UN 3480 - ExtraEnergy.org
UN 3480 - ExtraEnergy.org
UN 3480 - ExtraEnergy.org
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The importance of the Selection of Li-ion<br />
Batteries for Vehicle Manufacturer‘s View<br />
International Seminar of Lithium-ion Batteries Technology Applied to Electric-Bike<br />
Hannes Neupert, President <strong>ExtraEnergy</strong> e.V. ,<br />
Treasurer EnergyBus e.V. and independent Consultant<br />
Shanghai 27th of April 2008
Table of contents<br />
- Battery types used in the european pedelec market<br />
- Transport rules by the United-Nations are binding law!<br />
- 8 key factors for battery selection<br />
- Potential danger of batteries - safety first!<br />
- How to know if a battery is safe!<br />
- BATSO tests a worldwide solution!<br />
Non chinese speakers please refer for most of the<br />
following slides to the print provided - most of the<br />
presentation will be for time reasons only presented in<br />
chinese!<br />
3
Battery types used in the european pedelec<br />
market:<br />
5
Kano-Model: Today’s batteries in pedelecs<br />
Customer wishes for batteries are light weight and small volume!<br />
1.6<br />
Li-Ion<br />
customer expectation<br />
unfulfilled<br />
satisfied customer<br />
exalted<br />
unexpected requirement<br />
spoken requirement<br />
expected<br />
dissatisfied customer<br />
4.2<br />
NiMHd<br />
unspoken requirement<br />
satisfied<br />
customer expectation<br />
fulfilled<br />
NiCd<br />
Lead acid PB<br />
10.1 5.3<br />
7
Kano-Model: Future batteries in pedelecs<br />
Customer wishes for batteries are light weight and small volume!<br />
1.6 ?<br />
customer expectation<br />
unfulfilled<br />
satisfied customer<br />
exalted<br />
unexpected requirement<br />
spoken requirement<br />
expected<br />
dissatisfied customer<br />
4.2<br />
unspoken requirement<br />
satisfied<br />
customer expectation<br />
fulfilled<br />
Li-Ion<br />
9
Lithium-batterie sales in general:<br />
more then 2500 Mio Li cells will be ruffly shipped in 2007 / worldwide sales of Li-Ion will exceed 5bn USD 2007 / this will be<br />
doubled 2010, pot. double digit rated growing 2010 with mobile/Automotive, source: Takeshida/JP IILP + other)<br />
11
Transport rules by the United-Nations are<br />
binding law:<br />
- All LEV‘s which use Lithium batteries have to be shipped<br />
according to <strong>UN</strong>-transport rules with proper marking<br />
- All batteries need to be tested for <strong>UN</strong>-T Test, the test is<br />
only valid for exactly the tested pack, it it will be modified<br />
the test has to be repeated!<br />
13
Why does the <strong>UN</strong>-T regulation exist?<br />
You all know about the reports about burning laptops and<br />
the recalls affected millions of battery sets!<br />
15
Example about a serious incident: UPS cargo Flight 1307,<br />
Feb 7 2006 Philadelphia, Pennsylvania USA:<br />
16
Good luck nobody was hurt - but would you like to sit in a<br />
airplane together with some lithium batteries?<br />
Lithium Batteries carried at<br />
cargo position 3 and 14<br />
17
International penal or criminal codes:<br />
For all parties involved in handling lithium batteries which<br />
do not fulfill the <strong>UN</strong>-T regulations (not proper tested/not<br />
correctly labeled and shipped,... )<br />
- It is a serious criminal offense<br />
- Esp. traffic offense<br />
- terms of imprisonment are claimed: …3 to…max. 5<br />
years…! Personal ignorance is no excuse!<br />
20
<strong>UN</strong> 3090/<strong>UN</strong>3091 Lithium batteries/ Equipment<br />
Rules Packaging rules<br />
<strong>UN</strong> 3090<br />
(<strong>UN</strong> <strong>3480</strong>)<br />
Special<br />
regulations<br />
Packaging rules<br />
<strong>UN</strong> 3091<br />
(<strong>UN</strong> 3481)<br />
Special<br />
regulations<br />
ADR P 903 188, 230, 310, 636 P 903 188, 230, 636<br />
IMDG-Code P 903 188, 230, 310 P 903 188, 230<br />
ICAO-TI /<br />
IATA-DGR<br />
PAX-A/C CAO-A/C<br />
903 903<br />
max. 5 kg br. max. 35 kg br.<br />
A45, A88, A99 912 A45, A48<br />
Orange Book P 903 188, 230, 310 P 903 188, 230<br />
22
ELECT RICALLY POWERED VEHICLES / EQUIPMENT<br />
<strong>UN</strong> 3171 Battery Powered Vehicle, Class 9,<br />
24
Executive summary<br />
Various Dangerous-Goods (DG)-regulations for different<br />
battery systems.<br />
Batteries as DG`s can be shipped as Class 9 DG`s<br />
worldwide accordingly to regulations.<br />
Lithium batteries have to pass <strong>UN</strong> 38.3 safety tests prior<br />
shipping.<br />
A lot of detailed material about correct shipping is<br />
available at www.<strong>ExtraEnergy</strong>.<strong>org</strong><br />
26
Executive summary<br />
Various Dangerous-Goods (DG)-regulations for different<br />
battery systems.<br />
Batteries as DG`s can be shipped as Class 9 DG`s<br />
worldwide accordingly to regulations.<br />
Lithium batteries have to pass <strong>UN</strong> 38.3 safety tests prior<br />
shipping.<br />
A lot of detailed material about correct shipping is<br />
available at www.<strong>ExtraEnergy</strong>.<strong>org</strong><br />
28
8 key factors for battery selection:<br />
29
Known example of pay by use: Why are cell phones so cheap to by?<br />
Many people never think about that since it was ever like that since they<br />
use a cell phone. When I remember that the first mobile phones in the<br />
80‘s have cost more than a small car it was out of imagination that a cell<br />
phone will be such a consumer item as of today!<br />
The key to it was to my observation that the payment system has been<br />
changed from an upfront payment to a pay by usage payment combined<br />
with some monthly payments.<br />
This has made the cell phone affordable to much more user groups who<br />
have never imagined how much the cell phone would change their<br />
lifestyle - you all know it the break through has happened but it has taken<br />
huge investments into the infrastructure by the operators.
Similar approach is common practice for purchasing printers:<br />
All printer companies sell their printers usually below their costs and<br />
recover their losses and create their profits by selling the ink refills with<br />
high margins added.<br />
This scheme seems to be well accepted by the consumers. Even some<br />
ink refills are more expensive than printers...
How would it work for a pedelec from the business?<br />
There are 3 players needed - a comparison to the cell phone business again:<br />
monthly payment by the user Many service providers available radio network infrastructure<br />
??<br />
monthly payment by the user Who will be the Service provider? Battery and charger infrastructure
How would it work for a pedelec from the technology?<br />
Function based on common standards - a comparison to the cell phone again:<br />
Mechanical standardization of SIM card<br />
one size used by all providers and phone<br />
makers!<br />
Standardized secure communication<br />
between the SIM card and the cell phone<br />
Mechanical standardization of Battery case<br />
and connector together with the standard<br />
EnergyBus protocol allow full<br />
interchangeability between pedelecs of<br />
different manufacturers!<br />
Standardized Battery-Safety-Test BATSO<br />
allow to select only safe Batteries<br />
standardized radio bands are used for cell<br />
phones to communicate with the radio<br />
towers and roam to stations of other<br />
providers if no own available<br />
Standardized identification procedures<br />
allow the network to identify the user<br />
Mechanical standardization of Battery<br />
case, exchange station interface and<br />
connector together with the standard<br />
EnergyBus protocol allow full<br />
interchangeability between exchange<br />
stations of different manufacturers as well<br />
privately owned chargers!<br />
The public rental scheme like proposed in Stuttgart can only work due to the existence of a non proprietary<br />
communication protocol as well a worldwide recognized safety test protocol which allows to identify safe battery<br />
packs to be used in such a system
Common Battery for rental systems may change LEV‘s!<br />
Mechanical standardization of Battery case<br />
and connector together with the standard<br />
EnergyBus protocol allow full<br />
interchangeability between pedelecs of<br />
different manufacturers!<br />
Standardized Battery-Safety-Test BATSO<br />
allow to select only safe Batteries<br />
Batteries may fit to many different pedelecs<br />
Mechanical standardization of Battery<br />
case, exchange station interface and<br />
connector together with the standard<br />
EnergyBus protocol allow full<br />
interchangeability between exchange<br />
stations of different manufacturers as well<br />
privately owned chargers!
Potential danger of batteries - safety first:<br />
Exploding and/or burning lithium-batteries have caused<br />
several electric bike businesses to go bankrupt or suffer<br />
heavy loss of customers.<br />
To take it easy is like playing with a fire in a wooden<br />
house!<br />
<strong>ExtraEnergy</strong> is very concerned about that some severe<br />
incident could stop the growth of the european LEV<br />
market.<br />
38
Potential danger of batteries - safety first:<br />
Battery safety test developed for Deutsche Post AG by Mo-<br />
Hua Yang and Hannes Neupert 2003/04<br />
40
First Battery-Safety-Laboratory of <strong>ExtraEnergy</strong> build in 2004<br />
41
2005 sell 50% of<br />
the first lab to<br />
BMZ battery<br />
packing company<br />
located near<br />
Frankfurt/M<br />
Germany<br />
42<br />
Still jointly owned<br />
used mainly for<br />
safety test of BMZ
Enax Safety Movie: Example of a Successful Test:<br />
43
Example of a Non Successful Overcharge Test:<br />
44
2006 new improved test-laboratory<br />
joint project by <strong>ExtraEnergy</strong> and IT RI<br />
Installed in spring 2007 at<br />
IT RI facility Hsinchu Taiwan
Batteries which have passed the test have<br />
been delivered by the following companies:<br />
Sanyo NiCd 5 Ah 24 V<br />
Panasonic NiMhd 9 Ah 36 V<br />
Enax 16 Ah 24V<br />
LG Li-Ion 10 Ah 36 V<br />
Phylion 10 Ah 24 V<br />
Panasonic NEC-Tokin 8 Ah 24V<br />
AEE Energy 10 Ah 36V<br />
Phylion 10 Ah 36V<br />
Please consider that if you find a battery of one of the listed makers that this<br />
statement just mean that the battery which was tested by <strong>ExtraEnergy</strong> was<br />
safe and that similar batteries in different packs or after some of the common<br />
modification may behave much different.<br />
78
Paris: January 26, 2006<br />
Lithium Is The Promising Technology! Taiwanese DIY electric bike<br />
kit customers garage fire!<br />
40 000 Euro damage only<br />
But Lithium Technology is potentially dangerous and several Lithium Batteries on<br />
the market should not be sold anymore.<br />
A accident with a EU customer of a Taiwanes electric bike system has<br />
experienced in January 06 a tremendous fire in his bicycle garage. Fortunately<br />
due to good luck! Since<br />
Customer was still awake<br />
and fire department was<br />
called immediately!<br />
79
Lithium Is The Promising Technology!<br />
But Lithium Technology is potentially dangerous and several Lithium Batteries on<br />
the market should not be sold anymore.<br />
A accident with a EU customer of a Taiwanes electric bike system has<br />
experienced in January 06 a tremendous fire in his bicycle garage. Fortunately<br />
81
A serious incident could destroy the LEV market very quickly!<br />
82
How to know if a battery is safe?<br />
The <strong>UN</strong>-T Test does only check it a battery behaves safely<br />
during transportation not during usage!<br />
Reference to other battery packs even to some of the same<br />
supplier may not be correct since the history show that<br />
sometimes even previous safe tested cells become like a<br />
bomb when packed in a different way or just in a different<br />
casing!<br />
84
BATSO Test a worldwide solution!<br />
The BATSO Test which was released 18th of March 2008<br />
offers a unique opportunity to the LEV industry to prove<br />
the safety of the used lithium-battery-system as well as to<br />
communicate it to all involved parties.<br />
Please check out for the full test manual www.BATSO.<strong>org</strong><br />
it is available free of charge for download.<br />
86
BATSO Test a worldwide solution!<br />
- Battery types used in the European Pedelec market<br />
- Transport rules by the United Nations are binding law!<br />
- 8 key factors for battery selection<br />
- Potential danger of batteries - Safety first!<br />
- How to know if a battery is safe!<br />
- BATSO Tests and their history<br />
90
Thank you for your time!<br />
91
Hannes Neupert<br />
hannes.neupert@extraenergy.<strong>org</strong><br />
http://www.batso.<strong>org</strong><br />
<strong>ExtraEnergy</strong> e.V.<br />
Koskauer Straße 98<br />
07922 Tanna<br />
Germany<br />
Tel. +49 36646 27094<br />
Fax. +49 36646 27095<br />
info@extraenergy.<strong>org</strong><br />
93
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