• It has been demonstrated that vehicle electrification reduces greenhouse gas emissions and operates more efficiently than conventional internal combustion engine (ICE) vehicles.
• Even the most technologically advanced ICE vehicles have an efficiency of less than 50%, but an EV has an efficiency of approximately 90%.
• Although EV manufacturers are not required to follow these requirements, only stricter application of battery safety policies and standards would lower the rising incidence of EV fires.
The global demand for electric cars (EVs) continues to increase each year. This is largely attributable to air quality and environmental legislation, as well as increased consumer demand and more affordable energy options. In addition, the increasing popularity of electric vehicles can be ascribed to major advances in EV and lithium-ion battery technology.
It has been established that vehicle electrification reduces greenhouse gas emissions and operates more effectively than conventional internal combustion engine (ICE) vehicles. Conventional powertrains and internal combustion engines (ICE) as power sources pose the greatest challenge. Even the most technologically advanced ICE vehicles have an efficiency of less than 50%, but an EV has an efficiency of over 85%.
However, as more EVs become operational worldwide, the likelihood of fire mishaps is anticipated to increase. This can cause damage to lithium-ion batteries, posing a threat to the business and people involved in post-crash efforts.
Each lithium-ion battery type has its own unique form factor, cell chemistry, and integration into electric vehicles. There are lithium-ion batteries with a swappable mechanism and a handful that function on a charge-and-drive basis, for example. To securely use lithium-ion batteries, it is crucial to maintain the cells within a specific voltage and temperature range. These restrictions may be exceeded in the event of an accident or a vehicle or battery pack malfunction.
In recent months, a number of fires involving electric two-wheelers have raised questions about the regulation and safety requirements of this fast-expanding area of the vehicle industry. Given the numerous incidents involving electric two-wheelers, it is anticipated that the Indian government will shortly release EV battery guidelines. The comprehensive strategy will include testing for performance and production standards, as well as the heat resistance of these batteries.
The Centre for Fire, Explosive and Environment Safety (CFEES), a laboratory of the Defence Research and Development Organization (DRDO), has been charged with researching the fire occurrences linked with these EVs.
Batteries are the most expensive, the largest, and the most vital part of an electric vehicle. The environment and driving conditions in India are tough, thus it is essential to maintain the battery and its charging requirements. Also capable of causing thermal runaway are faults and/or impurities in the assembling process. When a battery cell short circuits and begins to overheat, thermal runaway develops.
Aside from this, the selection of high-grade cells and the design of a battery pack with the most effective thermal management systems and an intelligent battery management system (BMS) also play a crucial role in enhancing the battery safety criteria.
The Bureau of Indian Standards (BIS) has standardised the performance specifications for lithium-ion batteries used in electric vehicles. Additionally, two new battery safety standards are being developed.
IS 17855:2022 is the name of this new BIS standard, which has been produced in compliance with ISO 12404-4:2018. They were created with real-world EV scenarios in mind, such as a car parked, a battery system being transported, battery operating at low and high temperatures, etc.
While it is not essential for EV manufacturers to embrace these requirements, we believe that only greater adoption of modern battery safety laws and standards would lower the escalating number of EV fires and help the EV market flourish in the long run.
Battery Safety Regulations Currently in Effect
Recent fire incidents involving electric vehicles have prompted worries about numerous areas of the manufacturing process for electric two-wheelers in the country. Regardless of whether the battery pack is locally produced, built, or imported, all units are subject to India’s Automotive Industry Standards (AIS) as established by the Automotive Research Association of India (ARAI). In India, the following regulatory criteria for battery safety under AIS are now in effect:
- AIS 038 REV 1 (2015): Vehicle Security
This standard addresses the functional safety of cars with electric powertrains. The tests cover, among others, protection from electric shock, direct/indirect touch, and water impacts.
• AIS 048 (2009): Safety of Batteries
These standard addresses safety criteria for batteries. It primarily addresses the following two types of testing:
o Electrical Abuse Test (done at the level of the cell): Short circuit and overcharge tests
o Mechanical Abuse Test (at the module or pack level): Vibration, mechanical shock, and rollover tests
Under AIS 048, a nail penetration test is also performed at the cell level.
This standard (AIS 048) will be phased down beginning in December 2022, according to recent Ministry of Road Transport and Highways (MoRTH) directives. The AIS 156 and AIS 038 Rev 2 standards will become mandatory on December 27, 2022, as declared by the Ministry of Road Transport and Highways (MoRTH) on December 27, 2021.
• AIS 038 Rev 2 (2020): Safety of Batteries and Vehicles (For Electric Cars, Buses & Trucks)
These standard tackles a system-level safety strategy that treats the battery and vehicle as a unit. AIS 038 Rev 2 is designed per GTR 20 Phase 1 (UNR100 Rev3).
• AIS 156 (2020): Safety of Batteries and Vehicles (For Electric 2-Wheeler, 3-Wheeler & Ecycles)
These standard tackles a system-level safety strategy that treats the battery and vehicle as a unit. AIS 156 is manufactured in accordance with UN R136.
Are These Tests Adequate?
Similar to the internationally approved UN-certified R136 standard, the AIS-156 standard lays a heavy emphasis on testing, shock protection measures, and how a normal battery performs while overcharged and depleted.
Regarding standards, they appear to be quite inclusive. However, just one battery pack is tested. In addition, the tests do not account for the performance of a battery and its management systems over time. To achieve this, Original Equipment Manufacturers (OEMs) must implement a system that surpasses the stringency and rigour of these tests in every way and for all manufactured battery packs.
The Bureau of Indian Standards (BIS) has standardised the performance specifications for lithium-ion batteries used in electric vehicles. Additionally, two new battery safety standards are being developed.
IS 17855:2022 is the name of this new BIS standard, which has been produced in compliance with ISO 12404-4:2018. They were created with real-world EV scenarios in mind, such as a car parked, a battery system being transported, a battery operating at low and high temperatures, etc.
While it is not essential for EV manufacturers to embrace these requirements, we believe that only greater adoption of modern battery safety laws and standards would lower the escalating number of EV fires and help the EV market flourish in the long run.
