SURFACEVEHICLE

SAEInternationalRECOMMENDED

PRACTICE

SAEJ2464NOV2009

IssuedRevised

1999-03

2009-11

SupersedingJ2464MAR1999

(R)ElectricandHybridElectricVehicleRechargeableEnergyStorageSystem(RESS)SafetyandAbuseTesting

RATIONALE

AbusetestingisperformedtocharacterizetheresponseofaRechargeableEnergyStorageSystem(RESS)tooff-normalconditionsorenvironments.Theprimarypurposeofabusetestingistogatherresponseinformationtoexternalinternalinputsthataredesignedtosimulateactualuseandabuseconditions.Thisresponseinformationisusedtoexposethehazards,ifany,associatedwithagivenRESSunderagivensetofuseandabuseconditionsandtohelpquantifythehazardmitigationeffortsthatshouldbetakenforaparticularRESSdesign.

TherevisionsareintendedtoexpandthescopeofSAEJ2464toincludeothertypesofelectricenergystoragedevicesandvehicularapplications,makethetestresultsmorequantitativeaswellasincorporateimprovementsintestproceduresanddataanalysis.

TABLEOFCONTENTS

1.sCOPE 3

1.1Purpose 3

2.REFERENCES 4

2.1ApplicablePublications 4

2.1.1SAEPublications 4

2.2RelatedPublications 4

2.2.1ElectrochemicalSocietyPublications 4

2.2.2SandiaNationalLaboratoriesPublications 4

2.2.3AIHAPublication 5

2.2.4EUCARPublication 5

2.2.5UnitedNationsPublication 5

3.DEFINITIONS 5

3.1ActiveProtectionDevice 5

3.2AmbientTemperature 5

3.3Battery 5

3.4Capacitor 5

3.5Capacity 5

3.6Cell 5

3.7CombustibleandFlammableLiquids 6

3.8DeviceUnderTest(DUT) 6

3.9Effluent 6

3.10EmergencyResponsePlanningGuidelines,Level2(ERPG-2) 6

3.11Explosion 6

3.12FireorFlame 6

SAETechnicalStandardsBoardRulesprovidehatThisrepotispubishedbySAEtoadvancehesateofechricalandengineeringsciences.Theuseothisrepotis

entrelyvoluntary,andisapplicabityandsuitabityforanypaticularuse,includinganypatentintingementarisingtherefrom,isthesoleresponsibiyofheuser.

SAEreviewseachtechnicalropotateastoveryfvayearsatwhichtimeitmaybereafimed,revused,orcanclled.SAEinvtesyourwitencommentsandsuggestions

CopyrightO2009SAEInternational

Aightsreserved.Nopartofthispublcatonmaybereproduced,storedinaretievalsystemorransmitedinanyformorbyanymeans,lectonic,mechanica,

photocopying.recording.orotherwise,withoutthepriorwrittenpermissionofSAE

TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)

Fax;724-776-070outsideUSA)

Email:CustomerService@sae.org

SAEWEBADDRESS:http://www.sae.org

SAEJ2464RevisedNOV2009Page2of33

3.13FlammableGas 6

3.14FlammableSolid 6

3.15FlashPoint 6

3.16FullyCharged 7

3.17FullyDischarged 7

3.18Integrator 7

3.19Leak 7

3.20LFL 7

3.21Overcharge 7

3.22PercentofOvercharge 7

3.23OSHA 7

3.24OverCurrentProtectionDevice 7

3.25Overdischarge 7

3.26Pack 7

3.27PassiveProtectionDevice 7

3.28Release 8

3.29Reversal 8

3.30RESS 8

3.31RESSCell 8

3.32RESSModule 8

3.33RESSPack 8

3.34Rupture 8

3.35StateofCharge(SOC) 8

3.36TestArticle 8

3.37ThermalRunaway 8

3.38ThermalStabilityLimit 8

3.39UFL 8

3.40Venting 9

4.TECHNICALREQUIREMENTS 9

4.1GeneralTestGuidelines 9

4.1.1Number,Condition,andSizeofBatteriestobeTested 9

4.1.2TypesofAbuseTestsAddressedinthisDocument 10

4.1.3TestConditionsandMeasurementAccuracies 11

4.1.4HazardousSubstanceMonitoring 11

4.1.5FlammabilityDetermination 12

4.1.6ldentificationofSeverity 12

4.1.7MeasuredData 13

4.1.8TestPlansandReporting 13

4.2HazardousSubstanceMonitoringTests(CellLevelandAbove) 13

4.2.1TestDescription 13

4.2.2MeasuredData 14

4.3MechanicalAbuseTests 15

4.3.1ShockTests(CellLevelorAbove) 15

4.3.2DropTest(PackLevelOnly) 16

4.3.3PenetrationTest(CellLevelorAbove) 16

4.3.4Roll-overTest(ModuleandPackLevel) 17

4.3.5ImmersionTest(ModuleorPackLevel) 17

4.3.6CrushTest(CellLevelorAbove) 18

4.4ThermalAbuseTests 19

4.4.1HighTemperatureHazardTest(PackModuleLevelandAbove) 19

4.4.2ThermalStabilityTest(CellLevel) 21

4.4.3CyclingwithoutThermalManagement(ModuleandPackLevel) 2

4.4.4ThermalShockCycling(CellLevelorAbove) 22

4.4.5PassivePropagationResistanceTest(ModuleorPackLevel) 23

4.5ElectricalAbuseTests 24

4.5.1ShortCircuitTests(CellandModuleorPack) 24

4.5.2OverchargeTest(CellandModuleorPack) 26

SAEJ2464RevisedNOV2009Page3of33

4.5.3

Overdischarge(ForcedDischarge)Test(CellLevelandModule)27

4.5.4

SeparatorShutdownIntegrityTest28

5.

NOTES28

5.1

MarginalIndicia28

APPENDIXA

………………………………29

APPENDIXB

………………………………31

TABLE1

RECOMMENDEDANDOPTIONALABUSETOLERANCETESTS,INCLUDINGTHENUMBER

OFRESSCELLS,MODULESANDPACKSFOREACHTEST10

TABLE2

MEASUREMENTACCURACIES11

TABLE3

HAZARDSEVERITYLEVELSANDDESCRIPTIONS(ADAPTEDFROMEUCARAND

SAND2005-3123)12

TABLE4

SHOCKLEVELSANDDURATIONS15

TABLE5

PENETRATIONCHARACTERISTICS16

FIGURE1

EXAMPLEOFACRUSHTESTPLATENFORMODULESANDPACKS18

FIGURE2

PHOTOGRAPHOFANEXAMPLEOFACYLINDRICALCRUSHTESTFIXTUREFORCELLS………18

FIGURE3

RADIANTHEATINGFIXTURETESTFIXTURE20

FIGURE4

SCHEMATICREPRESENTATIONOFCELLLOCATIONS1THRU5ATWHICHCELLSARE

TRIGGEREDINTOTHERMALRUNAWAYCONDITIONINPASSIVEPROPAGATIONTEST………24

1.sCOPE

ThisSAERecommendedPracticeisintendedasaguidetowardstandardpracticeandissubjecttochangetokeeppacewithexperienceandtechnicaladvances.ItdescribesabodyoftestswhichmaybeusedasneededforabusetestingofelectricorhybridelectricvehicleRechargeableEnergyStorageSystems(RESS)todeterminetheresponseofsuchelectricalenergystorageandcontrolsystemstoconditionsoreventswhicharebeyondtheirnormaloperatingrange.

Abusetestproceduresinthisdocumentareintendedtocoverabroadrangeofvehicleapplicationsaswellasabroadrangeofelectricalenergystoragedevices,includingindividualRESScells(batteriesorcapacitors),modulesandpacks.ThisdocumentappliestovehicleswithRESSvoltagesabove60volts.ThisdocumentdoesnotapplytoRESSthatusesmechanicaldevicesstoreenergy(e.g.,electro-mechanicalflywheels).

1.1Purpose

ThisdocumentisdesignedtoprovideacommonframeworkofteststoevaluatetheresponseofvariousRESStechnologiestoabusiveconditions.ThesetestsareintendedtocharacterizetheRESSresponsetoundesirableabusiveconditionsalsotermed“off-normal”conditionsorenvironmentsthatmayariseasaresultofoperatornegligence,vehicleaccidents,deviceorsystemdefects,poorlyinformedortrainedusersormechanics,failureofspecificRESScontrolandsupporthardware,ortransportation/handlingincidentsoraccidents.

TestsinthisdocumentrepresentconditionsforwhichtheRESSwasnotdesignedorintendedforuse,butcanreasonablybeexpectedtobeencounteredinfrequentlyduringfielduse.

ThisdocumentisnotintendedtocerifytheRESSforshipping.ThesetestswerederivedfromFailureModeandEffect

Analysis,userinputandhistoricalabusetesting.Theoutcomeoftestingshallbedocumentedforusebypotentialusers

ofthetestedRESS.Itisnottheintentofthisproceduretoestablishacceptancecriteriasinceeachapplicationhasits

ownuniquesafetyrequirements.Moreover,cellsafetyisonlyonecomponentofthesafetyapproachthatwillemploy

activeandpassiveprotectiondevicessuchasthermalandelectroniccontrols,stateofhealthmonitoring,automatic

disconnectsaswellasancillarysupportsystems.Usersofthesetechnologiesshallmaketheirowndeterminationasto

whatmeasurestotaketoensureasoundapplicationofsaidtechnology.ThetestdatafromSAEJ2464maybeusedas

inputto"BatterySafetyandHazardsRiskMitigation"approachthathasbeendeveloped(see“AnalysisofBatterySafety

andHazards'RiskMitigation”,CyrusAshtiani,ECSTrans.11(19),1(2008)).

SAEJ2464RevisedNOV2009Page4of33

Thescopeofthisdocumentistoevaluatetheresponsetoabusiveconditionsatthecell,moduleandpacklevelsofRESS

integration.Whiletheabusiveconditionsdevelopedinthistestareintendedtoberepresentativeofpotentialhazardousconditionsinthevehicleenvironment,notalltypesofvehiclelevelhazardsarewithinthescopeofthisdocument.

Thetestsdescribedinthisdocumentshouldbesupplementedwithadditionaltesting(performedatthetestsponsor'sormanufacturer'sdiscretion)basedontheirneedfordataandtheirdeterminationofthemostsusceptibleconditionofthetechnology.Theprimarypurposeofthetestsistogatherresponseinformationtoexternalinternalinputs.Specifictestsand/ormeasurementsinthisdocumentmaynotbeappropriateforsomeRESStechnologiesanddesignsifitcanbedemonstratedbytheRESSusers(orsystemintegrators)thatthetestisnotapplicableortheresultswillbeduplicatedbyothertests.

2.REFERENCES

2.1ApplicablePublications

Thefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwisespecified,thelatestissueofSAEpublicationsshallapply.

2.1.1SAEPublications

AvailablefromSAEInternational,400CommonwealthDrive,Warrendale,PA15096-0001,Tel:877-606-7323(insideUSAandCanada)or724-776-4970(outsideUSA),.

SAEJ1715HybridElectricVehicle(HEV)andElectricVehicle(EV)Terminology

SAEJ1739PotentialFailureModeandEffectsAnalysisinDesign(DesignFMEA),PotentialFailureModeandEffects

AnalysisinManufacturingandAssemblyProcesses(ProcessFMEA)

SAEJ1950ProvingGroundVehicleCorrosionTestingSAEJ2344GuidelinesforElectricVehicleSafety

2.2RelatedPublications

Thefollowingpublicationsareprovidedforinformationpurposesonlyandarenotarequiredpartofthisdocument.

2.2.1ElectrochemicalSocietyPublications

AvailablefromtheElectrochemicalSociety,65SouthMainStreet,BuildingD,Pennington,NJ08534-2839,Tel:609-737-1902,

/vsearch/servletVerityServlet?KEY=ECSTF8&ONLINE=YES

.

“AnalysisofBatterySafetyandHazards'RiskMitigation”,CyrusAshtiani,ECSTransactions11(19),1(2008)

2.2.2SandiaNationalLaboratoriesPublicationsAvailablefrom

l

.

ElectrochemicalStorageSystemAbuseTestProcedureManual,February1999Version1.0,T.UnkelhaeuserandD.Smallwood,publishedasSandiaLaboratoriesreportSAND99-0497

FreedomCARElectricalEnergyStorageSystemAbuseTestManualforElectricandHybridElectricVehicleApplications,June2005,DanielH.DoughtyandChrisC.Crafts,publishedasSandiaNationalLaboratoriesreportSAND2005-3123

SAEJ2464RevisedNOV2009Page5of33

2.2.3AIHAPublication

AvailablefromAmericanIndustrialHygieneAssociation,2700ProsperityAve.,Suite250,Fairfax,VA22031,Tel:703-849-8888,.SeethefollowinglinkforEmergencyResponsePlanningGuidelines,Level2(ERPG-2)description.

/topic

subtopicentry.php?RECORDKEY%28entrysubtopictopic%29=entryid,subtopicid,topicid&entryid(entrysubtopictopic)=663&subtopicid(entrysubtopictopic)=24&topicid(entrysubtopi

ctopic)=1

2.2.4EUCARPublication

AvailablefromEUCAROfice,AvenuedesNerviens85,1040Brussels,Belgium,Tel:+32-2-73-87-352,www.eucar.be.

Josefowitz,W.,etal."AssessmentandTestingofAdvancedEnergyStorageSystemsforPropulsion-EuropeanTesting

Report".Proceedingsofthe21WorldwideBattery,HybridandFuelCellElectricVehicleSymposiumandExhibition.

Monaco,EU.April2-6,2005.p.6

2.2.5UnitedNationsPublication

AvailablefromUNEconomicCommissionforEurope,InformationService,PalaisdesNations,CH-1211Geneva10,Switzerland,Tel:+41-0-22-917-44-44,wW.

TransportationofDangerousGoods,ManualofTestsandCriteria,4"EditionRevised,2003.ST/SG/AC.10/11/Rev.4

3.DEFINITIONS

3.1ActiveProtectionDevice

Safetydevicethatconsistsofasensorandactuatorandisintendedforprotectionfromormitigationofabusive,out-ofrangeconditionsexperiencedbytheDUT.

3.2AmbientTemperature

Theambienttemperatureforanytestdefinedinthisdocumentshallbewithintherangeof25℃±5℃.

3.3Battery

Energystoragedevicethatreliesonoxidation/reduction(Faradaic)reactions.SeeRESS

3.4Capacitor

EnergystoragedevicethatdoesnotrelyonFaradaicreactions.SeeRESS.

3.5Capacity

Thechargemeasuredinamp-hours(Ah)ofaRESSfromthefullychargedtothefullydischargedstateusingthedischargeprofileasspecifiedbythemanufacturer.

3.6Cell

SeeRESSCell.

SAEJ2464RevisedNOV2009Page6of33

3.7CombustibleandFlammableLiquids

Acombustibleliquidhasaflashpointbetween100°Fto200°F(37.8℃to93.3°℃);aflammableliquidhasaflashpointthatisbelow100F(38℃).

3.8DeviceUnderTest(DUT)

Ageneraltermusedtodescribethedevicebeingtested.Thistermincludesallevelsofintegrationofthetestarticleandcanrefertoasingleunit(cell),amultipleunitassembly(moduleorpack),oracompletesystem.

3.9Effluent

LiquidorgasreleasedwhenaRESScellleaksorvents.

3.10EmergencyResponsePlanningGuidelines,Level2(ERPG-2)

ERPG-2levelsaredefinedasthemaximumairborneconcentrationbelowwhichitisbelievedthatnearlyallindividualscouldbeexposedforupto1hwithoutexperiencingordevelopingirreversibleorotherserioushealtheffectsorsymptomswhichcouldimpairanindividual'sabilitytotakeprotectiveaction.ThisguidelineistakenfromtheAmericanIndustrialHygieneAssociation(

/Content

).

3.11Explosion

Veryfastreleaseofenergysuficienttocausepressurewavesand/orprojectilesthatmaycauseconsiderablestructuraland/orbodilydamage,dependingonthesizeoftheRESS.ThekineticenergyofflyingdebrisfromtheRESSmaybesufficienttocausedamageaswell.

3.12FireorFlame

lgnitionandsustainedcombustionofflammablegasorliquid(approximatelymorethanonesecond).Sparksarenotflames.

3.13FlammableGas

TheOSHAHazardCommunicationStandard(29CFR1910isavailableat

/pls/oshaweb/owadisp.show

document?ptable=standards&pid=10099)definitionforflammablegasis"agasthat,atambienttemperaturesandpressures,formsaflammablemixturewithairataconcentrationoflessthanthirteen(13)percentbyvolume;orformsarangeofflammablemixtureswithairwiderthantwelve(12)percentbyvolume."Thus,agascanbecategorizedasflammableifthegasburnsinairataconcentrationoflessthan13%byvolumeorthedifferencebetweenthelowerflammabilitylimit(LFL)andtheupperflammabilitylimit(UFL)isgreaterthan12%byvolume

3.14FlammableSolid

TheOSHAHazardCommunicationStandard(29CFR1910isavailableat

/pls/oshaweb/owadisp.showdocument?ptable=standards&p

id=10099)definitionofaflammablesolidis"asolid,otherthanablastingagentorexplosiveasdefinedin29CFR1910.109(a),thatisliabletocausefirethroughfriction,absorptionofmoisture,spontaneouschemicalchange,orretainedheatfrommanufacturingorprocessing,orwhichcanbeignitedreadilyandwhenignitedburnssovigorouslyandpersistentlyastocreateaserioushazard.Achemicalshallbeconsideredaflammablesolidif,whentestedbythemethoddescribedin16CFR1500.44,itignitesandburnswithaself-sustainedflameatarategreaterthanonetenthofaninchpersecondalongitsmajoraxis."

3.15FlashPoint

FlashpointisdefinedinOSHA's29CFR1910.106astheminimumtemperatureatwhichaliquidgivesoffvaporwithinatestvesselinsufficientconcentrationtoformanignitablemixturewithairnearthesurfaceoftheliquid.

SAEJ2464RevisedNOV2009Page7of33

3.16FullyCharged

100%StateofCharge.ThechargestateofaRESSaftercompletionofchargingprocedurespecifiedbytheRESSmanufacturer(suchasreachingthevoltage,currentand/ortemperaturelimits).Forpurposesofthisdocument,aRESSisconsideredfullychargedafterthecompletionofthechargecycleprovidedthatthestateofchargeshallnotfallbelow95%beforeinitiatingthetestsequence.

3.17FullyDischarged

0%StateofCharge.ThestateofaRESSafterreachingtheminimumvoltageatzeroloadasspecifiedbytheRESSmanufacturer.

3.18Integrator

Forthepurposesofthismanual,theintegratoristhevehiclemanufacturerorvendorwhoinstallstheRESSforuseinanEVorHEV.

3.19Leak

LossofhermeticityoftheRESScellcontainerleadingtoslowescapeofgasorliquidwithoutactuationofadesignedvent.

3.20LFL

Lowerflammabilitylimit.See

/msds/ref/flammablelimits.html

.

3.21Overcharge

SupplyingcurrenttotheRESSexceedingthefullychargedstateasspecifiedbythemanufacturer.

3.22PercentofOvercharge

TheamountofoverchargeinAhdividedbytheRESScapacitymultipliedby100.

3.23OSHA

OccupationalSafetyandHealthAdministration,partofU.S.DepartmentofLabor.Seel.

3.24OverCurrentProtectionDevice

Afuse,circuitbreaker,intlligentcontactor,orotherdeviceplacedinanelectricalcircuittoprovidecurrentoverload

protection

3.25Overdischarge

Forceddischargebeyondthemanufacturer'srecommendedlimitsthatmayleadtovoltagereversal.Seereversal.

3.26Pack

SeeRESSpack.

3.27PassiveProtectionDevice

Safetydevicethatisintendedforprotectionfromormitigationofabusive,out-ofrangeconditionsexperiencedbytheRESSthatdoesnotrequireactivecontrolsorelectricalenergysupply(e.g.,shutdownseparator).

SAEJ2464RevisedNOV2009Page8of33

3.28Release

Areleasemeansanyspilling,leaking,pumping,pouring,emiting,emptying,discharging,injecting,escaping,leaching,dumping,ordisposingintotheenvironment.

3.29Reversal

Forceddischarge(overdischarge)ofaRESStothepointthatthecel'selectricalterminalschangepolarity.

3.30RESS

RechargeableEnergyStorageSystem.Anyenergystoragesystemthathasthecapabiitytobechargedanddischarged.(Example:batteries,capacitors,andelectro-mechanicalflywheels).

3.31RESSCell

Anassemblyofatleastonepositiveelectrode,onenegativeelectrode,andothernecessaryelectrochemicalandstructuralcomponents.Acellisaself-containedenergystoragedevicewhosefunctionistodeliverelectricalenergytoanexternalcircuit.

3.32RESSModule

Agroupingofinterconnectedcellsinseriesand/orparallelarrangementintoasinglemechanicalandelectricalunit.

3.33RESSPack

Interconnectedmodulesincludingallancillarysubsystemsformechanicalsupport,thermalmanagement,andelectroniccontrol.

3.34Rupture

LossofmechanicalintegrityoftheRESScontainer,resultinginreleaseofcontents.ThekineticenergyofreleasedmaterialisnotsufficienttocausephysicaldamageexternaltotheRESS.

3.35StateofCharge(SOC)

TherelativecapacityoftheRESSexpressedasapercentageofthefullychargedcapacity.

3.36TestArticle

See'DeviceUnderTest.'

3.37ThermalRunaway

TheuncontrolledincreaseinthetemperatureofaRESSdrivenbyexothermicprocesses.

3.38ThermalStabilityLimit

MaximumtemperatureatwhichRESSisstableindefinitely.

3.39UFL

Upperflammabilitylimit.See

/msds/ref/flammablelimits.html

.

SAEJ2464RevisedNOV2009Page9of33

3.40Venting

ThereleaseofexcessiveinternalpressurefromaRESScell,moduleorpackinamannerintendedbydesigntoprecluderuptureorexplosion.

4.TECHNICALREQUIREMENTS

4.1GeneralTestGuidelines

Beforestartingabusetests,atestplanwillbedevelopedbythetestingorganizationandtheplanmaybereviewedbytheRESSmanufacturerandtestsponsor.Specificationsforeachabusetestshouldbesettodeterminerelevantabuseresponsestotheexpectedrangeofnormalandoff-normalconditions.Thetestsshouldbedesignedtogenerateresponsedatathatcanquantitativelydeterminethecellandsystemresponseofthedeviceundertestaswellasserveasaguideforfuturedesigns

SubjectingtheRESStoconditionsoutsidetheirintendedoperatingrangenecessarilyinvolvessomeriskofunintendedfailures.TheresponsibletestingorganizationshouldconsulttheRESSmanufacturerforinformationregardingthepossibleconsequencesofsuchfailures,includingthepotentialreleaseofhazardoussubstances,sothatappropriateprecautionscanbetakentoensurethesafetyoftestingpersonnel.

ThetestfaciityneedstoassurethatitcanaccommodatethesizeoftheRESSbeingtestedaswellastoassurethesafetyofpersonnelandfacilitystructures.Thetestfacilityshouldbeevaluatedbytherespectiveexpertsforstructuralintegrityunderconditionsofhighoverpressureandextendedfire,aswellasevaluationofventilationsystemandcontainmentofpotentiallytoxicmaterials.ConsiderationneedstobegiventothetotalenergycontentandthepotentialhighvoltageoftheRESS(whereapplicable)oftheRESS,thesizeofthetestroomandthematerialsofconstruction.Secondarycontainment(suchasovenorothertestchamber)oftheRESSisrecommendedifpossible.FiresuppressionsystemsmaybeincorporatedintothefacilitybutshouldnotbeusedtomitigatethemainabuseresponseoftheRESS.

4.1.1Number,Condition,andSizeofBatteriestobeTested

InitialtestingwilluseanewRESSandadditionaltestingofagedorcycledRESSshouldbeperformedatthetestsponsor'sormanufacturer'sdiscretionbasedontheirdeterminationofthemostsusceptibleconditionofthetechnology.IncorporatingRESSmanufacturer'sknowledgeandexistinginformationonhowtheirdevicesperformunderabusiveconditionsintheformulationofthetestplanwillimprovethequalityofthedataandvalidityofthetestresults.Themanufacturerwilldiscloseinthetestplananyhazardoussubstancesthatmaybereleasedduringabusetests.

ThesetestsareintendedtocharacterizetheRESSresponsetoundesirable"of-normal"conditionsorenvironmentsthatmayariseasaresultofoperator