment Bank
• “The EU must therefore secure access to the supply chains for batteries raw materials. Lithium-ion is currently the main
chemistry of choice for electro-mobility and will dominate the market in the coming years. Various raw materials are
required in lithium-ion batteries including lithium, cobalt, nickel, manganese, graphite, silicon, copper and aluminium.
The supply of some of these materials, in particular cobalt, natural graphite and lithium, is of concern today and for the
future in view of the large quantities needed and/or very concentrated supply sources. The sustainability of the
extraction and exploitation of these resources is fundamental and recycling of materials will increasingly become
important for diversifying the EU's supply and should be encouraged in the context of the transition to a circular
economy.”1
