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Test Procedures and Evaluation Methods for Prevent Electric Shock Protection After Collision for Electric Vehicles

Testing Methods

There are more and more opportunities for users to purchase electric vehicles with the rapid spread of electric vehicles and electric hybrids (except vehicles in which working voltage of motor is less than AC30V and DC60V) so it is required for occupants not to be electrocuted by high voltage even if they have a collision accident. At Japan New Car Assessment Program, evaluations of "requirements for protection from electric shock", "leakage of electrolyte in high-voltage battery" and "fixing state of high voltage battery" are carried out as evaluation to protection from electric shock after each collision test and the results are announced to users from 2011 when Full-wrap Frontal Collision Test, Offset Collision Test, which is changed into New Offset Collision Test from 2024, and Side Collision Test are conducted.
Also, in case that high-voltage automatic disconnect is mounted, the operating status is checked, too.
However, requirements for protection from electric shock is evaluated "inside a vehicle" to 2013 and "inside and outside a vehicle" from 2014.

The evaluation method of a result

Evaluation item Evaluation criteria
Electric Shock Protection※1 ①Direct Contact Protection ＋ Indirect Contact Protection
  • The protection for the live parts of the power system (excluding the coupling system for the charging system) shall meet Protection Degree IPXXB.
  • The resistance between exposed conductive parts except for the coupling system for the charging system and the electrical chassis shall be < 0.1Ω in a state with the electric current of 0.2A or more flowing.
②Measurement of Isolation Resistance
  • The following requirements shall be satisfied except for the coupling system for the charging system.
    However, they shall not be applied if two or more electric potential in a part of the live parts aren't protected under the conditions of Protection Degree IPXXB.
    • The working voltage in AC circuits and circuits including AC circuits shall be ≧ 500Ω/V. If the requirements of Protection Degree IPXXB are satisfied or the voltage at device position in AC circuits is ≦ 30V, the working voltage shall be ≧ 100Ω/V.
    • The working voltage in DC circuits shall be ≧ 100Ω/V.
③Residual Voltage
  • Residual voltage present in high-voltage parts measured in 60 seconds after a collision (between 5 and 60 seconds after a collision to 2023) shall be ≦ AC 30V or ≦ DC 60V.
④Residual Energy Measurement
  • Energy present in the high-voltage parts measured in 60 seconds after a collision (between 5 and 60 seconds after a collision to 2023) shall be ≦ 0.2J.
High-voltage battery electrolyte leakage performance
  • No leakage of electrolyte into the cabin.
  • Leakage quantity should be ≦ 7% of total electrolyte quantity 30 minutes after a collision if there is leakage of electrolyte outside the cabin. However, open type traction battery shall be ≦ 7% of total electrolyte quantity and 5L.
High-voltage battery fixation status
  • RESS inside the cabin shall be fixed at a prescribed position.
  • RESS outside the cabin shall not be penetrated into the inside of the cabin.

※1 Electric shock protection of all high-voltage parts of the power system after a collision is checked by combining ① to ④ measuring method in the above table.

Displaying results of the tests

The compliance is shown by the right mark if all requirements of electric shock protection, electrolyte leakage at high-voltage batttery and fixation state of high-voltage battery are satisfied. Also, if one of the requirements is satisfied, that is announced as a comment.

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