Skip to main content
Sister Publication Links
  • Automotive News
  • Automobilwoche
  • Automotive News Canada
  • Automotive News China
Subscribe
  • Subscribe
  • Newsletters
  • Login
  • HOME
    • Latest news
    • Automakers
    • Suppliers
    • New Product
    • Environment/Emissions
    • Sales By Market
    • On The Move
    • Auto Shows
    • Munich Auto Show
    • Geneva Auto Show
    • Paris Auto Show
    • Beijing Auto Show
    • Shanghai Auto Show
  • Features
    • Long Read
    • Interview of the Month
    • Focus on Electrification
    • Focus on Technology
    • Segment Analysis
    • Cars & Concepts
    • Supplier Spotlight
    • Europe By The Numbers
  • Opinion
    • Blogs
    • Commentary
    • Guest columnists
  • Photos
    • Photo Galleries
    • Geneva Photo Gallery
    • Beijing Photo Gallery
    • Frankfurt Photo Gallery
    • Paris Photo Gallery
    • Shanghai Photo Gallery
  • Podcasts
  • Car Cutaways
  • EVENTS
    • ANE Congress
    • ANE Rising Stars
    • ANE Eurostars
  • More
    • Publishing Partners
    • Social Media
    • Contact Us
    • Media Kit
    • About Us
    • Capgemini: All or nothing: Why circular business models require a holistic approach
    • Capgemini: Invent Head on automotive takeaways from CES 2023
    • Capgemini: Securing the industry's future through a radical rethink
    • Capgemini: Succeeding with the automated driving journey through AI
    • Capgemini: The circular economy is spurring new thinking on EV batteries
    • Capgemini: Toyota and Capgemini leaders on how OEMs can handle industry changes and succeed
    • HEXAGON: Plugging into data is the only way to make winning EVs
    • TUV Rheinland: Ideas, services and certifications for smart mobility
    • TUV Rheinland: Testing of automated and autonomous vehicles on test tracks
    • Toyota Europe
    • UFI Filters
    • Facebook
    • Instagram
    • LinkedIn
    • Twitter
MENU
Breadcrumb
  1. Home
  2. Guest Columnist
January 29, 2021 03:36 AM

How testing can prevent costly EV recalls

Artur Schneider
  • Tweet
  • Share
  • Share
  • Email
  • More
    Print

    Artur Schneider is managing director of TÜV Rheinland's Automotive Component Testing division.

    Testing and type approval are central building blocks of automotive component and vehicle development.

    In many cases, independent testing laboratories support their customers through the entire development process until commercialization of the vehicles.

    For batteries and electric vehicles, testing is essential in the development process, as functionality and safety of the components and the entire vehicle can be evaluated by internal processes and verified by third parties.

    The EU prescribes a series of mandatory tests for type approval.

    • Mechanical tests ensure the stability of the battery housing for prevention of dangerous deformation or damage of the battery.
    • Electrical tests prove the technical protection of cells and systems, for example, making sure battery management system is not at risk of causing overcharge or over-discharge.
    • Thermal tests show the suitable design of the thermal management and ensure the stability of the cells at low and elevated temperatures.
    • Electromagnetic compatibility tests ensure that the battery does not interfere with other surrounding systems and eventually cause a malfunction through electromagnetic radiation.

    For type approval, each battery has to fulfill precisely defined test procedures within the aforementioned test categories. This test catalog represents the least minimum amount of testing that is required to prove technical and environmental safety of the system.

    However, along with the increasing performance and safety requirements of the automotive industry, the demand for testing also increases.

    Usually, upfront quality assurance is economically more advantageous than a root cause analysis on malfunctions in the field. Such analyses often include detailed examination of incidents, which are difficult to reconstruct. Moreover, in severe cases, for example a battery fire, most of the evidence is destroyed and conclusive evaluation is impossible.

    Battery development is an iterative process, following project phases and distinct milestones from functional sample, to prototype and series production.

    In each step and along the development life cycle of the system mandatory verification tests are integrated and augmented by additional tests to prove performance, functionality and safety under extreme conditions.

    The test results in the early stage provide important information that can be directly incorporated into the development process.

    During the type approval, the mandatory test procedure is applied to test objects already being manufactured using a series production process. For this purpose, production processes are defined, and product-specific, expensive tools are manufactured to map the defined dimensions of the system and ensure estimated tolerances.

    A comprehensive, state-of-the-art testing procedure within the battery development is therefore of exceptional importance for manufacturers to avoid costly recalls and continuously improve the product.

    Despite extensive testing before type approval, malfunctions or potential sources of danger sometimes force manufacturers to issue recalls. Among other root causes, impurities in the battery materials, immature production processes and malfunctions of electronic components can lead to overheating of the battery and eventually to reduction of battery quality.

    In the worst case, this can also result in material harm or personal injury. The consequences for the manufacturer of the affected product can, in addition to the loss of credibility, range from considerable financial impact to insolvency of the company.

    While severe battery disasters in the field are extremely rare, these events have to be eliminated under any circumstances. Therefore, it is very importance to simulate extreme situations to verify the safety of the battery during operation.

    In addition to the aforementioned procedures, functional and misuse tests are extremely relevant. These include a variety of extreme conditions such as temperature shock, electrical shortcut, mechanical deformation and fire.

    The demand for misuse tests is rising rapidly. However, the performance of misuse tests requires specialized testing facilities, equipment and expertise. That is why it has become a major bottleneck in the EV development process.

    In summary, testing of the vehicle, components and battery is an essential part of vehicle development to confirm technical and functional safety of the overall system.

    The verification of the product along the various sample phases requires know-how, investment and effort.

    However, it is an important prerequisite for continuous product improvement, quality assurance and safe operation of the vehicle in the field. Although costly recalls cannot be entirely prevented by rigorous testing, it can definitely help to reduce the odds of occurrence.

    RECOMMENDED FOR YOU
    How the metaverse is helping the car industry
    Recommended for You
    Getac Russell Younghusband
    How the metaverse is helping the car industry
    Testbirds CEO Georg Hansbauer
    The rise of the smart green machine
    Juergen Reers and Dennis Roehr Accenture
    How automakers can succeed in the $3.5 billion battle for digital mobility services revenue
    Sign up for free newsletters
    EMAIL ADDRESS

    Please enter a valid email address.

    Please enter your email address.

    Please verify captcha.

    Please select at least one newsletter to subscribe.

    You can unsubscribe at any time through links in these emails. For more information, see our Privacy Policy.

    Get Free Newsletters

    Sign up and get the best of Automotive News Europe delivered straight to your email inbox, free of charge. Choose your news – we will deliver.

    You can unsubscribe at any time through links in these emails. For more information, see our Privacy Policy.

    SUBSCRIBE TODAY

    Get 24/7 access to in-depth, authoritative coverage of the auto industry from a global team of reporters and editors covering the news that’s vital to your business.

    SUBSCRIBE NOW
    Connect with Us
    • Twitter
    • Facebook
    • LinkedIn
    • Instagram

    Founded in 1996, Automotive News Europe is the preferred information source for decision-makers and opinion leaders operating in Europe.

    Contact Us

    1155 Gratiot Avenue
    Detroit MI  48207-2997
    Tel: +1 877-812-1584

    Email Us

    ISSN 2643-6590 (print)
    ISSN 2643-6604 (online)

     

    Resources
    • About us
    • Contact Us
    • Advertise with us
    • Advertise with Us
    • Ad Choices Ad Choices
    • Sitemap
    Awards
    • Rising Stars
    • Eurostars
    • Leading Women
    Legal
    • Terms and Conditions
    • Privacy Policy
    • Privacy Request
    Automotive News Europe
    Copyright © 1996-2023. Crain Communications, Inc. All Rights Reserved.
    • HOME
      • Latest news
      • Automakers
      • Suppliers
      • New Product
      • Environment/Emissions
      • Sales By Market
      • On The Move
      • Auto Shows
        • Munich Auto Show
        • Geneva Auto Show
        • Paris Auto Show
        • Beijing Auto Show
        • Shanghai Auto Show
    • Features
      • Long Read
      • Interview of the Month
      • Focus on Electrification
      • Focus on Technology
      • Segment Analysis
      • Cars & Concepts
      • Supplier Spotlight
      • Europe By The Numbers
    • Opinion
      • Blogs
      • Commentary
      • Guest columnists
    • Photos
      • Photo Galleries
      • Geneva Photo Gallery
      • Beijing Photo Gallery
      • Frankfurt Photo Gallery
      • Paris Photo Gallery
      • Shanghai Photo Gallery
    • Podcasts
    • Car Cutaways
    • EVENTS
      • ANE Congress
      • ANE Rising Stars
      • ANE Eurostars
    • More
      • Publishing Partners
        • Capgemini: All or nothing: Why circular business models require a holistic approach
        • Capgemini: Invent Head on automotive takeaways from CES 2023
        • Capgemini: Securing the industry's future through a radical rethink
        • Capgemini: Succeeding with the automated driving journey through AI
        • Capgemini: The circular economy is spurring new thinking on EV batteries
        • Capgemini: Toyota and Capgemini leaders on how OEMs can handle industry changes and succeed
        • HEXAGON: Plugging into data is the only way to make winning EVs
        • TUV Rheinland: Ideas, services and certifications for smart mobility
        • TUV Rheinland: Testing of automated and autonomous vehicles on test tracks
        • Toyota Europe
        • UFI Filters
      • Social Media
        • Facebook
        • Instagram
        • LinkedIn
        • Twitter
      • Contact Us
      • Media Kit
      • About Us