bigmoose
1 MW
I have started to research shipping regulations for large Li batteries, since I had a good idea and a potential launch customer for a 36 V (nominal) 12 AHr LiFePO4 derivative battery. Here is the just "peachy" news so far:
... I have to be missing something! How in the world can you take the battery in the Chevrolet Volt Directly short it and not have a plasma ball?
- Primary batteries are defined as Li Metal so those regs don't apply.
- Secondary batteries (rechargeable) are Li Ion irregardless of type, so these are our regs.
- Lithium-ion & Polymer Cell / Battery Max. Lithium Content >5.0 grams / >25 grams We convert at 0.3 gm per cell AHr = 0.3 * 12 AHr * 12 cells = 43.2 gm Li equivalent so we are greater than 25 grams and classified as "Large" As such the following Apply:
- Requires Class 9 markings, label, specification packaging, and shipping papers
- Here is the KILLER: The battery must PASS ALL UN Tests Class 9 / T1-T8 This will destroy 24 batteries in testing! As I read the regs the battery must pass the following tests even if shipped by truck or rail
- Test T.1: Altitude simulation stored at a pressure of 11.6 kPa or less for at least six hours at ambient temperature (20 ± 5 °C) with no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test cell or battery after testing is not less than 90% of its voltage immediately prior to this procedure
- Test T.2: Thermal test stored for at least six hours at a test temperature equal to 75 ± 2 °C, followed by storage for at least six hours at a test temperature equal to –40 ± 2 °C. The maximum time interval between test temperature extremes is 30 minutes. This procedure is to be repeated 10 times with no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test cell or battery after testing is not less than 90% of its voltage immediately prior to this procedure
- Test T.3: Vibration The vibration shall be a sinusoidal waveform with a logarithmic sweep between 7 Hz and 200 Hz and back to 7 Hz traversed in 15 minutes. This cycle shall be repeated 12 times for a total of 3 hours for each of three mutually perpendicular mounting positions of the cell (Thats 9 Freaking hours on the shaker!) The logarithmic frequency sweep is as follows: from 7 Hz a peak acceleration of 1 gn is maintained until 18 Hz is reached. The amplitude is then maintained at 0.8 mm (1.6 mm total excursion) and the frequency increased until a peak acceleration of 8 gn occurs (approximately 50 Hz). A peak acceleration of 8 gn is then maintained until the frequency is increased to 200 Hz. With no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test cell or battery after testing is not less than 90% of its voltage immediately prior to this procedure
- Test T.4: Shock large cells and large batteries shall be subjected to a half-sine shock of peak acceleration of 50 gn and pulse duration of 11 milliseconds. Each cell or battery is subjected to three shocks in the positive direction followed by three shocks in the negative direction of each of three mutually perpendicular mounting positions of the cell for a total of 18 shocks. With no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test cell or battery after testing is not less than 90% of its voltage immediately prior to this procedure
- Test T.5: External short circuit The cell or battery to be tested shall be temperature stabilized so that its external case temperature reaches 55 ± 2°C and then the cell or battery shall be subjected to a short circuit condition with a total external resistance of less than 0.1 ohm at 55 ± 2 °C. This short circuit condition is continued for at least one hour after the cell or battery external case temperature has returned to 55 ± 2°C. Cells and batteries meet this requirement if their external temperature does not exceed 170 °C and there is no disassembly, no rupture and no fire within six hours of this test. Right- Dead short to exhaustion and only 170 deg C!
- Test T.6: Impact component cell is to be placed on a flat surface. A 15.8 mm diameter bar is to be placed across the centre of the sample. A 9.1 kg mass is to be dropped from a height of 61 ± 2.5 cm onto the sample. Cells and component cells meet this requirement if their external temperature does not exceed 170 °C and there is no disassembly and no fire within six hours of this test.
- Test T.7: Overcharge The charge current shall be twice the manufacturer's recommended maximum continuous charge current. when the manufacturer's recommended charge voltage is more than 18V, the minimum voltage of the test shall be 1.2 times the maximum charge voltage for 24 hours. Rechargeable batteries meet this requirement if there is no disassembly and no fire within seven days of the test.
- Test T.8: Forced discharge Each cell shall be forced discharged at ambient temperature by connecting it in series with a 12V D.C. power supply at an initial current equal to the maximum discharge current specified by the manufacturer. Primary or rechargeable cells meet this requirement if there is no disassembly and no fire within seven days of the test.
... I have to be missing something! How in the world can you take the battery in the Chevrolet Volt Directly short it and not have a plasma ball?