AIS-156
AUTOMOTIVE INDUSTRY STANDARDS
SPECIFIC REQUIREMENTS FOR
L CATEGORY ELECTRIC POWER
TRAIN VEHICLES
PART I: REQUIREMENTS OF A VEHICLE WITH REGARD
TO ITS ELECTRICAL SAFETY
PART II: REQUIREMENTS OF A RECHARGEABLE
ELECTRICAL ENERGY STORAGE SYSTEM (REESS) WITH
REGARD TO ITS SAFETY
PRINTED BY
THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA
P.B. NO. 832, PUNE 411 004
ON BEHALF OF
AUTOMOTIVE INDUSTRY STANDARDS COMMITTEE
UNDER
CENTRAL MOTOR VEHICLE RULES – TECHNICAL STANDING COMMITTEE
SET-UP BY
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)
GOVERNMENT OF INDIA
Sept 2020
I
Amendment 2 to AIS-156 (08/2022)
Specific Requirements for L Category Electric
Power Train Vehicles
1.0 Page 15/80, Clause 6.1
Substitute following text for existing text:
6.1 General
6.1.1 REESS Ingress protection requirement.
REESS with 100% SoC shall be tested for water ingress protection IP
X7 as per IEC 60529. There shall be no fire or explosion during IP X7
testing of REESS
6.1.2 Battery Management System (BMS) of REESS
6.1.2.1 BMS shall be microprocessor/microcontroller-based circuit.
6.1.2.2 BMS shall comply EMC requirements as per AIS 004 Part 3 or AIS 004
Part 3 Rev 1 as applicable.
6.1.2.3 BMS of REESS shall be verified for following safety features during
REESS testing as per Annex 8 of this standard.
a) Over-voltage protection
b) Over-charge protection
c) Over-discharge protection
d) Over-temperature protection:
e) Overcurrent protection
f) Short circuit protection
6.1.3 Onboard/portable charger
a) Charger shall have Charge voltage cut-off to avoid over charging of
REESS (Traction Battery)
b) Charger shall have time-based charge cut-off function which shuts
off further charging based on timeout.
c) Charger shall have soft-start function every time REESS is
connected for charging.
d) Charger shall have Pre-charge Function to detect over-discharge
condition of battery.
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e) Charger shall have input supply variation protection, output voltage
and current regulation.
f) Charger shall have earth leakage detection.
g) On-board/portable charger shall have communication with battery
(BMS).
h) The procedures prescribed in Annex 8 of this Standard shall be
applied.
2.0 Page 19/80,
Add new clause 6.11 after clause 6.10
6.11 Thermal Propagation Test
This procedure is added to evaluate the ability of REESS to withstand
thermal propagation which is triggered by an internal short circuit leading
to a single cell thermal runaway and subsequent thermal propagation and
shall not result in fire and explosion of REESS.
6.11.1 REESS manufacturer shall submit a risk reduction analysis using
appropriate industry standard methodology (for example, IEC 61508,
MIL-STD 882E, ISO 26262, AIAG DFMEA, fault analysis as in SAE
J2929, or similar), which documents the risk to vehicle user and
bystanders caused by thermal propagation which is triggered by an
internal short circuit leading to a single cell thermal runaway and
documents the reduction of risk resulting from implementation of the
identified risk mitigation functions or characteristics.
6.11.2 REESS manufacturer shall submit a system diagram of all relevant
physical systems and components. Relevant systems and components are
those which contribute to the protection of vehicle user and bystanders
from hazardous effects caused by thermal propagation triggered by a
single cell thermal runaway.
6.11.3 REESS manufacturer shall submit a diagram showing the functional
operation of the relevant systems and components, identifying all risk
mitigation functions or characteristics.
6.11.4. REESS shall be tested for thermal propagation tests as per Annex 8J.
6.11.4.1 Acceptance criteria
a. During the thermal propagation test of REESS, there shall be no
evidence of fire and explosion triggered by a single cell thermal
runaway.
b. REESS shall have audio visual warning for early detection of thermal
event/gases in case of thermal run away of cells. This warning shall
be activated.
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3.0 Page 75/80,
Add new Annex 8J and 8K after Annex 8I
ANNEX 8J (See 6.11)
THERMAL PROPAGATION TEST
1.0 THERMAL PROPAGATION
In order to ensure the overall safety of vehicles equipped with a REESS,
the vehicle user and bystanders should not be exposed to the hazardous
environment resulting from a thermal propagation (which is triggered by a
single cell thermal runaway due to an internal short circuit).
Heating initiation methods shall be used to verify that the hazard of the
thermal propagation is prevented or eliminated by design and shall not
result in fire and explosion of REESS.
2.0 THERMAL PROPAGATION TEST
The test shall be conducted in accordance with paragraph 3.
(a) If no thermal runaway occurs, the tested device meets thermal
propagation requirement for the heating method of initiating thermal
runaway.
(b) If thermal runaway occurs: If no external fire or explosion occurs, the
tested device meets thermal propagation requirement. The observation
shall be made by visual inspection without disassembling the Tested-
Device;
3.0 TEST PROCEDURES
3.1 Purpose
The purpose of the thermal propagation test is to ensure the user and
bystander safety from a vehicle if thermal runaway occurs in the battery
system.
3.2 Installations
This test shall be conducted with the complete REESS or with related
REESS subsystem(s) including the cells and their electrical connections.
If the manufacturer chooses to test with related subsystem(s), the
manufacturer shall demonstrate that the test result can reasonably represent
the performance of the complete REESS with respect to its safety
performance under the same conditions. In case the electronic management
unit (Battery Management Systems (BMS) or other devices) for the
REESS is not integrated in the casing enclosing the cells, it must be
operational.
3.3 Procedures
3.3.1 General test conditions
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The following condition shall apply to the test:
(a) The test shall be conducted at temperature: 25 ± 2 °C;
(b) A standard cycle as per ANNEX 8 – APPENDIX 1 shall be done on
REESS. At the beginning of the test, the state of charge (SOC) shall
be adjusted not less than 95% SOC.
(c) At the beginning of the test, all test devices shall be operational;
(d) The test may be performed with a modified Tested-Device which is
intended to minimize the influence of modification. The manufacturer
should provide a modification list;
(e) The test shall be conducted at an indoor test facility or in a shelter to
prevent the influence of wind.
3.3.2 Initiation method
Cell Heating methods used to initiate the thermal runaway of a single
cell.
Use a block heater, film heater or other heating device to initiate thermal
runaway. In the case of a block heater of the same size of the component
cell, one of the component cells is replaced with the heater. In the case of
a block heater that is smaller than a component cell, it can be installed in
the module contacting the surface of the initiation cell. In the case of a film
heater, it shall be attached on the initiation cell surface.
Heating: Heating shall be conducted with the following conditions:
(i) Shape: Plate or rod heater covered with ceramics, metal or insulator
shall be used. Heating area of heater contacting the cell shall not be
larger than area of cell surface wherever possible;
(ii) Heating procedure: After installation, the heater should be heated up
to its maximum power. Stop the initiation when the thermal runaway
occurs or the measured temperature following 3.3.2 is over [300 °C].
The stop of initiation by heating should be reached within [30min];
(iii) Set position: Heating area of the heater is directly contacting the cell
surface. Set the heater to conduct its heat to initiation cell. The
heater position is correlated with the temperature sensor position,
which is described in 3.3.6.
If no thermal runaway occurs and the heating test is stopped, refer to
paragraph 1 and 2 of this Annexure.
3.3.3 Detection of thermal runaway.
Thermal runaway can be detected by the following conditions:
(i) The measured voltage of the initiation cell drops;
(ii) The measured temperature exceeds [the maximum operating
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temperature defined by the manufacturer];
(iii) dT/dt ≥ [1 °C/s] of the measured temperature.
Thermal runaway can be judged when:
(a) Both (i) and (iii) are detected; or
(b) Both (ii) and (iii) are detected.
If no thermal runaway occurs and the test stops, refer to paragraph 1
and 2 of this Annexure.
The definition of the measured temperature is in paragraph 3.3.6.
3.3.4 Initiation method
Heating initiation method is selected here for this test.
3.3.5 Selection of initiation cell
Select an initiation cell, which is accessible by the selected trigger method
described in paragraph 3.3.2. and also whose heat generated by thermal
runaway is most easily conducted to adjacent cells. For example, select the
cell that is the nearest to the centre of battery casing or the cell that is
surrounded by other cells which makes it difficult for the triggered cell to
dissipate heat.
3.3.6 Measurement of voltage and temperature
Measure the voltage and temperature in order to detect thermal runaway of
the initiation cell.
In measuring voltage, the original electric circuit shall not be modified.
The measured temperature means the maximum temperature of
Temperature A, as defined below. The accuracy of the temperature sensor
shall be within ± 2 °C, and the sampling interval should be less than 1 s.
The diameter of the tip of the sensor shall be less than 1 mm.
Temperature A: The maximum surface temperature of the initiation
cell measured during the test.
Note: As for the set-up using a heater, place a temperature sensor on the far
side of heat conduction, for example, an opposite side of the position where
heater is placed (see Figure 1). If it is difficult to apply the temperature
sensor directly, place it at the location where the continuous temperature
rise of initiation cell can be detected.
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Figure 1
Example of set positions of heater and temperature sensor in Heating method
Annexure 8 K
Technical Requirements for Traction Battery (REESS) of L Category
Electric Power Train Vehicles
0. The Traction Battery Pack (REESS) design and manufacture guidelines as
specified in this Annexure, to be followed by REESS manufacturer. Same shall
be verified by test agency at the time of type approval and CoP of REESS
1. The manufacturing date of battery cells shall be clearly written / embossed on
the cells used to build REESS, with clear month and year of manufacture.
Manufacture date in the form of code is not acceptable as it cannot be
interpreted properly.
2. Cells used to make REESS, shall be certified as per as per IS 16893-Part 2 and
Part 3 by NABL accredited lab.
3. Cells used to make REESS, shall undergo minimum 5 cycles of charge-
discharge at C/3 current rate. Data of this cycling shall be maintained at REESS
pack manufacturer.
4. REESS shall have pressure release vent provided, to avoid building up of
internal pressure and release of gases in case internal single cell short circuit.
5. REESS shall have at least 4 temperature sensors in the battery pack to measure
the cells temperature and decision thereon by battery management system
(BMS). The position of the temperature sensors should be appropriately placed
to obtain the true temperature values. In case the temperature crosses 60 °C
(the temperature limit to be decided based on Indian conditions) an alarm
should come as an alert, and if the vehicle is in use, BMS should cut off the
power supply. Active thermal management should be ensured in the battery by
use of air-cooling fins
6. REESS shall have Active paralleling circuits for the parallel connection of cells
and strings to eliminate circulating currents. These power semiconductor devices
used for interconnecting strings will also act as protection/safety switches which
will detect any faulty strings and isolate them. They will allow bidirectional flow
of currents to charge and discharge the pack. The parallel cells and strings will get
isolated if it is detected to be faulty. Therefore, active paralleling should be
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mandatory in the battery packs.
Alternatively, fuses / bond wires can also be used to prevent circulating currents
flowing through the cells connected in parallel. Such precautionary devices will
help in isolation of faulty cells connected in parallel.
7. Sufficient cell-to-cell spacing distance should be maintained for effective heat
transfer from the cell and also to isolate the cells in case of thermal run away
in REESS. The inter cell gap in REESS should be decided based on the type
of cell geometry used viz., cylindrical, prismatic or pouch and capacity of cells.
8. REESS shall have additional safety fuse or circuit breaker in addition to the
features available in Battery Management System (BMS).
9. Each REESS manufactured should have a traceability document in which the
details of cells, BMS, charger used along with serial/batch number, charge
discharge data values etc should be maintained with the REESS manufacturer.
10. Adequate protection of cells in case of regenerative braking must be considered
in REESS design.
11. Data logging feature is required in BMS which has also been mentioned in
IS17387 standard and should be adhered
12. Each battery pack must be associated with RFID tags and the BMS should be
capable of RF reading and writing. Important battery parameters relating to
history, transactions and state of health should be dynamically written onto the
RFID tag which can be useful during swapping and also for tracking and
debugging in case of damages.
PRINTED BY
THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA
P. B. NO. 832, PUNE 411 004
ON BEHALF OF
AUTOMOTIVE INDUSTRY STANDARDS COMMITTEE
UNDER
CENTRAL MOTOR VEHICLES RULES - TECHNICAL STANDING COMMITTEE
SET-UP BY
MINISTRY OF ROAD TRANSPORT & HIGHWAYS
(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)
GOVERNMENT OF INDIA
29th August 2022
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