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1、EV Vehicle Safety,Manuel Bartolo Automotive Safety Office, Ford Motor Company Electric Vehicle Safety Technical Symposium May 18, 2012,2,ELECTRIFIED VEHICLES,PRODUCTION CAPACITY IN NORTH AMERICA BY 2013,TRIPLING,3,MORE EFFICIENT BATTERY TEMPERATURES,110 MPGe Advanced Li-Ion Battery 5 PASSENGER 25-30
2、% smaller FASTER CHARGING 50% lighter,23kWh,LIQUID-COOLED,LITHIUM-ION BATTERY PACK,4,RELIABILITY,Researching and developing modern electrified vehicles for decades,Ford Ranger Electric,1998,1996,Cell Testing and Research,2004,2009,2010,Ford Escape Hybrid,Ford Fusion Hybrid,Graphical Crash Requiremen
3、ts - FMVSS 305,30mph Rigid Barrier,30mph 30o Left & Right Angular,33.5mph Left & Right 27o Crabbed Cart,50mph 70% Overlap V-to-V Left & Right,Frontal Crash Events,Side Crash Events,Rear Crash Events,Graphical Crash Testing for Public Domain & Internal,40mph 40% IIHS Offset,NCAP 20mph Oblique Left &
4、Right Pole (5th/50th%),High Speed V-to-V Left & Right Side,38.5mph NCAP Left & Right Side MDB,High Speed V-to-V Left & Right Rear,31mph Left IIHS Cart,35mph NCAP Rigid Barrier,7,Focus Electric Battery Location,BEV Battery Packs,BEV Lower Battery Pack is mounted under the vehicle below the second row
5、 seats,BEV Upper Battery Pack is mounted in the trunk behind the second row seats. Lower portion of pack extends through trunk floor to the outside of the vehicle,8,FMEA Analysis,Over Temperature Over Charge Over Discharge External Short Internal Cell Short,No Effect Protection Activated Damage/ Ret
6、ention Leakage Venting Fire/Flame,Noise Factors & Failure Modes,Stress,Vehicle Level Design Actions Pack Level Design Actions Cell Level Design Actions,Potential Effects,Normal Conditions Noise Factors Off-Normal Conditions Failure Modes,Prevent Actions,9,Vehicle, Pack & Cell Level Actions,Vehicle L
7、evel Actions Vehicle Structure Vehicle Cooling Sys Vehicle Controls Sys Charging Control Sys,Pack Level Actions Battery Pack Structure Vent Management Sys Pack Cooling Sys Battery Controls Sys Power Limits (Temp, Age, others) Over Temp Over Charge/Discharge ENS Control Cell Balancing Battery Sensors
8、 (V, I, T) Fusing,Cell Level Actions Cell Chemistry Cell Design Cell Manufacturing (occurrence reduction),10,Typical Testing and Verification,Examples of typical tests that may be conducted on battery cells, battery pack assemblies, and/or entire vehicles.,Mechanical: Vibration, Shock, Battery Enclo
9、sure Integrity Electrical: Electrical Short circuit, Over Charge & Dis-charge Protection Environmental: High/Low Temperature Exposure Thermal Shock, Humidity and Moisture Exposure, Corrosion, Immersion,11,Focus Electric Vehicle Level Structural Components,Unique Designed (Material &/or gauge revised
10、),Structural additions for battery pack crash protection (Purple),12,Focus Electric Battery Pack Structural Components,Battery Pack Casing,Casing modifications for enhanced crash protection. (Blue),Focus Electric Rear Body Structure,Guidance for Potentially Damaged Batteries,Guidance for Ford Motor
11、Company Electric and Hybrid-Electric Vehicles Equipped With High Voltage Batteries (Vehicle Owner/Operator/General Public) Electric and Hybrid-Electric Vehicle Considerations in the event of damage or fire involving an electric vehicle (EV) or hybrid-electric vehicle (HEV): Always assume the high vo
12、ltage (HV) battery and associated components are energized and fully charged. Exposed electrical components, wires, and HV batteries present potential HV shock hazards. Venting/off-gassing HV battery vapors are potentially toxic and flammable. Physical damage to the vehicle or HV battery may result
13、in immediate or delayed release of toxic and/or flammable gases and fire. Vehicle Information and General Safety Practices Know the make and model of your vehicle. Review the owners manual and become familiar with your vehicles safety information and recommended safety practices. Do not attempt to r
14、epair damaged electric and hybrid-electric vehicles yourself. Contact an authorized Ford Dealer or vehicle manufacturer representative for service. Crashes A crash or impact significant enough to require an emergency response for conventional vehicles would also require the same response for an elec
15、tric or hybrid-electric vehicle. If possible Move your car to a safe, nearby location and remain on the scene. Roll down windows before shutting vehicle off. Place vehicle in Park, set parking brake, turn off the vehicle, activate hazard lights, and move key(s) at least 16 feet (5 meters) away from
16、the vehicle.,Always Call 911 if assistance is needed and advise that an electric or hybrid-electric vehicle is involved. Do not touch exposed electrical components or the engine compartment, as a shock hazard may exist. Avoid contact with leaking fluids and gases, and remain out of the way of oncoming traffic until emergency responders arrive. When emergency responders arrive, tell them that the vehicle involv
