Vehicle crash test

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Crush test

Deforming a cell or pack between a platen and a round bar or sphere until the voltage drops or a set force is reached, to reproduce a crash. It checks whether the case and separator fail gracefully or cause a short.

Enclosure

The sealed case that carries the modules, protects them in a crash, keeps water out to an IP67 rating or better and vents gas in a thermal event. In many cars it is a structural part of the body.

FMVSS 305a

The US vehicle safety standard that replaces FMVSS 305 and largely adopts GTR 20. Besides protection against electric shock and electrolyte spillage, it adds requirements for the traction battery itself — overcharge, short-circuit and over-temperature protection, management of vented gases, water exposure — and extends coverage to heavy vehicles. The December 2024 final rule applies from September 2027 for light vehicles and 2028 for heavy ones.

Insulation resistance

The resistance between the high-voltage circuit and the vehicle chassis, which must stay above about 100 Ω per volt of pack voltage so a person touching the chassis is safe. An insulation monitoring device measures it continuously.

Pyrofuse

A high-voltage disconnect fired by a small pyrotechnic charge on command, typically from the airbag controller in a crash. It cuts the pack from the vehicle in milliseconds, faster and more reliably than a contactor can open under fault current.

R100 Part II

The part of UN R100 that tests the battery system as a unit: vibration, thermal shock and cycling, mechanical shock and crash impact, fire resistance, external short circuit, overcharge and over-discharge protection, over-temperature protection and, from the 03 series, thermal propagation. Each test ends with a check that there is no fire, explosion, electrolyte leakage or loss of isolation.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Battery Test Manual For Electric Vehicles, Revision 3

   Jon P. Christopherson · Idaho National Laboratory · 2015

   Topic background · Performance characterization, pulse resistance/power, life testing and reference performance tests; historical 2015 edition.