United States Department of Transportation
i
DC and AC Charging Safety Evaluation Procedure Development, Validation, and Assessment
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2019-07-01
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[PDF-5.19 MB]
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Edition:Final Report
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Abstract:Charging a plug-in electric vehicle exposes new hazards and risks different from internal combustion engine vehicles. These hazards and risks must be defined and mitigated through proper system design and verified via functional system performance testing. DC charging represents additional challenges. Unlike AC charging where the on-board charger and battery system are under direct control of a vehicle, DC charging uses an external charger and requires the vehicle, high-voltage system controls, and battery management systems to interact with an external device directly connected to the vehicle’s high-voltage battery. This report focuses on system-level safety verification procedures to test if a connected vehicle/charging system can safely handle failure modes and hazards commonly associated with charging. This project developed a DC fast-charging safety test procedure, a holistic collection of tests based on 24 FMEAs conducted by the battery system developer for real-world applications and clients reflecting a broad range of in-field scenarios. This project report presents validation and refinement of the test procedures maintaining the holistic approach initially used by SAE. This report also addresses a broader range of vehicle charging technologies to include AC charging technology presently available for electric vehicles. This report documents these efforts to independently evaluate, refine, and validate test procedures that can be applied to a range of vehicles, charger technologies, and battery configurations.
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Content Notes:Suggested APA Format Citation: Rask, E., Harper, J., Dobrzynski, D., & Iliev, S. (2019, July). DC and AC charging safety evaluation procedure development, validation, and assessment (Report No. DOT HS 812 778). Washington, DC: National Highway Traffic Safety Administration.
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