Otis Singleton
Testing electric vehicles is a critical aspect of the automotive industry's shift towards electrification and the growing EV market. With the increasing voltage levels in electric vehicles, it is essential to conduct thorough tests to ensure the safety of both technicians and vehicles. EV testing involves evaluating electric vehicle models at the full-vehicle level and the component level, including subsystems and modules. Testing procedures cover various aspects, such as battery health, range, efficiency, and compliance with safety and performance standards. To meet industry standards and consumer expectations, manufacturers must navigate evolving regulations and advancements in technology, such as high-voltage components and battery management systems.
| Characteristics | Values |
|---|---|
| Testing type | Fuel economy, EV range, battery health, safety, functionality, standards compliance, lifetime and aging, quality control, safety compliance, performance validation, end-of-line |
| Testing standards | EPA regulations, CFR 600.116-12, CFR 600.210-12, ECE-R100, EMC |
| Testing equipment | Multimeter, battery testers, OBD2 reader, Scienlab Charging Discovery System (CDS), DT4261, LoZ mode, RM3548-50, DTC scan |
| Testing process | City test, highway cycle, mid-test constant speed cycle, end-of-test constant speed cycle, charging for a specific amount of time, comparing battery percentage to battery capacity, monitoring vehicle's range, measuring voltage on surfaces |
| Testing location | EPA's NVFEL facility, vehicle manufacturers' facilities |
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What You'll Learn
Testing the health of an electric car's battery
State of Charge (SOC)
One simple method is to monitor the State of Charge (SOC), which indicates the amount of charge left in the battery at a given moment. This information is typically displayed on the dashboard or infotainment screen of the vehicle. By tracking the SOC over time, you can get a sense of the battery's health and identify any abnormal drops.
Battery Management System (BMS)
Many electric vehicles are equipped with a Battery Management System (BMS) that continuously monitors the battery's performance. The BMS provides valuable data such as temperature, voltage, and current. Some BMS systems also offer an overall assessment of the battery's condition. This information can be accessed through the vehicle's dashboard, infotainment display, or companion apps provided by the manufacturer, such as those offered by Tesla and Hyundai.
Third-Party Apps and Tools
Third-party battery health data providers offer apps and tools that can help test the real-range capability and battery health of any electric car. These apps, such as ClearWatt EV Health Checker, utilize mobile telematics and AI to measure the efficiency of the vehicle across sample journeys, providing a more accurate assessment by eliminating factors like driving style and environmental conditions. Additionally, popular third-party apps like Tessie offer insights into battery health, degradation, and other detailed information specifically for Tesla vehicles.
Multimeter and Battery Testers
A multimeter is a multipurpose tool that can measure voltage, current, and resistance. It can be used to diagnose issues with electric vehicle batteries, but it requires some research to ensure it is suitable for open-circuit and circuit tests on electric vehicles and can make accurate temperature measurements. Battery testers are also available for purchase and are designed specifically to test the health of electric vehicle batteries by measuring state of charge, voltage, and temperature, as well as identifying failure or damage.
Visual Inspection and Digital Trouble Codes (DTC) Scan
Before performing any electrical testing or measurement, it is important to shut down the vehicle's high-voltage (HV) system by disconnecting the service plug or switch. A visual inspection can help identify any potential issues, and a DTC scan can detect engine faults.
Voltage Measurement
When unplugging the HV battery's connector, ensure that the HV system is shut down by measuring the voltage between specific points and the chassis ground of the vehicle. It should display zero volts (0 V) to ensure safety and prevent electric shock.
Resistance Measurement
When high-voltage components have been installed or replaced, it is crucial to electrically verify that all chassis, shields, and other components are properly connected. Measuring the resistance of the ground connection at the junction of the chassis and HV components can help identify any potential installation issues.
It is important to note that battery testing can be complex, and specialized equipment and expertise may be required for comprehensive assessments. The methods mentioned above offer a range of options for individuals to test the health of their electric car's battery, from simple visual inspections to more advanced diagnostic tools and apps.
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Safety standards and compliance
NHTSA is also working to establish FMVSS No. 305a, "Electric-Powered Vehicles: Electric Powertrain Integrity," which would expand upon the requirements of FMVSS No. 305. This proposed standard aims to enhance electric vehicle safety by addressing new aspects, such as the performance and risk mitigation requirements for the propulsion battery, referred to as the Rechargeable Electrical Energy Storage System (REESS). It also includes provisions to ensure first and second responders have access to vehicle-specific information for addressing REESS fires and mitigating associated safety risks.
In addition to FMVSS, there are other groups of standards that contribute to EV safety. The Society of Automotive Engineers (SAE) International standards, for instance, focus on advancing the engineering of vehicular mobility. SAE J2464 (2021) defines an abuse test that includes hazardous substance monitoring and mechanical, thermal, and electrical abuse testing. Another standard, SAE J2990/2_202011, addresses the hazards of potential EV-related accidents, providing recommended practices for first and second responders.
ISO standards are also widely recognized in the EV industry, with ISO 26262 focusing on vehicle safety, including EVs. Some ISO standards specifically address electrical safety, such as ISO 17409, which aims to minimize shock hazards during high-voltage testing. Other relevant ISO standards for EV performance testing include ISO 12405, ISO 18243, and ISO 15118. Additionally, ISO 19453-6 (2020) defines environmental conditions and testing procedures for the electrical components of electric propulsion vehicles' drive systems, specifically targeting lithium-ion traction battery packs and systems.
Beyond these standards, the international Electrotechnical Commission (IEC) plays a crucial role in developing standards for electrical and electronic systems. IEC 61851, for instance, addresses electromagnetic compatibility (EMC) and electromagnetic interference (EMI) testing. IEC 62660-2 (2018) provides a reliability and abuse test for auto-traction lithium-ion batteries, encompassing various stress tests such as high-temperature endurance, vibration, and electrical short circuit.
To ensure compliance with these standards, EV manufacturers can avail of testing and certification services offered by organizations like TÜV SÜD. These services help manufacturers comply with global safety requirements and ensure the safety, reliability, and performance of their EV batteries through various tests, including abuse tests and tests under extreme conditions.
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Testing high-voltage components
One of the critical tests for high-voltage components is to measure the resistance of the ground connection between the chassis of the vehicle and the HV components. This can be done using a four-terminal (four-wire Kelvin) DC milliohm meter, which meets the ECE-R100 standard for precision. If the resistance value is high or deviates significantly from the expected value, it indicates a potential issue with the installation or connection of the HV component.
Another important aspect of testing high-voltage components is voltage measurement. It is essential to measure the voltage on surfaces that are likely to be touched when unplugging the HV connector to prevent electric shock. After unplugging the HV battery connector, the voltage between specific points and the chassis ground of the vehicle should be measured and should read zero volts (0 V). This ensures that the HV system is completely shut down before proceeding with any repairs or maintenance.
Technicians should also be trained to test the functions, durability, safety, and performance of high-voltage components and systems. This includes testing battery packs, inverters, electric motors, and charging systems. Specialized testing equipment, similar to that used for residential and commercial wiring systems, is employed to accurately assess these components. Computer simulations and various testing methods are used to evaluate voltage levels and simulate real-world driving conditions, providing a comprehensive understanding of the vehicle's performance and reliability.
Overall, testing high-voltage components in electric vehicles requires a combination of skilled technicians, specialized equipment, and strict safety protocols to ensure accurate diagnostics and the safe handling of electrical systems.
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Fuel economy and EV range testing
One of the key tests for fuel economy and EV range is the city test, which is part of the defined test cycles created to represent typical driving conditions. This test is conducted without the use of heating, ventilation, or air conditioning (HVAC) operation. The results of this test are combined and weighted to estimate average fuel economy, resulting in official miles per gallon (MPG) values. For plug-in electric vehicles (PEVs), the MPGe (miles per gallon equivalent) is used to convey energy consumption in terms of how far the vehicle can travel on an amount of fuel with the same energy content as a gallon of gasoline.
To ensure accurate testing, automakers must follow specific test procedures and submit fuel economy data to organizations like the US Environmental Protection Agency (EPA) annually. The EPA conducts tests at its NVFEL facility, while also auditing data and performing tests on selected vehicles to confirm the results provided by manufacturers. The vehicles are tested in a dynamometer test cell, simulating typical driving conditions with specific speeds, acceleration, temperatures, and HVAC usage.
Additionally, EV range testing can be done by charging the vehicle for a specific duration and then comparing the change in battery percentage to the change in battery capacity (SOC). Monitoring the vehicle's range against EPA estimates and historical data can also provide valuable insights into battery health.
Furthermore, third-party battery health data providers offer apps that can test the real-range capability and battery health of any electric car. These apps use a combination of mobile telematics and AI to establish the vehicle's normalized range capability, eliminating external factors like driving style and environmental conditions.
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Conformance and interoperability testing
One key aspect of conformance and interoperability testing is verifying the compatibility of EV charging systems with different EV models. This involves emulating real-world charging stations in a laboratory setting and conducting tests on the charging interfaces and communication protocols between the vehicle and chargers. The system-in-the-middle test is one such example, where a charging analyser is placed between the charger and the EV to observe the actual voltage, current, and protocol decryption. This test allows for the evaluation of all combinations of AC and DC charging interfaces and communication protocols, ensuring that the charging infrastructure conforms to worldwide standards and can interoperate with different EV models.
Another important focus of conformance and interoperability testing is the evaluation of EV supply equipment (EVSE) or electric vehicle supply equipment. This includes testing the charging analyser combined with an electronic load that emulates an automotive battery, effectively mimicking an EV. By conducting these tests, manufacturers can ensure that the EVSE meets the required standards and can safely and effectively charge EVs.
To facilitate conformance and interoperability testing, organisations like Keysight offer solutions such as the Charging Discovery System and Charging Discover test software. These tools enable automated in-lab testing of EV and EVSE charging interfaces, accelerating the process of verifying conformance and interoperability. Additionally, the Keysight Scienlab Charging Discovery System, in conjunction with a regenerative DC power supply, can emulate an EV for comprehensive testing.
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Frequently asked questions
The standard tests for electric vehicles (EVs) include testing for safety, functionality, and standards compliance. Testing is done at the EPA's NVFEL facility and by vehicle manufacturers at their own facilities. The EPA audits the data provided by vehicle manufacturers and performs its own testing to confirm the results.
One of the simplest ways to test the battery is to charge the car for a specific amount of time and then compare the change in battery percentage to the change in battery capacity (SOC). You can also use a multimeter to measure voltage, current, and resistance. Many electric vehicles come with a Battery Management System (BMS) that continuously monitors the battery's performance.
Measure the voltage on surfaces that are likely to be touched when unplugging the HV connector. After unplugging, make sure that the HV system is shut down by measuring the voltage between specific points and the chassis ground of the vehicle, which should be zero volts (0 V).
There are three types of electric vehicles: battery, plug-in, and hybrid. Battery electric vehicles (BEVs) run solely on battery power and are charged from an external source. Plug-in electric vehicles (PEVs) use MPGe to convey the energy consumption in terms of how many miles the vehicle can go on an amount of fuel with the same energy content as a gallon of gasoline. Hybrid electric vehicles (HEVs) contain both an electric motor and an internal combustion engine.
