GB 38031-2025 PDF English
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Electric vehicles traction battery safety requirements
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Electric Vehicles Traction Battery Safety requirements
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Excerpted PDFs (Download full copy in 9 seconds upon purchase)PDF Preview: GB 38031-2025
Overview:-- Overview:
GB 38031-2025 "Electric vehicles traction battery safety requirements" is a Chinese national standard issued in March 2025. It will be mandatorily enforced for new products, from July 2026, for the safety of traction batteries of electric vehicles.
-- Product continuity and transition:
If an Electric vehicle is type-approved under GB 38031-2020, before July 2026, such products are allowed to continue to market, manufacture and sales after July 2026 until end of life (so called "continuity"). However, after July 2027 (12 months grace period from July 2026), if there is "technically-significant" change of the previously type-approved product (GB 38031-2020), then, such change / product shall be subjected to re-type approval/certification (GB 38031-2025).
-- Standard transition:
Before July 2026, a manufacturer may comply its products with previous version GB 38031-2020 or the latest version GB 38031-2025. However, if it decides to comply with older version, it shall carefully assess the risk of product continuity and transition.
-- Scope:
This standard specifies the safety requirements and test methods for power batteries, battery packs or systems of electric vehicles.
-- Safety for battery cells, battery packs or systems:
No-fire no-explosion under various scenarios. This is the new and most challenging requirement from the previous version. Additionally, it shall also subject to other tests such as mechanical impact, collision, extrusion, water immersion, high altitude, thermal stability, over-temperature protection, over-current protection, short circuit, over-charge/discharge and environmental tests.
For battery pack or system level tests, the smoke shall not cause danger to the passenger compartment within 5 minutes after the thermal event alarm signal is issued; for vehicle level tests, no smoke enters the passenger compartment within 5 minutes after the thermal event alarm signal is issued.
-- Full copies of English version of GB 38031-2025 and GB 38031-2020:
Both versions have been translated by www.ChineseStandard.net and the PDFs will be auto-delivered/downloaded in 9 seconds (Click "Add to Cart" as above). Excerpt from the full-PDF copy of GB 38031-2025_English is as follows.GB 38031-2025: Electric vehicles traction battery safety requirements---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GB38031-2025
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.120
CCS T 47
Replacing GB 38031-2020
Electric vehicles traction battery safety requirements
Issued on. 2025-03-28
Implemented on. 2026-07-01
Issued by. State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword... 3
Introduction... 6
1 Scope... 7
2 Normative references... 7
3 Terms and definitions... 7
4 Symbols and abbreviations... 11
4.1 Symbols... 11
4.2 Abbreviations... 11
5 Safety requirements... 12
5.1 Safety requirements for battery cells... 12
5.2 Safety requirements for battery pack or system... 12
6 Test conditions... 14
6.1 General conditions... 14
6.2 Accuracy of measuring instruments and meters... 16
6.3 Test process error... 16
6.4 Data recording and recording interval... 17
7 Test preparation... 17
7.1 Preparation for battery cell test... 17
7.2 Preparation for battery pack or system test... 18
8 Test methods... 19
8.1 Test methods for battery cell safety... 19
8.2 Battery pack or system safety test method... 22
9 Determination of the same type... 40
10 Implementation of the standard... 43
Appendix A (Informative) Examples of typical structures of battery packs and systems
... 44
Appendix B (Normative) Test method for battery pack or system insulation resistance
... 47
Appendix C (Normative) Thermal diffusion analysis and verification report... 49
References... 57
Electric vehicles traction battery safety requirements
1 Scope
This document specifies the safety requirements and test methods for power batteries
(hereinafter referred to as batteries) for electric vehicles, battery packs or systems.
This document applies to power batteries for electric vehicles.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB/T 2423.4 Environmental testing for electric and electronic products - Part 2.Test
method - Test Db. Damp heat, cyclic (12 h + 12 h 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,
broadband 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
The terms and definitions defined in GB/T 19596, as well as the following terms and
definitions, apply to this document.
3.1
3.19
End-of-discharge voltage
The minimum voltage allowed when the battery cell, module, battery pack or system
is discharged according to the conditions specified by the manufacturer.
3.20
Body frame
The space frame structure that is formed 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
The following symbols apply to this document.
I1.1 h rate discharge current (A), whose value is equal to the rated capacity value.
I3.3 h rate discharge current (A), whose value is equal to 1/3 of the rated capacity
value.
4.2 Abbreviations
The following abbreviations apply to this document.
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 cells
5.1.1 The battery cells shall not catch fire or explode, when subjected to the over-
discharge test in accordance with 8.1.2.
5.1.2 The battery cells shall not catch fire or explode, when subjected to the over-charge
test in accordance with 8.1.3.
5.1.3 The battery cells shall not catch fire or explode, when subjected to the external
short-circuit test in accordance with 8.1.4.
5.1.4 The battery cells shall not catch fire or explode, when subjected to the heating test
in accordance with 8.1.5.
5.1.5 The battery cell shall not catch fire or explode, when subjected to temperature
cycle test in accordance with 8.1.6.
5.1.6 The battery cell shall not catch fire or explode, when subjected to extrusion test
in accordance with 8.1.7.
5.1.7 The battery cell shall not catch fire or explode, when subjected to fast charge cycle
in accordance with 8.1.8.
5.2 Safety requirements for battery pack or system
5.2.1 The battery pack or system shall be subjected to vibration test in accordance with
8.2.1; it shall not have leakage, housing crack, fire or explosion. The insulation
resistance after the test shall be not less than 100 Ω/V. If there is an AC circuit, the
insulation resistance shall be not less than 500 Ω/V.
5.2.2 The battery pack or system shall be subjected to mechanical impact test in
accordance with 8.2.2; it shall not have leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be not less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be not less than 500 Ω/V.
5.2.3 The battery pack or system shall be subjected to a simulated collision test in
accordance with 8.2.3; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be no less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be no less than 500 Ω/V.
5.2.4 The battery pack or system shall be subjected to an extrusion test in accordance
with 8.2.4; there shall be no fire or explosion. The insulation resistance after the test
shall be no less than 100 Ω/V. If there is an AC circuit, the insulation resistance shall be
no less than 500 Ω/V.
5.2.5 The battery pack or system shall be subjected to a damp heat cycle test in
accordance with 8.2.5; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance within 30 minutes after the test shall be no less than 100 Ω/V. If
there is an AC circuit, the insulation resistance shall be no less than 500 Ω/V.
5.2.6 The battery pack or system shall be subjected to water immersion test in
accordance with 8.2.6; it shall meet one of the following requirements.
a) According to method 1, no fire or explosion shall occur;
b) According to method 2, after the test, it shall meet the IPX7 requirements of GB/T
4208-2017, and there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall not be less than 100 Ω/V. If there is an AC
circuit, the insulation resistance shall not be less than 500 Ω/V.
5.2.7 Thermal stability test shall be carried out in accordance with 8.2.7 (except for
nickel-metal hydride battery packs or systems). The requirements are as follows.
a) The battery pack or system shall be subjected to external fire test in accordance
with 8.2.7.1 and shall not explode;
b) The battery pack or system or the whole vehicle shall be subjected to thermal
diffusion analysis and verification in accordance with 8.2.7.2; it shall.
1) Be no fire or explosion;
2) Provide a thermal event alarm signal, meanwhile the alarm signal shall be
issued no later than 5 minutes after the thermal runaway of the battery cell is
triggered;
3) For battery pack or system level tests, provide technical description documents
that smoke does not cause danger to the passenger compartment before and
within 5 minutes after the thermal event alarm signal is issued; for vehicle level
tests, no smoke enters the passenger compartment before and within 5 minutes
after the thermal event alarm signal is issued.
5.2.8 The battery pack or system shall be subjected to temperature shock test in
accordance with 8.2.8; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be no less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be no less than 500 Ω/V.
6 Test conditions
6.1 General conditions
6.1.1 Unless otherwise specified, the test environment temperature is 22 °C ± 5 °C, the
relative humidity is 10% ~ 90%, the atmospheric pressure is 86 kPa ~ 106 kPa.
6.1.2 If the test object is a battery cell, it can be tested with a fixture. If the battery cell
cannot work independently, the battery module shall be used for testing; the safety
requirements of 5.1 shall be met.
6.1.3 For battery packs or systems that are covered by a body frame and constitute the
battery pack box, they can be tested with the box or body frame.
6.1.4 The test delivery of the battery pack or system shall include the necessary
operating documents and the interface components required for connection to the test
equipment, such as connectors, plugs, cooling system interfaces. The typical structure
of the battery pack or system is shown in Appendix A. In addition, additional sensors,
wires, fixtures shall not affect the test results. The manufacturer shall provide the safe
working limits of the battery pack or system.
6.1.5 The battery pack or system shall be tested for insulation resistance before all tests
and after some tests. The test location is between the positive-negative output terminals
and the electrical platform. The specific test method shall be carried out in accordance
with Appendix B.
6.1.6 If the battery pack or system is not suitable for partial testing due to size or mass,
the manufacturer and the testing agency may agree to use the battery subsystem as the
test object for all or part of the test. However, the battery subsystem used as the test
object shall include all parts related to the vehicle requirements (such as connection
components or protection components, etc.); it may include the battery management
system. If the battery subsystem is selected for testing, it shall be proved that the test
results can represent the safety performance of the battery pack or system under the
same conditions.
7 Test preparation
7.1 Preparation for battery cell test
7.1.1 Standard charging
Discharge at a current specified by the manufacturer and not less than 1I3 to the end-of-
discharge voltage specified in the manufacturer's technical conditions; let it stand for 1
hour (or the standing time provided by the manufacturer not more than 1 hour); then
charge according to the charging method provided by the manufacturer; let it stand for
1 hour after charging (or the rest time provided by the manufacturer not more than 1
hour).
If the manufacturer does not provide a charging method, the testing agency and the
manufacturer shall negotiate to determine a suitable charging method, or charge
according to the following method.
Charge at a constant current of a current specified by the manufacturer and not less than
1I3 to the end-of-charge voltage specified in the manufacturer's technical conditions;
then switch to constant voltage charging; stop charging when the charging current drops
to 0.05 I1; let it stand for 1 hour after charging (or the standing time provided by the
manufacturer not more than 1 hour).
7.1.2 Pretreatment
7.1.2.1 Before the formal test begins, the battery cell shall be preconditioned first. The
steps are as follows.
a) Perform standard charging on the battery cell according to 7.1.1;
b) Discharge at a current specified by the manufacturer and not less than 1 I3 to the
end-of-discharge condition specified by the manufacturer;
c) Let it stand for 1 hour (or a standing time of not more than 1 hour provided by the
manufacturer);
d) Repeat steps a) ~ c) for no more than 5 cycles.
7.1.2.2 If the extreme difference of the discharge capacity of the battery cell is less than
3% of the rated capacity for 3 consecutive times, the battery cell is deemed to have
completed the pretreatment; the pretreatment cycle can be terminated; the average of
the last 3 test results is taken as the actual capacity.
7.2 Preparation for battery pack or system test
7.2.1 Confirmation of working status
Before the formal test begins, the battery electronic components or BCU shall be in
normal working condition.
7.2.2 Pretreatment
7.2.2.1 Before the formal test begins, the battery pack or system shall be preconditioned.
The steps are as follows.
a) Charge at a current of not less than 1 I3 or according to the charging method
recommended by the manufacturer to the end-of-charge condition specified by
the manufacturer;
b) Let it stand for 30 min or the time specified by the manufacturer;
c) Discharge at a current specified by the manufacturer and not less than 1 I3 to the
end-of-discharge condition specified by the manufacturer;
d) Let it stand for 30 min or the time specified by the manufacturer;
e) Repeat steps a) ~ d) no more than 5 cycles.
8 Test methods
8.1 Test methods for battery cell safety
8.1.1 General requirements
All safety tests are conducted under environmental conditions with adequate safety
protection. If the test object has additional active protection circuits or devices, they
shall be removed.
8.1.2 Over-discharge
8.1.2.1 The test object is a battery cell.
8.1.2.2 Adjust the state of charge of the test object to the end-of-discharge voltage state;
discharge at a current of 1 I1 for 30 min.
8.1.2.3 After completing the above test steps, observe for 1 h at the test environment
temperature.
8.1.3 Over-charge
8.1.3.1 The test object is a battery cell.
8.1.3.2 The test object is charged according to the method in 7.1.1.
8.1.3.3 Stop charging after charging at a constant current of not less than 1 I3 specified
by the manufacturer to 1.1 times the end-of-charge voltage specified by the
manufacturer or 115% SOC.
8.1.3.4 After completing the above test steps, observe at the test environment
temperature for 1 hour.
8.1.4 External short circuit
8.1.4.1 The test object is a battery cell.
8.1.4.2 The test object is charged according to the method of 7.1.1.
8.1.4.3 The positive terminal and negative terminal of the test object are externally
short-circuited for 10 minutes. The external circuit resistance shall be less than 5 mΩ.
8.1.4.4 After completing the above test steps, observe at the test environment
temperature for 1 hour.
8.1.5 Heating
8.1.8.2 Test according to the following steps.
a) Adjust to 20% SOC according to the method provided by the manufacturer;
b) Let it stand for 30 minutes or the time specified by the manufacturer;
c) Charge to 80% SOC according to the charging method provided by the
manufacturer; the charging time shall not exceed 15 minutes;
d) Let it stand for 30 minutes or the time specified by the manufacturer;
e) Repeat steps a) ~ d) 300 times;
f) Perform external short-circuit test according to 8.1.4.
8.2 Battery pack or system safety test method
8.2.1 Vibration
8.2.1.1 The test object is a battery pack or system.
8.2.1.2 Install the test object on the vibration table according to the installation position
and fixing method of the test object vehicle and the requirements of GB/T 2423.43.
Random and fixed frequency vibration loads are applied in each direction; the loading
sequence shall be z-axis random, z-axis fixed frequency, y-axis random, y-axis fixed
frequency, x-axis random, x-axis fixed frequency (the direction of vehicle travel is the
x-axis direction; the other horizontal direction perpendicular to the travel direction is
the y-axis direction). The testing agency can also choose the sequence by itself to
shorten the conversion time. The test process is carried out in accordance with GB/T
2423.56.
8.2.1.3 For battery packs or systems loaded on vehicles other than categories M1 and
N1, the vibration test parameters are set according to Table 2 and Figure 2, where the
RMS of the x-axis, y-axis, z-axis are 0.52 g, 0.57 g, 0.73 g, respectively. Where there
are multiple installation directions (x/y/z) for the test object, the test is carried out in
the installation direction with the largest RMS. For battery packs or systems installed
on the top of the vehicle, vibration tests shall be carried out according to the vibration
test parameters provided by the manufacturer that are not less than those in Table 2 and
Figure 2.
8.2.1.4 For battery packs or systems installed on categories M1 and N1 vehicles, the
vibration test parameters shall be set according to Table 3 and Figure 3, where the RMS
of the x-axis, y-axis, z-axis are 0.50 g, 0.45 g, and 0.64 g, respectively.
8.2.6 Water immersion
8.2.6.1 The test object is the battery pack or system after passing the vibration test in
8.2.1.
8.2.6.2 The test object is connected to the wiring harness, connectors and other
components according to the vehicle connection method; one of the following two
methods is selected for testing.
a) Method 1.The test object is placed in a 3.5% (mass fraction) sodium chloride
solution in the actual vehicle assembly direction for 2 hours; the water depth shall
submerge the test object;
b) Method 2.The test object is tested according to the method and process described
in 14.2.7 of GB/T 4208-2017.The test object is fully immersed in water according
to the installation status specified by the manufacturer. For test objects with a
height of less than 850 mm, the lowest point shall be 1000 mm below the water
surface; for test objects with a height equal to or greater than 850 mm, the highest
point shall be 150 mm below the water surface. The test duration is 30 minutes.
The temperature difference between the water temperature and the test object is
not greater than 5 °C.
8.2.6.3 Take the test object out of the water completely; observe it at the test
environment temperature for 2 hours.
8.2.7 Thermal stability
8.2.7.1 External fire
8.2.7.1.1 The test object is a battery pack or system. The vehicle body structure that
protects the battery pack or system can participate in the fire test.
8.2.7.1.2 The test environment temperature is above 0 °C and the wind speed is not
more than 2.5 km/h.
8.2.7.1.3 During the test, the size of the flat pan containing gasoline exceeds the
horizontal projection size of the test object by 20 cm and does not exceed 50 cm. The
height of the flat pan is not higher than 8 cm above the gasoline surface. The test object
shall be placed in the center. The distance between the gasoline liquid level and the
bottom of the test object is set to 50 cm, or the height of the bottom of the test object
from the ground when the vehicle is unloaded. Water is injected into the bottom of the
flat pan. The burning time shall start or end when the test object, the fireproof partition,
the oil pan are all in a stationary state. The schematic diagram of external fire is shown
in Figure 9.
8.2.7.1.4 The external fire test is divided into the following 4 stages.
temperature determined according to a) or b) (as applicable) is reached; then maintained
at or above this temperature until the end of the test.
a) If the battery system is equipped with internal overheating protection measures,
the temperature shall be increased to the operating temperature threshold
corresponding to the overheating protection measures of the battery system, to
ensure that the temperature of the test object is increased in accordance with
8.2.11.3.
b) If the battery system is not equipped with any internal overheating protection
measures, the temperature shall be increased to the maximum operating
temperature specified by the battery system manufacturer.
8.2.11.5 The test is terminated when any of the following conditions are met.
a) The test object automatically terminates or limits charging or discharging;
b) The test object sends a signal to terminate or limit charging or discharging;
c) The temperature of the test object is stable; the temperature change is less than
4 °C within 2 hours.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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