GB 38031-2025 Electric vehicles traction battery safety requirements
Electric vehicles traction battery safety requirements
1 Scope
This document specifies the safety requirements for cell, pack or system of electric vehicle traction battery (hereinafter referred to as battery), and describes corresponding test methods.
This document is applicable to electric vehicle traction battery.
2 Normative references
The following documents contain requirements which, through reference in this text, constitute provisions of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2423.4 Environmental testing for electric and electronic products - Part 2: Test method - Test Db: Damp heat, cyclic (12h+12h cycle)
GB/T 2423.17-2024 Environmental testing - Part 2: Test methods - Test Ka: Salt mist
GB/T 2423.43 Environmental testing for electric and electronic products - Part 2: Test methods - Mounting of specimens for vibration impact and similar dynamic tests
GB/T 2423.56 Environmental testing - Part 2: Test methods - Test Fh: Vibration, broad-band random and guidance
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB/T 19596 Terminology of electric vehicles
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 19596 and the following apply.
3.1
battery cell
basic unit device that converts chemical energy and electric energy to each other
Note: It generally includes electrode, diaphragm, electrolyte, housing and terminal, and is also designed to be rechargeable.
3.2
battery module
an assembly composed of two or more battery cells in series connection, parallel connection or combination thereof, which is used as a power supply
3.3
battery pack
unit which is capable of obtaining external electric energy and outputting electric energy outwards
Note: It generally includes battery cell, battery management module (excluding BCU), battery compartment and corresponding accessories (cooling components, connecting cables, etc.).
3.4
battery system
energy storage device consisting of one or more battery pack(s) and corresponding accessories (management system, high voltage circuit, low voltage circuit, mechanical assembly, etc.)
3.5
battery subsystem
arbitrary energy storage collection consisting of components of a battery pack or system
3.6
battery electronics
electronic device collecting or simultaneously monitoring the electric and thermal data of battery pack
Note: The battery electronics may include cell controllers and the electronics for equalization of battery cells. The equalization between battery cells may be controlled by the battery electronics or battery control unit.
3.7
battery control unit
electronic device controlling, managing, detecting, or calculating relevant electric and thermal parameters of the battery system and providing communication between the battery system and other vehicle controllers
3.8
rated capacity
capacity of battery cell, battery module, battery pack or system declared by the manufacturer after measurement under the conditions specified by the manufacturer
Note: Generally, the rated capacity is expressed in Ah or mAh.
3.9
practical capacity
capacity released from a fully charged battery cell, battery module, battery pack or system under the conditions specified by the manufacturer
3.10
state-of-charge
percentage of capacity which may be released by the current battery cell, battery module, battery pack or system under the discharge conditions specified by the manufacturer in respect of the practical capacity
3.11
explosion
sudden release of energy sufficient to generate pressure waves or jets
Note: The pressure waves or jets may cause structural or physical damage to the surrounding area.
3.12
fire
situation that any part of the battery cell, battery module, battery pack or system keeps burning (for a duration of greater than 1s)
Note 1: The burning duration of greater than 1s refers to the duration of single fire other than cumulative time of multiple ones.
Note 2: Visual judgment shall be made without disassembling the test object. The spark and arc discharge is not considered as combustion.
3.13
housing crack
mechanical damage to the housing of battery cell, battery module, battery pack or system due to internal or external factors, resulting in exposure or spillage of inner matter
3.14
leakage
phenomenon that visible matter is leaked out of the test object from battery cell, battery module, battery pack or system
Note: Visible matters are judged visually without disassembling the test object.
3.15
thermal event
phenomenon that the temperature within the battery pack or system is significantly higher than the maximum operating temperature (as defined by the manufacturer)
3.16
thermal runaway
uncontrollable temperature rise of the battery caused by the exothermic chain reaction of the battery cell
3.17
thermal propagation
successive thermal runaway of the rest battery cells caused by the thermal runaway of a battery cell in a battery pack or system
3.18
end-of-charge voltage
allowable maximum voltage of battery cell, battery module, battery pack or system during charging under the conditions specified by the manufacturer
3.19
end-of-discharge voltage
allowable minimum voltage of battery cell, battery module, battery pack or system during discharging under the conditions specified by the manufacturer
3.20
body frame
space frame structure constructed to ensure the strength and rigidity of the vehicle body
[Source: GB/T 4780-2020, 4.4.3]
4 Symbols and abbreviations
4.1 Symbols
For the purposes of this document, the following symbols apply.
I1: 1h rate discharge current (A), which is equal to the rated capacity.
I3: 3h rate discharge current (A), which is equal to 1/3 of the rated capacity.
4.2 Abbreviations
For the purposes of this document, the following abbreviations apply.
BCU: battery control unit
FS: full scale
PSD: power spectral density
RMS: root mean square
SOC: state-of-charge
5 Safety requirements
5.1 Safety requirements for battery cell
5.1.1 When subjected to overdischarge test in accordance with 8.1.2, the battery cell shall be free from fire and explosion.
5.1.2 When subjected to overcharge test in accordance with 8.1.3, the battery cell shall be free from fire and explosion.
5.1.3 When subjected to external short circuit test in accordance with 8.1.4, the battery cell shall be free from fire and explosion.
5.1.4 When subjected to heating test in accordance with 8.1.5, the battery cell shall be free from fire and explosion.
5.1.5 When subjected to temperature cycle test in accordance with 8.1.6, the battery cell shall be free from fire and explosion.
5.1.6 When subjected to extrusion test in accordance with 8.1.7, the battery cell shall be free from fire and explosion.
5.1.7 When subjected to safety test after fast charging cycle in accordance with 8.1.8, the battery cell shall be free from fire and explosion.
5.2 Safety requirements for battery pack or system
5.2.1 When subjected to vibration test in accordance with 8.2.1, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
5.2.2 When subjected to mechanical shock test in accordance with 8.2.2, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
5.2.3 When subjected to simulated collision test in accordance with 8.2.3, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
Foreword i Introduction iv 1 Scope 2 Normative references 3 Terms and definitions 4 Symbols and abbreviations 4.1 Symbols 4.2 Abbreviations 5 Safety requirements 5.1 Safety requirements for battery cell 5.2 Safety requirements for battery pack or system 6 Test conditions 6.1 General conditions 6.2 Accuracy of measuring apparatuses and meters 6.3 Error in test process 6.4 Data recording and its interval 7 Test preparation 7.1 Test preparation of battery cell 7.2 Test preparation for battery pack or system 8 Test methods 8.1 Test methods for battery cell safety 8.2 Safety test methods for battery pack or system 9 Judgment of the same type 10 Implementation of this standard Annex A (Informative) Examples for typical structure of battery pack and system Annex B (Normative) Test method for insulation resistance of battery pack or system Annex C (Normative) Thermal propagation analysis and verification report Bibliography
GB 38031-2025 Electric vehicles traction battery safety requirements
Electric vehicles traction battery safety requirements
1 Scope
This document specifies the safety requirements for cell, pack or system of electric vehicle traction battery (hereinafter referred to as battery), and describes corresponding test methods.
This document is applicable to electric vehicle traction battery.
2 Normative references
The following documents contain requirements which, through reference in this text, constitute provisions of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2423.4 Environmental testing for electric and electronic products - Part 2: Test method - Test Db: Damp heat, cyclic (12h+12h cycle)
GB/T 2423.17-2024 Environmental testing - Part 2: Test methods - Test Ka: Salt mist
GB/T 2423.43 Environmental testing for electric and electronic products - Part 2: Test methods - Mounting of specimens for vibration impact and similar dynamic tests
GB/T 2423.56 Environmental testing - Part 2: Test methods - Test Fh: Vibration, broad-band random and guidance
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB/T 19596 Terminology of electric vehicles
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 19596 and the following apply.
3.1
battery cell
basic unit device that converts chemical energy and electric energy to each other
Note: It generally includes electrode, diaphragm, electrolyte, housing and terminal, and is also designed to be rechargeable.
3.2
battery module
an assembly composed of two or more battery cells in series connection, parallel connection or combination thereof, which is used as a power supply
3.3
battery pack
unit which is capable of obtaining external electric energy and outputting electric energy outwards
Note: It generally includes battery cell, battery management module (excluding BCU), battery compartment and corresponding accessories (cooling components, connecting cables, etc.).
3.4
battery system
energy storage device consisting of one or more battery pack(s) and corresponding accessories (management system, high voltage circuit, low voltage circuit, mechanical assembly, etc.)
3.5
battery subsystem
arbitrary energy storage collection consisting of components of a battery pack or system
3.6
battery electronics
electronic device collecting or simultaneously monitoring the electric and thermal data of battery pack
Note: The battery electronics may include cell controllers and the electronics for equalization of battery cells. The equalization between battery cells may be controlled by the battery electronics or battery control unit.
3.7
battery control unit
electronic device controlling, managing, detecting, or calculating relevant electric and thermal parameters of the battery system and providing communication between the battery system and other vehicle controllers
3.8
rated capacity
capacity of battery cell, battery module, battery pack or system declared by the manufacturer after measurement under the conditions specified by the manufacturer
Note: Generally, the rated capacity is expressed in Ah or mAh.
3.9
practical capacity
capacity released from a fully charged battery cell, battery module, battery pack or system under the conditions specified by the manufacturer
3.10
state-of-charge
percentage of capacity which may be released by the current battery cell, battery module, battery pack or system under the discharge conditions specified by the manufacturer in respect of the practical capacity
3.11
explosion
sudden release of energy sufficient to generate pressure waves or jets
Note: The pressure waves or jets may cause structural or physical damage to the surrounding area.
3.12
fire
situation that any part of the battery cell, battery module, battery pack or system keeps burning (for a duration of greater than 1s)
Note 1: The burning duration of greater than 1s refers to the duration of single fire other than cumulative time of multiple ones.
Note 2: Visual judgment shall be made without disassembling the test object. The spark and arc discharge is not considered as combustion.
3.13
housing crack
mechanical damage to the housing of battery cell, battery module, battery pack or system due to internal or external factors, resulting in exposure or spillage of inner matter
3.14
leakage
phenomenon that visible matter is leaked out of the test object from battery cell, battery module, battery pack or system
Note: Visible matters are judged visually without disassembling the test object.
3.15
thermal event
phenomenon that the temperature within the battery pack or system is significantly higher than the maximum operating temperature (as defined by the manufacturer)
3.16
thermal runaway
uncontrollable temperature rise of the battery caused by the exothermic chain reaction of the battery cell
3.17
thermal propagation
successive thermal runaway of the rest battery cells caused by the thermal runaway of a battery cell in a battery pack or system
3.18
end-of-charge voltage
allowable maximum voltage of battery cell, battery module, battery pack or system during charging under the conditions specified by the manufacturer
3.19
end-of-discharge voltage
allowable minimum voltage of battery cell, battery module, battery pack or system during discharging under the conditions specified by the manufacturer
3.20
body frame
space frame structure constructed to ensure the strength and rigidity of the vehicle body
[Source: GB/T 4780-2020, 4.4.3]
4 Symbols and abbreviations
4.1 Symbols
For the purposes of this document, the following symbols apply.
I1: 1h rate discharge current (A), which is equal to the rated capacity.
I3: 3h rate discharge current (A), which is equal to 1/3 of the rated capacity.
4.2 Abbreviations
For the purposes of this document, the following abbreviations apply.
BCU: battery control unit
FS: full scale
PSD: power spectral density
RMS: root mean square
SOC: state-of-charge
5 Safety requirements
5.1 Safety requirements for battery cell
5.1.1 When subjected to overdischarge test in accordance with 8.1.2, the battery cell shall be free from fire and explosion.
5.1.2 When subjected to overcharge test in accordance with 8.1.3, the battery cell shall be free from fire and explosion.
5.1.3 When subjected to external short circuit test in accordance with 8.1.4, the battery cell shall be free from fire and explosion.
5.1.4 When subjected to heating test in accordance with 8.1.5, the battery cell shall be free from fire and explosion.
5.1.5 When subjected to temperature cycle test in accordance with 8.1.6, the battery cell shall be free from fire and explosion.
5.1.6 When subjected to extrusion test in accordance with 8.1.7, the battery cell shall be free from fire and explosion.
5.1.7 When subjected to safety test after fast charging cycle in accordance with 8.1.8, the battery cell shall be free from fire and explosion.
5.2 Safety requirements for battery pack or system
5.2.1 When subjected to vibration test in accordance with 8.2.1, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
5.2.2 When subjected to mechanical shock test in accordance with 8.2.2, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
5.2.3 When subjected to simulated collision test in accordance with 8.2.3, the battery pack or system shall be free from leakage, housing crack, fire or explosion. The insulation resistance after the test shall not be less than 100Ω/V. If there is an AC circuit, the insulation resistance shall not be less than 500Ω/V.
Contents of GB 38031-2025
Foreword i
Introduction iv
1 Scope
2 Normative references
3 Terms and definitions
4 Symbols and abbreviations
4.1 Symbols
4.2 Abbreviations
5 Safety requirements
5.1 Safety requirements for battery cell
5.2 Safety requirements for battery pack or system
6 Test conditions
6.1 General conditions
6.2 Accuracy of measuring apparatuses and meters
6.3 Error in test process
6.4 Data recording and its interval
7 Test preparation
7.1 Test preparation of battery cell
7.2 Test preparation for battery pack or system
8 Test methods
8.1 Test methods for battery cell safety
8.2 Safety test methods for battery pack or system
9 Judgment of the same type
10 Implementation of this standard
Annex A (Informative) Examples for typical structure of battery pack and system
Annex B (Normative) Test method for insulation resistance of battery pack or system
Annex C (Normative) Thermal propagation analysis and verification report
Bibliography
