Browse Topic: Safety testing and procedures

Items (5,489)
All-solid-state batteries (ASSBs) based on sulfide electrolytes hold great promise for next-generation energy storage, yet their performance is critically constrained by unstable cathode–electrolyte interfaces. Here, we report a dual-modification strategy utilizing ionic liquids (ILs) in combination with lithium salts to simultaneously improve interfacial wettability, ionic transport, and electrochemical stability in NCM811 composite cathodes. Three ILs (EMIMTFSI, Pyr₁₄FSI, and PP₁₃FSI) and three lithium salts (LiTFSI, LiDFOB, and LiBOB) were systematically evaluated and screened. While neat ILs improved initial capacities by reducing solid–solid contact resistance, they also triggered parasitic reactions with sulfides, resulting in capacity fading. Among the lithium salts, LiBOB was identified as the most chemically compatible additive, forming thin and uniform hybrid interphases enriched with B–O species. This interphase effectively suppressed high-voltage side reactions and reduced
Gu, Yu-YangTian, Shi-YuQi, JiYang, Li-PengZhan, Wen-WeiYang, Xiao-GuangYi, Yong
Due to limitations in available battery samples and testing costs, lithium-ion battery thermal runaway experiments are not practical to repeat multiple times, and the reliability of experimental results is frequently questioned. To systematically evaluate the repeatability of the heating wire-triggered method in thermal runaway tests, this study investigates two types of commercial 18650 cylindrical batteries with NCM/graphite chemistry under different heating power levels and health conditions. The results indicate that under the same heating power, batteries of the same type exhibit good repeatability in thermal runaway onset time and onset temperature, with the consistency of onset time outperforming that of onset temperature. As the heating power increases, the onset time of thermal runaway decreases significantly, while the variation in onset temperature remains relatively small. Compared to fresh batteries, aged batteries show reduced variability in thermal runaway
Wang, JiaYan, HongtaoZhang, YuemengLin, ChunjingLao, Li
Current studies about battery pack bottom strike usually focus on one test condition individually. To study the relation between quasi-static and dynamic crush in battery pack bottom strike, the paper combined quasi-static crush result and dynamic strike preset kinetic energy value with the same displacement damage on the battery pack bottom plate and cell. First, based on the finite element model of the battery pack, the quasi-static crush is applied. Several dynamic crush tests with different initial kinetic energy sets are also introduced. Then based on the same displacement damage, the pressure in quasi-static and kinetic energy in dynamic conditions are summarized. Fitting methods including polynomial regression, support vector regression (SVR), extreme learning machine (ELM), multilayer perceptron (MLP), Gaussian process regression (GPR), and K-nearest neighbor (KNN) regression are used to study the relation between the two different test load. The result shows that they have a
Tang, HongxiWang, ShengweiZhou, KaiLiu, Jinyu
One primary cause of NEV fires is thermal runaway initiated by internal short circuit in power batteries, leading to subsequent thermal diffusion throughout the battery system. Severe internal short circuit damage can precipitate thermal runaway phenomena in lithium-ion batteries, potentially culminating in fire incidents involving electric vehicles. Although mild internal short circuit may not immediately induce thermal runaway, continuous charge and discharge cycling can exacerbate such conditions, progressively elevating risks associated with thermal runaway and other pertinent safety hazards. Conventional safety testing methodologies, employing techniques such as crushing and nail penetration to simulate internal short circuit, often amplify the extent of these shorts and fail to accurately replicate less severe, deeper internal short circuit. Additionally, methods incorporating foreign objects like nickel pieces for simulating internal short circuit necessitate battery disassembly
Sun, ZhipengMa, TianyiHan, CeWang, FangRen, Gaohui
With the vigorous development and technological iteration of the new energy vehicle industry, the strategic position of inspection, certification, R&D and testing in the industrial chain has become increasingly prominent. As the core energy storage component of new energy vehicles, the potential safety risks and environmental hazards in the testing process of power batteries are particularly worthy of vigilance. Based on more than ten years of operational practice in battery laboratories, this paper summarizes experience and lessons in depth, focusing on problems such as smoke, fire, explosion and release of toxic and harmful substances caused by thermal runaway of batteries in lithium-ion battery safety abuse tests. From the dimensions of risk characteristics of safety abuse tests, laboratory security design, and laboratory environmental protection facilities, it systematically expounds the risk prevention and control strategies and environmental protection measures for lithium-ion
Ren, GaohuiLiu, LeiJiang, ChenglongSun, ZhipengChen, Liduo
Path selection for the transport of hazardous materials (Hazmats) is a multi-facet decision problem that needs to account for multiple factors such as accident risk as well as transportation cost. Most existing literature has modeled the risk of Hazmats transportation as the product of accident loss, and its probability-based expected utility theory, however, could be problematic since such a risk definition does not necessarily reflect the real perceived risk by the decision-maker. This article proposes a novel approach to the path selection of Hazmats transportation based on the cumulative prospect theory (CPT). Specific steps in the decision of path selection are first laid out in the framework of CPT. Value (Loss) functions of accident in Hazmats transportation are then derived, together with the decision weighting function reflecting accident probabilities. For illustration, a case study is conducted using transportation data from a Hazmats transportation firm in Shanghai
Wang, XuleiSun, Chunwei
The purpose of this study was to evaluate the thoracic responses of the 50th-percenitle male Hybrid III, THOR, and post mortem human surrogates (PMHS) in the rear seat during frontal sled tests using conventional and advanced restraints in multiple vehicle environments. Twenty-one sled tests were conducted using the Hybrid III and THOR in seven vehicle bucks, and 12 PMHS sled tests were performed using four vehicle bucks. Trends in chest deflections between vehicles and restraint conditions were compared between surrogates. The Hybrid III and THOR thoracic injury risk predictions were compared to the thoracic skeletal damage observed during the PMHS tests. The Hybrid III chest deflections were statistically significantly greater for vehicles equipped with conventional restraints compared to those equipped with advanced restraints. The THOR chest deflections generally followed this trend, but the differences between restraint types were not statistically significant. Hence, the THOR
Albert, Devon L.Bianco, Samuel T.Guettler, Allison J.Boyle, David M.Kemper, Andrew R.Hardy, Warren N.
Mining operations are important to industrial growth, but they expose the mining workers to risk including hazardous gases, elevated ambient temperatures, and dynamic structural instabilities within underground environments. Safety systems in the past, typically based on fixed sensor networks or manual patrols, fall short in accurate hazard detection amidst shifting mine conditions. The proposed project Miner's Safety Bot advanced this paradigm by leveraging an ESP 32 microcontroller as a mobile platform that integrates gas sensing, thermal monitoring, visual inspection and autonomous obstacle avoidance. The system incorporates MQ7 semiconductor gas sensor to monitor real time carbon monoxide (CO), offering detection range from 5 to 2000 ppm with accuracy of 5 ppm. Temperature and humidity are monitored through DHT11 digital sensor, calibrated to ensure reliability across the harsh microclimates in mines. Navigation and autonomous movement are enabled by Ultrasonic Sensor (HC-SR04
D, SuchitraD, AnithaMuthukumaran, BalasubramaniamMohanraj, SiddharthSubash Chandra Bose, Rohan
Treat foundational AV safety like seatbelts - make it non-proprietary and universal. An open safety stack, shared scenarios, benchmarks, and core validation tools can speed certification, reduce duplicated V&V and build public trust while preserving vendor differentiation. The bottleneck isn't compute - it's verification. Autonomous features are shipping in more vehicles and markets, but the gating factor is no longer raw compute. It's whether developers and regulators can verify systems against requirements and validate them against real-world operating design domains (ODDs) with confidence and repeatability. Today, many safety-critical components, from scenario libraries to pass/fail criteria, live in proprietary silos. That fragmentation slows regression testing, complicates regulator audits across regions, and duplicates effort across the industry. The result is an expensive, bespoke path to certification for every program and geography.
Musa, MohammadKhawaja, Muhammad Zain
At present, commercial air travel rules do not allow people to sit in their own wheelchairs during flight. However, airline seating often does not meet medical needs. In response to current requests to allow this seating option, we researched the crashworthiness and safety of wheelchairs for potential use in aircraft. For motor vehicle travel, many wheelchairs meet voluntary standards for crashworthiness and safety per RESNA WC19. This project assesses whether WC19-compliant wheelchairs can meet FAA aircraft seating standards when secured using 4-point tiedowns. For the FAA horizontal impact testing, computer modeling indicated that a trapezoidal sled pulse was sufficient to represent the more typical triangular pulse, and that due to the flexibility of the tiedown webbing, the effect of the simulated pitch/roll element was minimal. During the initial two horizontal impact tests, fracture of the left front wheelchair caster was observed. The remaining five wheelchairs were tested with
Klinich, Kathleen D.Manary, Miriam A.Boyle, Kyle J.Vallier, TylerOrton, Nichole R.
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads — a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, LakshmipathyP, PraveenK, ChandramohanC, Santhosh
This paper presents the design, structural analysis, structural test validation and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used the 2.5L and 3.0L (4-cylinder) engines that have standard power ratings based on existing requirements, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 15% uprate for 2.5L and 22% uprate for 3.0L from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. Multiple analysis led design iterations were performed using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure the structural integrity of the cylinder head under high thermal and mechanical loads, and to keep design margins within
Pathak, Arun JyotiAdiverekar, VaidehiSingh, RahulBiyani, Mayur
The proliferation of wireless charging technology in electric vehicles (EVs) introduces novel cybersecurity challenges that require comprehensive threat analysis and resilient design strategies. This paper presents a proactive framework for assessing and mitigating cybersecurity risks in wireless charger Electronic Control Units (ECUs), addressing the unique vulnerabilities inherent in electromagnetic power transfer systems. Through systematic threat modeling, vulnerability assessment, and the development of defense-in-depth strategies, this research establishes design principles for creating robust wireless charging ecosystems resistant to cyber threats. The proposed framework integrates hardware security modules, encrypted communication protocols, and adaptive threat detection mechanisms to ensure operational integrity while maintaining charging efficiency. Experimental validation demonstrates the effectiveness of the proposed security measures in preventing unauthorized access, data
Uthaman, SreekumarMulay, Abhijit BGadekar, Pundlik
With increased deterioration of road conditions worldwide, automotive OEMs face significant challenges in ensuring the durability of structural components. The tyre being the primary point of contact with the road is expected to endure harshest of impacts while maintaining the other performance functions such as Ride & Handling, Rolling resistance, Braking. Thus, it is considered as the most challenging component in terms of design optimization for durability. The current development method relies on physical testing of initial samples, followed by iterative construction changes to meet durability requirements, often giving trade-off in Ride & Handling performance. To overcome these challenges, a frugal simulation-based methodology has been developed for predicting tyre curb impact durability before vehicle-level testing so that corrective action can be taken during the design stage.
Sundaramoorthy, RagasruobanLenka, Visweswara
PU foam shows a excellent energy absorbing dissipation properties during impact load so it commonly used in car seats, cabin and crash protection system. Specifically, in vehicle seats PU foams play a critical role in protecting occupants during crash scenarios by absorbing energy, distributing forces, and improving seatbelt performance, additionally providing countermeasures for head impact protection. The movement of the seat and the direction of the force during crash testing are highly unpredictable. The material behaviour of PU foam is captured using an isotropic, hyper-elasticity-based constitutive model available in LS-DYNA through MAT_083. This model is designed to take into account the foam's compressibility, sensitivity to strain rates, low Poisson's ratio, and hysteresis. The characterization of a PU foam with a nominal density of 65 kg/m3 was performed using quasi-static compressive testing of 0.01/s and dynamic compressive testing of 1/s,13/s, 120/s, as well as a quasi
Gaurav, Ashish KumarKrishnamoorthy, KunjuVaratharajan, Senthilkumaran
Real-world crashes involve diverse occupants, but traditional restraint systems are designed for a limited range of body types considering the applicable regulations and protocols. While conventional restraints are effective for homogeneous occupant profiles, these systems often underperform in real-world scenarios with diverse demographics, including variations in age, gender, and body morphology. This study addresses this critical gap by evaluating adaptive restraint systems aligned with the forthcoming EURO NCAP 2026 protocols, which emphasize real-world crash diversity and occupant type. Through digital studies of frontal impact scenarios, we analyze biomechanical responses using adaptive restraints across varied occupant demographics, focusing on head and chest injury (e.g., Chest Compression Criterion [CC]). This study used a Design of Experiments (DOE) approach to optimize occupant protection by timing the actuating of these adaptive systems. The results indicate that activating
satija, AnshulSuryawanshi, YuvrajChavan, AvinashRao, Guruprakash
The number of female drivers in India is increasing alongside the rapid growth of the Indian automotive industry. A driving comfort survey conducted among female drivers revealed that many of them experienced discomfort when wearing safety belts—while driving and as front-seat passengers. This discomfort is primarily due to a phenomenon referred to as “neck cutting.” The root cause of neck cutting is likely related to vehicle design, which is traditionally based on Anthropometric Test Devices (ATD’s) representing the 5th, 50th & 95th percentile (%tile) of the global population. However, a literature review indicated that the anthropometric dimensions of the Indian populations are generally smaller than those of the global for the respective candidate. To validate the neck-cutting issue, various female candidates were asked to sit in the Driver’s seat for physical measurements trials. Accordingly, methodology was developed to quantify neck cutting parameters objectively. A correlation
Kulkarni, Nachiket AChitodkar, Vivek VEknath Chopade, SantoshMahajan, RahulYamgar, Babasaheb S
Vehicle door-related accidents, especially in urban environments, pose a significant safety risk to pedestrians, infrastructure and vehicle occupants. Conventional rear view systems fails to detect obstacles in blind spots directly below the Outside Rear View Mirror (ORVM), leading to unintended collisions during door opening. This paper presents a novel vision-based obstacle detection system integrated into the ORVM assembly. It utilizes the monocular camera and a projection-based reference image technique. The system captures real-time images of the ground surface near the door and compares them with calibrated reference projections to detect deviations caused by obstacles such as pavements, potholes or curbs. Once such an obstacle is detected the vehicle user is alerted in the form of a chime.
Bhuyan, AnuragKhandekar, DhirajJahagirdar, Shweta
The objective of the present study is to examine trends in occupant kinematics and injuries during side impact tests carried out on vehicle models over the period of time. Head, shoulder, torso, spine, and pelvis kinematic responses are analysed for driver dummy in high speed side impacts for vehicle model years, MY2016-2024. Side impact test data from the tests conducted at The Automotive Research Association of India (ARAI) is examined for MY2016-2024. The test procedure is as specified in AIS099 or UNECE R95, wherein a 950kg moving deformable barrier (MDB) impacts the side of stationary vehicle at 50km/hr. An Instrumented 50th percentile male EUROSID-2 Anthropomorphic Test Device is positioned in the driver seat on the impacting side. Occupant kinematic data, including head accelerations, Head Injury Criterion (HIC15), Torso deflections at thorax and abdominal ribs, spine accelerations at T12 vertebra, and pelvis accelerations are evaluated and compared. The “peak” and “time to
Mishra, SatishBorse, TanmayKulkarni, DileepMahajan, Rahul
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