No.302012 EV 26 Development of Crash Safety Performance for EV 1 2 3 Ichiro Kamimoto Masaki Motoki Masaki Ueno SKYACTIV engine HEVHybrid Electric VehicleBEVBattery Electric Vehicle, Summary There are growing concerns about environmental problems such as global warming and exhaustion of fossil fuel. Mazda is steadily adopting the Building Block Strategy as an approach to such environmental issues, starting with the SKYACTIV engine. As part of this approach, Mazda is also working on the development of HEV and BEV. Electric vehicles demand a lot of attention to ensure high crash safety performance for high voltage which the existing fossil fuel-powered cars are not equipped with. This paper introduces the development of crash safety performance for Electric Vehicle which contains high voltage such as the propulsive battery, inverter, motor and harness. EV HEV HEV EV EV EV EV EV EV EV Table 1 3 Condition 1 2 Condition 2 Condition 3 2 13 Crash Safety Development Dept. 135
No.302012 Table 2 Table 1 Electric Shock Conditions and Protections Electric shock Conditions Condition1 Condition2 Condition3 Electric Direct contact with more than one live. Requirement Protection against direct contact with hight IPXXB voltage live Protection against electrical shock with arise from indirect contact Electrical Isolation An electric leakage and direct contact with live part. Invesigation the conditions of protection IPXXB. Insulation resistance Electric leakage More than one electric leakage and exposed are not equivalent potential difference the electrical chassis. In order to equal potential difference, connect to the electrical chassis. Insulation resistance Table 1 Condition 1Condition 2 Table 1 Condition 3 EV EV Fig.1 HV Battery Pack ServiceMainRelay Requirement of the electrical power train operating on high voltage Ⅰ.Protection 1.Protection against electrical against Direct shock contact with hight voltage live 2.Protection against electrical shock with arise from indirect contact 3.Electirical Isolation 4.Automatic disconnection and low voltage,low electrical energy Ⅱ.Rechargeable energy storage system retention Rechargeable energy storage system(ress) retention Electrolyte spillage JPN EU ECER-94,R-95 USA FMVSS305 Table 2 Regulatory Requirement of the Electrical Power train Operating on High Voltage Inverter A/C Comp Heater Vehicle Control Module HV Harness JunctionBox Motor Charger,DC/DC convertor Fig.1 System of Electric Drive Vehicle EV 12 V 346 V 20 kwh 346 V 136
No.302012 DC-DC 12 V VCM PTC EV FEM EV Fig.2 Fig.3 Mounting Electric Drive Battery EV Fig.45 ABS Fig.2 Layout of High Voltage Cable and Battery EV Fig.3 137
No.302012 Cross-Beams Offset frontal Crash Fig.4 The Cross-Beams on Front Side Frames Harness Survival space Lateral Crash Fig.5 Survival Space for High Voltage Cables EV (1) CAE Fig.6 CAE CAE Rear-end Crash Fig. 6 CAE Evaluation in Various Crash Modes (2) Fig.7,, EV 138
No.302012 Offset frontal Crash Fig.8 Automatic Disconnect System EV Lateral Crash Rear-end Crash Fig. 7 Actual Vehicle Crash Tests EV Fig.8 RCM RCM VCM VCM SMR 100 ms 139