GB/T 45415-2025 PDF English
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GB/T 45415-2025: Defect analysis methods for battery electric vehicles fire accidents---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/GBT45415-2025
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.020
CCS T 40
GB/T 45415-2025
Defect analysis methods for battery electric vehicles fire
accidents
Issued on: FEBRUARY 28, 2025
Implemented on: FEBRUARY 28, 2025
Issued by. State Administration for Market Regulation;
Standardization Administration of the People’s Republic of China.
Table of Contents
Foreword... 3
1 Scope... 4
2 Normative references... 4
3 Terms and definitions... 4
4 General principles... 6
5 Analysis procedures... 7
6 In-depth analysis of fire accident information... 8
6.1 General... 8
6.2 Fire accident information collection... 8
6.3 Accident information integration and mining... 10
6.4 Identify failure cause... 10
7 Batch vehicle information analysis... 10
7.1 Batch vehicle information collection... 10
7.2 Batch vehicle data analysis... 11
7.3 Identify failure cause... 12
8 Defect engineering analysis and test... 12
8.1 General... 12
8.2 Collection of accident vehicle wreckage and vehicles/parts of the same model and
batch... 12
8.3 Defect engineering analysis and test... 13
8.4 Identify failure cause... 13
9 Defect identification and judgement... 13
10 Defect analysis report... 14
Annex A (informative) Batch vehicle operation cycle data analysis methods... 15
Annex B (informative) Defect engineering analysis and test methods... 19
Annex C (informative) Battery electric vehicle fire defect analysis report (template) 25
C.1 Overview of defect analysis... 25
C.2 Basic information of defect analysis objects... 25
C.3 In-depth analysis of fire accident information... 25
C.4 Batch vehicle information analysis... 25
C.5 Defect engineering analysis and test... 25
C.6 Summary of defect analysis work and related suggestions... 25
Bibliography... 26
Foreword
This document was drafted in accordance with the provisions of GB/T 1.1-2020
“Directives for standardization - Part 1.Rules for the structure and drafting of
standardizing documents”.
Attention is drawn to the possibility that some of the elements of this document may be
the subject of patent rights. The issuing authority of this document shall not be held
responsible for identifying any or all such patent rights.
This document was proposed by and shall be under the jurisdiction of National
Technical Committee on Product Defects and Safety Management of Standardization
Administration of China (SAC/TC 463).
Drafting organizations of this document. State Administration for Market Regulation
Defective Product Recall Technical Center, China Automotive Engineering Research
Institute Co., Ltd., Beijing CARI Technology Co., Ltd., Contemporary Amperex
Technology Co., Ltd., Tianjin Fire Science and Technology Research Institute of MEM,
Beijing University of Aeronautics and Astronautics, Xihua University, BYD Auto
Industry Co., Ltd., China Certification & Inspection (Group) Co., Ltd., Deep Blue
Automotive Technology Co., Ltd., Huizhou EVE Energy Co., Ltd., CALB Group Co.,
Ltd., Hozon New Energy Automobile Co., Ltd., Beijing CHJ Automotive Technology
Co., Ltd., Shanghai NEXTEV Automobile Co., Ltd., VOYAH Automobile Technology
Co., Ltd., WREMT Electric Vehicle Technology (Ningbo) Co., Ltd., Great Wall Motor
Co., Ltd., Beijing Benz Automotive Co., Ltd., Hefei Gotion High-tech Power Energy
Co., Ltd., BAIC Foton Motor Co., Ltd., Shanghai Motor Vehicle Inspection
Certification & Tech Innovation Center Co., Ltd., China People’s Police University,
China Merchants Testing Vehicle Technology Research Institute Co., Ltd., SAIC-GM-
Wuling Automobile Co., Ltd., Teld New Energy Co., Ltd., CARI New Energy
Technology Co., Ltd., University of Science and Technology of China, Southwest
Jiaotong University, Beijing Institute of Technology, Guangzhou Energy Testing
Institute, Chongqing Institute of Quality and Standardization, Chongqing LIVAN
Automobile Technology Co., Ltd.
Main drafters of this document. Li Yan, Wan Xinming, Xiao Lingyun, Dong Honglei,
Liang Xinmiao, Li Wei, Xu Jinze, Yang Shichun, Wang Peng, Wang Yan, Xi Ming, He
Xing, Zhang Liang, Ren Yi, Hu Wenhao, Zhao Xing, Lu Zhibao, Liu Zhengang, Li
Wenzhao, Li Pingfei, Zhou Chengyong, Xu Yuhong, Wang Qing, Shi Pengyu, Lin Weiyi,
Chen Ran, Gu Fenghua, Chen Chen, Sun Quan, Bao Longzhai, Zhao Jian, Ma Liuke,
Lin Ye, Li Jiale, Yan Lei, Meng Xiangfeng, Shen Chi, Xue Guozheng, Wang Dong, Lin
Dun, Zhao Zhiwei, Shao Dan, Ma Jiansheng, Guo Fenggang, Bao Huanhuan, Wang
Qingsong, Deng Pengyi, Cheng Ximing, Liu Fujian, Ma Ruijun, Yuan Changrong, Tan
Yuntao, Chen Bin, Hu Qingao, Chen Fei, Lu Yuliang, Li Jiayao, Zhang Desheng, Wang
Zhaojun, Zhu Yunyao, Li Yifan.
Defect analysis methods for battery electric vehicles fire
accidents
1 Scope
This document establishes the analysis procedure for defect analysis of battery electric
vehicle fire accidents, and describes the in-depth analysis method for battery electric
vehicle fire accident information, batch vehicle information analysis method, defect
engineering analysis and test method, defect identification and judgment, and defect
analysis report content.
This document applies to the defect analysis of battery electric vehicle fire accidents. It
is used as a reference for the defect analysis of other types of electric vehicle fire
accidents.
2 Normative references
The following referenced documents are indispensable for the application 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 5907.1 Fire protection vocabulary - Part 1.General terms
GB/T 19596 Terminology of electric vehicles
GB/T 34402 Safety of motor vehicle product - Guidelines for risk assessment and
risk control
GB 38031 Electric vehicles traction battery safety requirements
GB/T 43387 Product recall - Vocabulary
GB/T 43388 Judgment guidelines for serious safety-related fault of household
automobile
XF/T 812 Guide for fire cause investigation
3 Terms and definitions
For the purpose of this document, the terms and definitions defined in GB/T 5907.1,
GB/T 19596, GB 38031, GB/T 43387 and GB/T 43388 and the following apply.
6 In-depth analysis of fire accident information
6.1 General
Based on the on-site investigation of one or more fire accidents of battery electric
vehicles of the same model and batch, collect basic information on battery electric
vehicle fire accidents, accident vehicle data information, accident scene investigation
information, accident evidence analysis information and other relevant information,
comprehensively analyze the fault mode, and identify the fire failure cause.
6.2 Fire accident information collection
6.2.1 Basic accident information
Basic accident information generally includes but is not limited to.
- accident information. accident time, accident location, accident vehicle status and
driving conditions, accident vehicle power, casualties, accident vehicle storage
location, accident scene video, etc.;
- accident process information. information of processes such as vehicle fire accident
occurrence, discovery, firefighting;
- accident disposal information. storage, towing and disposal of accident vehicles
after fire extinguishing, etc.;
- fire investigation information. information obtained through investigation in
accordance with the requirements of XF/T 812, such as other traffic accidents that
occurred before the fire accident, chassis collision, wading, soaking in water,
battery replacement or repair, vehicle modification and installation, etc.,
preliminary analysis and judgment of the cause of the fire accident, etc.;
- accident vehicle dealer information. dealer registration name, contact number,
mailing address, accident vehicle sales date, etc.
6.2.2 Accident vehicle data information
Accident vehicle data information generally includes but is not limited to.
- accident vehicle information. electrical system layout of the accident vehicle,
power battery layout, maintenance record of the accident vehicle, vehicle operation
data and operation cycle data 7 days before the accident, etc.;
- accident vehicle operation cycle data analysis information. analysis of vehicle
usage such as fast charging ratio, maximum charging current, daily mileage, total
mileage, insulation changes, historical alarm information, battery abuse, etc. of the
accident vehicle, as well as safety parameter correlation analysis, consistency
analysis, etc.;
- accident vehicle power battery information. location, manufacturer, nominal total
capacity, nominal total voltage, total weight, charging power, system thermal
management form, series-parallel type, number and layout of voltage and
temperature sensors of the power battery; manufacturer, specification and model,
nominal capacity, cell weight, maximum sustainable charge and discharge power,
maximum sustainable charge and discharge current, battery electrochemical
system, positive electrode material type of the battery cell; module location,
module manufacturer, software manufacturer, hardware manufacturer, etc. of the
battery management system.
6.2.3 Accident scene investigation information
Accident scene investigation information generally includes but is not limited to.
- accident data pre-analysis information. safety parameter correlation analysis of
vehicle operating total voltage, total current, battery temperature, insulation
resistance, and background monitoring fault information 7 days before the accident,
as well as parameter consistency analysis of battery cell voltage, temperature probe
monitoring value, etc.;
- accident investigation information. analysis of burn damage and residual traces of
accident vehicle body, power compartment, trunk, chassis, passenger compartment,
main parts such as battery, motor, electronic control, and charging socket, data
analysis of charging piles of accident vehicles in charging state, fire spread trend
and fire location judgment, etc.;
- accident vehicle fault mode and accident cause analysis information. accident
vehicle fault mode identification process, fire cause.
6.2.4 Accident evidence analysis information
Accident evidence analysis information generally includes but is not limited to.
- electrical short circuit trace analysis information. analysis of melting marks caused
by vehicle high-voltage wiring harness, low-voltage wiring harness and its
connectors, and analysis of melting marks of charging piles and wiring harnesses;
- fire trace analysis information. analysis of melting marks caused by fire on vehicle
wiring harnesses, plastic parts, etc.;
- battery pack burn analysis information. analysis of battery pack shell, battery pack
internal parts and wiring harness burn conditions, analysis of mechanical
deformation and arcing of structural parts, modules or cells in battery packs,
production date, vehicle registration date, vehicle nature, vehicle category, power
type, chassis type; production and manufacturing data, operation cycle data, fault
and maintenance information of some vehicles;
- power battery information. battery cell supplier, module supplier, battery pack
supplier, battery management system software/hardware supplier, battery cell
shape, battery cell model, battery cell type, battery cell positive and negative
electrode materials, battery cell electrolyte composition, battery cell charge and
discharge power/current limit table, battery pack internal module series-parallel
mode, battery pack internal high and low voltage layout diagram, battery pack
internal module and battery cell layout diagram, battery pack internal temperature
and voltage sensor quantity and location, battery pack tray material, battery pack
waterproof design, battery system cooling form, battery system flame retardant
coefficient, battery system fuse curve, production and manufacturing process data
of some batteries and battery systems;
- motor system information. motor type, rated voltage, no-load current, rated current,
starting current, maximum continuous current, rated power, maximum output
power, rated speed, no-load speed, maximum speed, rated torque, maximum torque;
- electric control system information. software/hardware supplier, rated voltage,
rated current.
7.1.2 Production and manufacturing data, operation cycle data, fault and maintenance
information of some vehicles, and production and manufacturing process data of some
battery cells and battery systems should be randomly sampled from batches of vehicles
with similar operating conditions to the accident vehicle. The specific sampling quantity
is determined based on the results of the previous in-depth investigation and analysis
of the accident and the proposed analysis method to ensure the scientificity and
rationality of the analysis.
7.2 Batch vehicle data analysis
Systematically research the batch vehicle information collected in 7.1, by referring to
the analysis methods given in Annex A, analyze the vehicle operation cycle data
through the data platform to identify the common fault modes existing in vehicles of
the same model, same batch or using the same parts. The batch vehicle data analysis
process is shown in Figure 3.
- vehicle parts of the same model and batch. parts disassembled from vehicles of the
same model, same parts configuration, same vehicle production batch and parts
production batch, and same vehicle three-electric system software version as the
accident vehicle, including but not limited to the hardware and software of major
parts such as batteries, motors, and electronic controls.
8.3 Defect engineering analysis and test
8.3.1 Accident vehicle wreckage test analysis
The accident vehicle wreckage test analysis shall analyze and disassemble wreckage
parts such as battery, motor, electronic control, high and low voltage wiring harness of
the accident vehicle, and refer to the analysis methods given in Annex B to measure,
test, sample, and analyze the abnormal parts.
8.3.2 Analysis of in-use vehicles adjacent to the accident vehicle
Select 5 in-use vehicles from the same batch as the fire fault parts of the accident vehicle
and before and after the vehicle was produced, and perform test, analysis, and
disassembly on vehicle parts of the same model. Refer to the analysis methods given in
Annex B to measure, test, sample, and analyze the abnormal parts found.
8.3.3 New vehicle comparative analysis
The new vehicle comparative analysis shall be performed on the latest vehicles or parts
of the same model as the accident vehicle for assembly inspection, performance test
and analysis, fault injection test, disassembly analysis, etc., and refer to the analysis
methods given in Annex B to measure, test, sample and analyze the abnormal parts
found.
8.4 Identify failure cause
Combining the analysis results of 6.3, 7.2 and 8.3, identify the failure cause.
- if the failure cause can be identified, it should carry out defect identification and
judgement in accordance with the requirements of Clause 9;
- if the failure cause cannot be identified, terminate the defect analysis, form a
complete defect analysis report, and it should repeat the identification in
accordance with the method described in Clause 6.
9 Defect identification and judgement
During the defect identification and judgement process, it is necessary to determine
whether the failure of battery electric vehicle fire is related to the design, manufacturing
or labeling, etc. of the product itself.
Annex C
(informative)
Battery electric vehicle fire defect analysis report (template)
C.1 Overview of defect analysis
Including but not limited to the reasons for defect analysis, dimensions of analysis, etc.
C.2 Basic information of defect analysis objects
Including but not limited to fire accident information, batch vehicle information, etc.
C.3 In-depth analysis of fire accident information
Including but not limited to the analysis process and content of basic information of
battery electric vehicle fire accidents, accident vehicle data information, accident scene
investigation information, accident evidence analysis information and other related
information, and the identified fault modes.
C.4 Batch vehicle information analysis
Including but not limited to the selected analysis method, production and manufacturing
data analysis results, maintenance data analysis results, operation data analysis results
of vehicles of the same batch and model, and the identified common fault modes.
C.5 Defect engineering analysis and test
Including but not limited to test plan, test method, test process and test results, and
analyzed failure causes.
C.6 Summary of defect analysis work and related suggestions
Including but not limited to the fault modes and failure causes summarized through in-
depth analysis of fire accident information, batch vehicle information analysis and
defect engineering analysis and test results, and relevant solutions or suggestions.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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