1. UN 38.3 Lithium-ion Battery Testing
Vibration and Shock Testing Requirements

2. UN 38.3 Lithium-ion Battery Testing Topics
Key points of presentation
UN 38.3 test overview
UN 38.3 vibration and shock test details
Mild and full hybrid electrical vehicle battery systems
Vibration and shock issues
Vibration test analysis and recommended change
Shock test analysis and recommended change
Summary
Back-up
Transportation scenarios
Calculations
Vibration Isolation
Aviation shock specification

3. UN 38.3 Lithium-ion Battery Testing Requirements KEY POINTS
Lithium-ion batteries designed for hybrid electric vehicles (HEV) are large and complicated structures.
Lithium-ion HEV batteries are proven to be durable and safe for vehicle usage by extensive testing.
Applying the existing vibration and shock requirements to lithium-ion batteries designed for use in HEVs will increase the cost of HEVs and delay the adoption of HEVs in the market.
Existing vibration and shock requirements are not valid for heavier lithium-ion HEV batteries.
The existing requirements can be modified for large batteries and still assure safe transportation.

4. UN T1-T8 Tests UN 38.3 Manual Of Tests
T1 – Altitude Simulation
T2 – Thermal Shock
T3 – Vibration
T4 – Physical Shock
T5 – External Short Circuit
T6 – Impact
T7 – Overcharge
T8 – Forced Discharge
Tests were designed primarily for cell phone and laptop cells and batteries.
Tests simulate shipping environment and conditions, not the usage environment
All tests must be passed
Tests are without packaging

5. UN 38.3 Manual Of Tests T3 Vibration Testing Requirements
16 batteries
8 Fully charged
4 fresh and 4 with 50 cycles usage
8 Discharged
3 hrs in each of 3 mutually perpendicular mounting positions
Logarithmic sweep from 7Hz to 200Hz to 7Hz in 15 minutes
7Hz to 18Hz at 1gn; amplitude decreasing
18Hz to ~50Hz with 0.8mm amplitude; acceleration increasing to 8gn
~50Hz to 200Hz at 8gn; amplitude decreasing
200Hz to ~50Hz at 8gn; amplitude increasing
~50Hz to 18Hz with 0.8mm amplitude: acceleration decreasing to 1gn
18Hz to 7Hz at 1gn; amplitude increasing

6. UN 38.3 Manual Of Tests Current T4 Shock Testing Requirements
16 batteries
8 Fully charged
4 fresh and 4 with 50 cycles usage
8 Discharged
18 shocks: 3 in negative and positive direction of 3 mutually perpendicular mounting positions
Shock parameters
Normal batteries: Half-sine, 150 gn peak acceleration, seconds pulse duration
Large batteries: Half-sine, 50 gn peak acceleration, seconds pulse duration
Note: Large batteries have more than 500 grams ELC

7. UN 38.3 Manual Of Tests Pass Criteria for Both Tests
No mass loss
No leakage or venting
No disassembly
No rupture
No fire
OCV after test > 90% of OCV before test

8. HEV Lithium-Ion Batteries Mild and Full Hybrid Applications
Mild Hybrid Applications
One electric motor
Vehicle Functions
Assist during launch and acceleration
Stop/start engine when vehicle stops
Regen braking
120 volts (32-36 cells)
Less than 500Wh
14 kg battery assembly
400 x 250 x 150 mm
16 x 10 x 6 inches

9. HEV Lithium-Ion Batteries Mild and Full Hybrid Applications
Multiple electric motors
Vehicle Function
Allows electric only propulsion
Stop/start engine when vehicle stops
Regen braking
volts (approx cells)
Less than 2000Wh
45-50 kg battery
1000 x 350 x 300mm
40 x 14 x 12 inches

10. HEV Lithium-Ion Batteries Typical Usage, Vibration and Shock OEM Vehicle Requirements
Useful Life: 15 years/ 150,000 miles
Vibration Test Requirements
Random vibration
1.28 grms
10 to 2000 Hz
24 hours/axis
Shock Test Requirements
Mild HEV Battery Assembly
132 shocks/axis at 25g’s, half-sine, 15 ms
6 shocks/axis at 100g’s, 11 ms
Mild and Full HEV Package
10 shocks/axis at 50g’s, 6 ms

11. HEV Lithium-ion Battery Transportation
Prototype or Development Stage
Air and vehicle modes utilized but mostly vehicle
Domestic and international
Multiple shipments possible for the same battery (some in the vehicle)
Batteries have not passed UN 38.3 testing
Competent Authority will be used to allow shipping
Production
Vessel and vehicle modes normally
5 or less shipments of battery before vehicle installation
Starts in 2010
Must pass UN 38.3 tests or obtain special approval

12. UN 38.3 Vibration and Shock Testing Issues and Impact
Per Delphi Analysis and Experience:
Current battery pack designs for mild and full hybrid applications are expected to fail the T4 vibration test
They may also fail the T3 shock test
Redesigning to pass UN vibration and shock tests would add development time, mass and cost to HEV battery systems :
That have already met requirements for 15 years of vehicle usage
That will be shipped only a limited number of times and rarely be air
Impact
HEVs will be more costly to the consumer and possibly delayed
Adoption of HEVs will be delayed along with their ecological and energy benefits

13. UN 38.3 Vibration and Shock Testing Test Analysis
Mild hybrid lithium-ion battery packs are about 14kg gross.
Maximum T3 vibration force will be ~27,000N.
T4 shock will be ~41,000N.
Full hybrid lithium-ion packs are about 48kg gross. It is not a large battery by current definitions.
Maximum T3 vibration force will be ~94,000N.
T4 shock will be ~141,000N.

14. Vibration Test Analysis
HEV battery systems are assemblies of electronic controllers, sensors, air flow ducts, cabling, cell mounting fixtures, cells, trays, covers and attachment brackets.
They are not “solid” like cells and laptop batteries.
They will have several resonant frequencies under 200 Hz.
Estimated force exerted on mild HEV batteries due to damping and resonance is approximately 27,000N.
Full HEV battery force is approximately 94,000N.
With the understanding that vibration test parameters are based on air transportation of small lithium cells and batteries, these parameters do not realistically apply to larger batteries.

15. Vibration Test Analysis
UN T3 testing of HEV batteries at these frequencies and 8gn is unreasonable because:
Vibration of the transportation mode is reduced due to the mass of the pack.
Test requires vibration to be “faithfully” transmitted to device, yet vibration would not directly pass from the transportation mode to the battery due to the isolation provided by the skid or container and the package.
Force levels can not be transmitted by the transportation mode
Force required to vibrate a large notebook computer battery (0.5 kg) is ~1000N.
27,000N and 94,000N are very substantial forces
2750kg wrecking ball falling
Or stopping a 550kg wrecking ball after falling 1 second (35kph/22mph) in 1 meter
9500kg wrecking ball falling
Or stopping a 550kg wrecking ball after falling 1 second in 0.28 meters

16. Vibration Test Analysis and Recommendation
T3 Test Recommendation For batteries > 12kg:
Reduce force level from 8gn to 2gn
Basis for recommendation
Force levels are more realistic and exceed current exerted forces.
Force required to vibrate cell and notebook batteries at 8gn~1000N
1000N applied to vibrate a mild hybrid battery is ~0.33g.
2gn is equivalent to 5880N for a 12kg pack
9 hours of swept-sine vibration testing at 2gn is still a severe test for a large battery.

17. Shock Test Analysis and Recommendation
T4 shock forces on mild HEV batteries would exceed 40,000N.
Full HEV battery forces would be >140,000N.
Again, with the understanding that these shock values are based on air transportation of small lithium cells and batteries, these parameters do not realistically apply to larger batteries.
UN T4 testing of HEV battery packs at these forces is unreasonable because:
These force levels could not be transmitted by the transportation mode
Force required to shock cell phone and notebook batteries at 150gn~1500N
1500N applied to shock a mild HEV battery (~500Wh, 12Kg) is ~6.5gn.
There is no source for the additional 38,000N.
Aviation specifications (RTCA) test for Crash Shock at 20g maximum.
Recommend limiting acceleration to 50gn for all batteries > 12 kg
Far exceeds realistic and expected levels
50gn already is used in UN 38.3 for large batteries.

18. Summary
Mild and full HEVs will have lithium-ion batteries that will have to be tested according to UN 38.3 Manual of Tests
UN 38.3 T3 vibration and T4 shock tests are unrealistic when applied to large batteries
If these tests remain as currently written, conversion of the world vehicle fleet to hybrids will be delayed
Proposed T3 modification is to reduce g level from 8 to 2 for batteries 12kg or heavier
Proposed T4 modification is to reduce g level from 150 to 50 for batteries 12kg or heavier

19. Back-up Material Follows

20. Back-up HEV Lithium-ion Battery Transportation Scenarios
Prototype or Development Stage
Battery transported from manufacturer to airport by vehicle
Airport to airport
Airport to distribution center by vehicle
Distribution center to HEV system integrator by vehicle
HEV system from system integrator to OEM engineering by vehicle
HEV (car) from OEM engineering to test site by vehicle
HEV (car) back from test site to OEM engineering by vehicle
HEV system from OEM engineering back to integrator by vehicle
Production Stage
Battery transported from manufacturer to marine port by vehicle
Marine port to marine port
Marine port to distribution center by vehicle
HEV system from system integrator to OEM assembly plant by vehicle

21. Resonant Vibration Force at 8gn
Back-up Calculations
Resonant Vibration Force at 8gn
Force = [mass] x [acceleration]/[ξ, the damping constant]
Damping constant is set at .04, empirical value based on testing similar designs
Mild Hybrid Force = 14x8x9.8/(.04) N or ~27,000N.
Full Hybrid Force = 48x8x9.8/(.04) N or ~94,000N.
Shock Force at 150gn
Force = [mass] x [acceleration] x Dynamic Amplification Factor
Dynamic Amplification Factor is set at 2
Mild Hybrid Force = 14x150x9.8x2N or ~41,000N.
Full Hybrid Force = 48x150x9.8x2N or ~141,000N.

22. Back-up Vibration Isolation

23. Stopping a wrecking ball examples:
Back-up Calculations
Stopping a wrecking ball examples:
550kg wrecking ball after falling 1sec in 1 meter
Forceavg x distance = mass x velocity2/2
Forceavg = (mass x velocity2 ) / (2 x distance)
Forceavg = 550kg x (9.8m/s)2 / (2 x 1m)
Forceavg = kgm/s2
Forceavg = 26411N
550kg wrecking ball after falling 1sec in 0.28 meters
Forceavg = 550kg x (9.8m/s)2 / (2 x 0.28m)
Forceavg = kgm/s2
Forceavg = 94325N

24. Back-up Calculations
Vibration force required for a large notebook computer
Force = [mass] x [acceleration]/[ξ, the damping constant]
Damping constant is set at .04
Force = .5 x 8 x 9.8/(0.04) ~ 1000N.
Acceleration resulting from 1000N vibration force on a 12kg battery
Acceleration = Force x [ξ, the damping constant]/[mass]
Acceleration = 1000N x [.04]/12kg
Acceleration = 3.33m/sec2 or ~.33gn
2gn force applied to a 12kg pack
Force = 12 x 2 x 9.8/(.04)
Force = 5880N

25. Force required to shock 0.5kg notebook batteries at 150gn
Back-up Calculations
Force required to shock 0.5kg notebook batteries at 150gn
Force = [mass] x [acceleration] x Dynamic Amplification Factor
Force = 0.5 x 150 x 9.8 x 2N
Force ~ 1500N
Acceleration resulting from 1500N shock force on a 12kg battery
Acceleration = Force / [mass] / Dynamic Amplification Factor
Acceleration = 1500N / 12kg / 2
Acceleration = 62.5m/sec2 or ~6.5gn

26. Back-up Aviation Equipment Shock Requirements
“RTCA, Inc. is a private, not-for-profit corporation that develops consensus-based recommendations regarding communications, navigation, surveillance, and air traffic management (CNS/ATM) system issues. RTCA functions as a Federal Advisory Committee. Its recommendations are used by the Federal Aviation Administration (FAA) as the basis for policy, program, and regulatory decisions and by the private sector as the basis for development, investment and other business decisions.”
Source: rtca.org

27. Back-up RTCA Specification
DO-160D: Environmental Conditions and Test Procedures for Airborne Equipment
Shock
“Saw Tooth” configuration pulses
11ms pulse for standard testing or 20ms for low frequency testing
18 shocks, 3 per orientation 6g
Equipment operating
Crash Safety
Same as above except 1 shock/orientation at 20g