Avoiding EV Battery Thermal Events
It is critically important to thoroughly test new batteries, as well as batteries involved in accidents, before allowing them to go back into service in electric vehicles (EVs). New batteries must undergo rigorous battery safety testing to ensure they meet safety standards, function properly, and do not have manufacturing defects that could lead to dangerous situations, such as thermal runaway or loss of power. For batteries involved in accidents, even minor impacts can damage internal components or disrupt the integrity of the battery pack, increasing the risk of overheating, fires, or electrical malfunctions. Comprehensive testing ensures that any damage, such as compromised insulation or bonding, is detected and addressed before the battery is reinstalled. By testing batteries after accidents or damage, manufacturers and service providers help safeguard the vehicle, its occupants, and the surrounding environment from potential safety hazards, ensuring reliable performance when the vehicle is returned to service.
EV Battery Thermal Event Consequences
Putting out an electric vehicle (EV) battery thermal event, often referred to as a “thermal runaway,” is extremely challenging due to the nature of lithium-ion batteries. Once a cell within the battery pack overheats, it can trigger a chain reaction where adjacent cells also overheat, causing the entire pack to ignite. These battery fires burn at very high temperatures and can reignite even after they appear to be extinguished, making them particularly difficult for firefighters to control. Traditional methods, such as water or foam, are often insufficient to cool the internal temperatures of the battery pack, requiring large amounts of water over extended periods to contain the fire. Additionally, the presence of toxic fumes and potential for explosion add further complications. Specialized equipment, extensive training, and a strategic approach are often required to safely extinguish and manage these events, which can last for hours or even days.
How to Mitigate Risk for Your Customers & Potential Liability for Your Organization
The ALT 100 by Autel is a cutting-edge tool designed for testing the integrity of high-voltage battery enclosures and thermodynamic systems in electric and hybrid vehicles. This tool is essential for two key scenarios: when a car is brand new and when a battery has been involved in a structural accident. The theory behind this testing is to ensure the battery is properly sealed to prevent water, salt, or debris from entering the battery pack, which could lead to shorts and potential thermal events.
The battery enclosure, typically composed of two metal pieces with a layer of RTV-like substance, can degrade over time, even without an accident. A notable example that brought attention to this issue was a hurricane in Fort Myers, Florida, which led to battery thermal events due to compromised enclosures. The federal government now mandates testing to prevent such incidents.
The ALT 100 is invaluable for collision shops needing to verify battery enclosure integrity after accidents. It’s also beneficial for independent auto repair shops offering comprehensive services to ensure customer safety. Additionally, the tool is versatile for technicians working on AC systems or cooling systems in plug-in hybrids or hybrid vehicles, as it tests thermodynamics within the high-voltage battery pack. This makes the ALT 100 a must-have for any service repair shop involved with high-voltage systems. Check out our website today for more information!