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ONE FORDONE TEAM ONE PLAN ONE GOALEV Vehicle SafetyManuel Bartolo Automotive Safety Office, Ford Motor CompanyElectric Vehicle Safety Technical SymposiumMay 18, 2012 ONE FORDONE TEAM ONE PLAN ONE GOAL 2 ELECTRIFIED VEHICLESPRODUCTION CAPACITY IN NORTH AMERICA BY 2013TRIPLING ONE FORDONE TEAM ONE PLAN ONE GOAL 3MORE EFFICIENTBATTERY TEMPERATURES 110 MPGe Advanced Li-Ion Battery5 PASSENGER 25-30% smallerFASTER CHARGING 50% lighter ONE FORDONE TEAM ONE PLAN ONE GOAL 4 RELIABILITYResearching and developing modern electrified vehicles for decades Ford Ranger Electric 19981996Cell Testing and Research 2004 2009 2010Ford Escape Hybrid Ford Fusion Hybrid ONE FORDONE TEAM ONE PLAN ONE GOALGraphical Crash Requirements - FMVSS 30530mph Rigid Barrier 30mph 30o Left & RightAngular 33.5mph Left & Right27o Crabbed Cart 50mph 70% Overlap V-to-V Left & RightFrontal Crash Events Side Crash Events Rear Crash Events ONE FORDONE TEAM ONE PLAN ONE GOALGraphical Crash Testing for Public Domain & Internal 40mph 40% IIHS Offset NCAP 20mph ObliqueLeft & Right Pole (5th/50th%) High SpeedV-to-V Left & Right Side38.5mph NCAP Left & RightSide MDB High SpeedV-to-VLeft & RightRear31mphLeft IIHSCart 35mph NCAP Rigid Barrier ONE FORDONE TEAM ONE PLAN ONE GOAL 7 Focus Electric Battery LocationBEV Battery Packs BEV Lower Battery Pack is mounted under the vehicle below the second row seats BEV Upper Battery Pack is mounted in the trunk behind the second row seats. Lower portion of pack extends through trunk floor to the outside of the vehicle ONE FORDONE TEAM ONE PLAN ONE GOAL 8 FMEA AnalysisOver TemperatureOver ChargeOver DischargeExternal Short Internal Cell Short No EffectProtection ActivatedDamage/RetentionLeakageVentingFire/FlameNoise Factors &Failure Modes Stress PotentialEffectsNormal ConditionsNoise FactorsOff-Normal ConditionsFailure Modes PreventActions ONE FORDONE TEAM ONE PLAN ONE GOAL 9 Vehicle, Pack & Cell Level ActionsVehicle Level Actions Vehicle Structure Vehicle Cooling Sys Vehicle Controls Sys Charging Control Sys Pack Level Actions Battery Pack Structure Vent Management Sys Pack Cooling Sys Battery Controls Sys Power Limits (Temp, Age, others) Over Temp Over Charge/Discharge ENS Control Cell Balancing Battery Sensors (V, I, T) Fusing Cell Level Actions Cell Chemistry Cell Design Cell Manufacturing (occurrence reduction) ONE FORDONE TEAM ONE PLAN ONE GOAL 10 Typical Testing and VerificationExamples of typical tests that may be conducted on battery cells, battery pack assemblies, and/or entire vehicles.Mechanical: Vibration, Shock, Battery Enclosure IntegrityElectrical: Electrical Short circuit, Over Charge & Dis-charge ProtectionEnvironmental: High/Low Temperature Exposure Thermal Shock, Humidity and Moisture Exposure, Corrosion, Immersion ONE FORDONE TEAM ONE PLAN ONE GOAL 11 Focus Electric Vehicle Level Structural ComponentsUnique Designed(Material &/or gauge revised) Structural additions for battery pack crash protection(Purple) ONE FORDONE TEAM ONE PLAN ONE GOAL 12 Focus Electric Battery Pack Structural ComponentsBattery Pack Casing Casing modifications for enhanced crash protection. (Blue) ONE FORDONE TEAM ONE PLAN ONE GOALFocus Electric Rear Body Structure ONE FORDONE TEAM ONE PLAN ONE GOAL Guidance for Potentially Damaged BatteriesGuidance for Ford Motor Company Electric andHybrid-Electric Vehicles Equipped WithHigh Voltage Batteries(Vehicle Owner/Operator/General Public)Electric and Hybrid-Electric Vehicle Considerations in the event of damage or fire involving an electric vehicle (EV) or hybrid-electric vehicle (HEV): Always assume the high voltage (HV) battery and associated components are energized and fully charged. Exposed electrical components, wires, and HV batteries presentpotential HV shock hazards. Venting/off-gassing HV battery vapors are potentially toxic and flammable. Physical damage to the vehicle or HV battery may result in immediateor delayed release of toxic and/or flammable gases and fire.Vehicle Information and General Safety Practices Know the make and model of your vehicle. Review the owners manual and become familiar with your vehiclessafety information and recommended safety practices. Do not attempt to repair damaged electric and hybrid-electric vehiclesyourself. Contact an authorized Ford Dealer or vehicle manufacturerrepresentative for service.CrashesA crash or impact significant enough to require an emergency responsefor conventional vehicles would also require the same response for anelectric or hybrid-electric vehicle.If possible Move your car to a safe, nearby location and remain on the scene. Roll down windows before shutting vehicle off. Place vehicle in Park, set parking brake, turn off the vehicle, activatehazard lights, and move key(s) at least 16 feet (5 meters) away fromthe vehicle. Always Call 911 if assistance is needed and advise that an electric orhybrid-electric vehicle is involved. Do not touch exposed electrical components or the enginecompartment, as a shock hazard may exist. Avoid contact with leaking fluids and gases, and remain out of the wayof oncoming traffic until emergency responders arrive. When emergency responders arrive, tell them that the vehicle involvedis an EV or HEV.FiresAs with any vehicle, call 911 immediately if you see sparks, smoke, orflames coming from the vehicle. Exit the vehicle immediately. Advise 911 that an electric or hybrid-electric vehicle is involved. As with any vehicle fire, do not inhale smoke, vapors, or gas from the vehicle, as they may be hazardous. Remain a safe distance upwind and uphill from the vehicle fire. Stay out of the roadway and stay out of the way of any oncomingtraffic while awaiting the arrival of emergency responders.Post-Incident Do not store a severely damaged vehicle with a lithium-ion batteryinside a structure or within 50 feet (15 meters) of any structure orvehicle. Ensure that passenger and cargo compartments remain ventilated(i.e., open window, door, or trunk). For vehicles in the United States, notify Ford Motor Company1-800-392-3673 (then follow the prompts on the voice response menu),an authorized Ford dealer or service center as soon as possible as theremay be other steps to secure and/or discharge the HV battery. For vehicles in Canada, notify Ford Motor Company 1-800-565-3673 (then follow the prompts on the voice response menu), an authorizedFord dealer or service center as soon as possible as there may beother steps to secure and/or discharge the HV battery. Call 911 if you observe leaking fluids, sparks, smoke, or flames, orhear gurgling or bubbling from the HV battery.The da aged vehicle guidance that is outlined in the Focus EV “Emerg nc R spons Guide” is consist nt with NHTSA recomm ndati ns ONE FORDONE TEAM ONE PLAN ONE GOALGreat Products, Strong Business, Better World 15
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