EUCAR Hazard Levels
Electromobility is one of the keys to creating transport systems that are climate-friendly and sustainable. At the heart of hybrid and electric vehicles are lithium-ion batteries, which are subjected to significant levels of strain in traffic situations and yet are also expected to deliver standards of performance that are growing all the time. To determine their service life and ensure that they are both reliable and safe, it is essential to put these batteries through rigorous testing before vehicles hit the road.
EUCAR (the European Council for Automotive R&D), a consortium of European automotive manufacturers, has investigated the hazards that could arise when testing batteries and divided them into eight classes. BINDER has used these EUCAR Hazard Levels, as they are known, to develop a range of safety packages and systems designed to ensure that batteries can be tested reliably and safely. The Hazard Levels cover everything from normal signs of aging to defects, ruptures, fire, and explosions.
| Hazard level | Description | Classification criteria and effects |
|---|---|---|
| 0 | No effect | No defect; no leakage; no venting, fire, or flame; no rupture; no explosion; no exothermic reaction or thermal runaway. Cell reversibly damaged. Repair of protection device needed |
| 1 | Passive protection activated | No defect; no leakage; no venting, fire, or flame; no rupture; no explosion; no exothermic reaction or thermal runaway. Cell reversibly damaged. Repair of protection device needed |
| 2 | Defect, damage | Same as Hazard Level 1; however, the cell is damaged irreversibly and must be replaced |
| 3 | Leakage, loss of mass < 50% | No venting, fire or flame; no rupture; no explosion, < 50% weight loss in electrolyte solution (solvent + conducting salt) |
| 4 | Venting, loss of mass > 50% | No fire or flame; no rupture; no explosion, > 50% weight loss in electrolyte solution (solvent + conducting salt) |
| 5 | Fire or flame | No rupture; no explosion (e.g., no flying parts) |
| 6 | Rupture | No explosion, but flying parts of the active mass |
| 7 | Explosion | Explosion (e.g., disintegration of the cell) |
Battery tests are subject to various standards set out by the International Electrotechnical Commission (IEC), the International Organization for Standardization (ISO), and the Deutsches Institut für Normung (DIN). These include DIN EN IEC 62660-1 and -2, which govern secondary lithium-ion cells for the propulsion of electric road vehicles, and ISO 12405-4, which covers test specifications for lithium-ion battery packs and systems. Battery performance is tested at temperatures between minus 20 and 65 degrees Celsius, and with storage at 45 degrees for 28 days. If a battery or system is exposed to extremely low temperatures, it will discharge more rapidly – and excessively high temperatures will cause its service life to drop. Temperatures over 130 degrees Celsius are safety-critical as chemical reactions can trigger fires and explosions from this point. For this reason, the process of testing lithium-ion batteries places significant demands on test chambers and highlights the importance of fire safety. Battery test chambers need to deliver reliable test results while ensuring that those performing the tests stay safe.
Battery test chambers from BINDER – a gold standard for research and quality testing
BINDER battery test chambers are specifically designed to suit the needs of the automotive and electronics industries, and are also an ideal solution for not only research and development, but also production environments. Working in line with the Hazard Levels defined by EUCAR, BINDER creates temperature and climate chambers equipped with a range of safety packages. Safety package A is tailored to EUCAR Hazard Level 2 and is the perfect choice for conducting aging tests without the load cycle. Safety package P is designed with Hazard Level 4 in mind and is ideal for performance tests in which parameters such as the battery load state are tested at a range of temperatures. Both performance and aging tests are conducted within a safe temperature range for the battery, while stress tests are performed at the limit of the safe temperature range. For this purpose, BINDER provides safety package S: Designed for EUCAR Hazard Level 6, it is used to test charging and discharging currents at constant or dynamic temperatures. These chambers feature reversible stainless steel pressure relief flaps and an enhanced door-locking mechanism with reinforced brackets.
CO, H2, and O2 are monitored in the testing area atmosphere. Mechanical inertization equipment (which uses nitrogen, for example) and CO2 flushing equipment for suppressing fire ensure that maximum safety standards are maintained while batteries are being tested. Eliminate risks by choosing the best equipment for the best possible results. Installing ultra-safe systems is especially important in cases where test chambers are located in buildings – so don’t leave anything to chance when it comes to developing high-performance energy storage devices, and select BINDER solutions for a combination of outstanding products, maximum safety, and flexible options. Create a safety concept that’s specifically tailored to your needs.