Deconstruction of UN38.3 into a Process Flowchart

This paper will discuss a compliance demonstration methodology for UN38.3, an international regulation which includes a series of tests that, when successfully met, ensure that lithium metal and lithium ion batteries can be safely transported. Many battery safety regulations, such as FMVSS and ECE, include post-crash criteria that are clearly defined. UN38.3 is unique in that the severity of the tests drove changes to battery design and function. Another unique aspect of UN38.3 is that the regulatory language can lead to different interpretations on how to run the tests and apply pass/fail criteria; there is enough ambiguity that the tests could be run very differently yet all meet the actual wording of the regulation. A process was created detailing exactly how to run the tests to improve consistency among test engineers. As part of this exercise, several tools were created which assist in generating a test plan that complies with the UN38.3 regulation. The requirement configuration table and flowcharts can be used to determine testing requirements at both the module (sub-assembly) and pack (end-item assembly) levels. This paper describes the process used to develop the table and flowcharts and how they can be used to help identify appropriate UN38.3 test plans.