Electric Vehicle Safety: Design & Research - ARPA-e

24 Pages·2012·3.02 MB·English

Electric Vehicle Safety:
Design & Research
Alvaro Masias
Energy Storage Research, Ford Motor Company
ARPA-E Crash-Safe Energy Storage Systems for
Electric Vehicles Workshop
Denver, CO – November 12, 2012
Page 1
Table of Contents
Design
Research
Page 2
Table of Contents
Design
Research
Page 3
Power of Choice
ELECTRIFIED VEHICLES
TRIPLING
PRODUCTION CAPACITY
IN NORTH AMERICA BY 2013
Page 4
Ford Focus Electric
110 MPGe Advanced Li-Ion Battery
5 PASSENGER 25-30% smaller
LLIIQQUUIIDD--CCOOOOLLEEDD
FASTER CHARGING 50% lighter
2233kkWWhh
LLIITTHHIIUUMM--IIOONN
BBAATTTTEERRYY PPAACCKK
MORE EFFICIENT
BATTERY
TEMPERATURES
Page 5
Reliability
Researching and developing modern electrified vehicles
for decades
1996 1998 2004 2009 2010
Cell Testing and Research Ford Escape Hybrid
Ford Ranger Electric Ford Fusion Hybrid
Page 6
Focus Electric Battery Location
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
BEV Lower Battery Pack is
mounted under the
vehicle below the second
row seats
Page 7
Crash Requirements – FMVSS 305
30mph
Rigid
Barrier
30mph
50mph 70% Overlap
30o Left & 33.5mph
V-to-V Left & Right
Left & Right
Right
27o Crabbed Cart
Angular
Frontal Crash Events Side Crash Events Rear Crash Events
Page 8
Public Domain & Additional Ford
Crash Testing
NCAP 20mph Oblique
35mph
Left & Right Pole (5th/50th%)
NCAP
Rigid
Barrier
High Speed
V-to-V
Left & Right
Rear
40mph 40%
High Speed
IIHS Offset
V-to-V
Left & Right Side
38.5mph
NCAP Left & Right
Side MDB
31mph
Left IIHS
Cart
Page 9
FMEA Analysis
Noise Factors & Potential Prevent
Stress
Failure Modes Effects Actions
Normal Conditions Over Temperature No Effect Vehicle Level
Design Actions
Over Charge Protection
Noise Factors Activated
Pack Level
Over Discharge
Damage/ Design Actions
Off-Normal Conditions External Short Retention
Cell Level
Internal Cell Short Leakage
Design Actions
Failure Modes
Venting
Fire/Flame
Page 10