Traction Battery Approvals

TÜV SÜD is actively supporting the efforts of OEMs of xEV batteries and battery systems to validate the safety and performance of their products, and to successfully navigate the homologation process in major markets around the world. Our homologation experts have in-depth know-how about key safety and performance issues that must be addressed in all xEV battery designs, as well as the specialized requirements that apply to xEV battery systems in the EU, the U.S., China and other key battery markets around the world.

About traction battery approvals

Any manufacturer that wishes to sell traction batteries (or vehicles powered by them) in Europe or other international markets requires battery approval from the respective authorities. This procedure is also known as homologation. For producers of xEV battery and battery systems, the acceptance of their products is therefore dependent on successfully demonstrating compliance with the requirements and standards imposed by regulatory authorities in major automotive markets around the world, like the UNECE Regulation 100 (ECE R 100).

The UN World Forum for the Harmonization of Vehicle Regulations and UNECE Regulation No. 100

Established in the early 1950s, the United Nations’ World Forum for the Harmonization of Vehicle Regulations is responsible for harmonizing global technical requirements and protocols for the homologation of all types of vehicles and vehicle components. More than 50 countries are signatories to the 1958 Agreement that provides the legal framework for the World Forum’s activities. Signatory countries include all EU member states, as well as Australia and New Zealand, Japan and Thailand.

UNECE Regulation No. 100 is the internationally recognized standard for rechargeable energy storage systems (REESS) used in xEVs. The second revision of ECE R100 provides an expanded set of specific tests applicable to REESS and rechargeable battery packs.

Why battery homologation Is important

As the market for advanced electrified vehicles (xEVs) continues to expand globally, developers and original equipment manufacturers (OEMs) are confronted with a growing array of regulations and standards for the safety and performance of rechargeable battery systems. Although many of these regulations touch on similar considerations, there are also important differences that must be taken into account.

Traction batteries without type approval cannot be placed on global markets. Type testing according to ECE-R100. and other global regulations is therefore essential for manufacturers of traction batteries used in both electric and hybrid-electric vehicles.

Achieving traction battery type approval brings manufacturers multiple benefits:

With ECE R100 type approval received from the regulatory authority in one of the Forum’s signatory countries, your traction battery can be legally imported, sold and used in other signatory nations.
Traction battery tests identify issues early so that you can implement any redesigns before production and avoid costly reworks and delays in market access.
Ensures the safety of the traction battery which increases your customers’ confidence in your battery products.

TÜV SÜD supports you along the type approval process for your traction battery

TÜV SÜD has extensive experience conducting traction battery approval testing in line with UNECE Regulation 100 and other international standards and regulations like FMVSS 305, GB 18384-2020, GB 38032-2020 and GB 38031-2020. Our testing laboratories are equipped with state-of-the-art test benches for testing traction batteries according to your required country regulation. TÜV SÜD technicians are also engaged in the development of standards around battery safety and are fully informed of all regulatory developments and forthcoming changes.

After conducting tests, TÜV SÜD as Technical Service prepares the necessary technical reporting and assists in handling the approval process with the authorities (homologation). This provides manufacturers with a one-stop solution for achieving traction battery type approval.

Our traction battery approval services

TÜV SÜD is actively supporting OEMs of xEV batteries and battery systems to validate the safety and performance of their products, and access global markets. The scope of our service includes:

Technical advice
Documentation review
Preparation of technical reports
Type approval testing and certification for most major markets
Complete homologation support

We provide battery homologation support according to various regulations

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Traction battery type approval for the European Union
Besides the demonstration of compliance with the requirements of ECE R100 xEV battery OEMs must still navigate a complex set of steps to successfully achieve EU type approval for their products.

These steps include:
- Selecting one of the three testing approval routes authorised under the Directive.
- Preparing and assembling the required documentation (referred to as the ‘information folder’ in the Regulation) that includes detailed specifications of the xEV battery, drawings, photographs, test reports and other technical information as required.
- Under the UNECE’s type approval scheme, a recognised ‘technical service’ needs to conduct or witness testing and report testing results to the chosen approval authority. The approval authority in turn reviews and recognises the testing results and assigns a registration number together with an E-mark. We are recognised as technical service by nine authorities.
Our laboratories are equipped to carry out all tests of high-voltage traction batteries of ECE-R100. In detail these are:
- Vibration tests
- Thermal shock and cycling tests
- Mechanical shock tests
- Mechanical integrity tests
- Fire resistance tests
- External short circuit protection tests
- Overcharge protection tests
- Over-discharge protection tests
- Over-temperature protection tests
In addition to testing according to ECE-R100.02, we can also carry out electromagnetic compatibility (EMC) testing according to ECE-R10 Rev. 6 and offer testing of light electric vehicles (LEV) according to ECE-R136.
Traction battery type approval for North America

The U.S. National Highway Transportation and Safety Administration (NHTSA) has developed vehicle standards intended to establish requirements for motor vehicles consistent with U.S. law. More than 50 individual Federal Motor Vehicle Safety Standards (FMVSS) address a wide variety of automotive systems and components.

FMVSS 305, electric-powered vehicles: electrolyte spillage and electrical shock protection, is the FMVSS to which manufacturers of xEV battery systems must self-certify. Self-certification to the requirements of FMVSS 305 must be based on credible test data and most OEMs rely on third-party testing organisations to conduct the rigorous testing necessary to verify compliance. TÜV SÜD supports you as your testing partner, here for all required battery testing.
Traction battery type approval for China
Early in 2020, China’s Ministry of Industry and Information Technology (MIIT) issued three new national standards for xEVs and their batteries. The new standards represent an effort by China’s authorities to more closely align the country’s requirements with international regulations and standards, including the UNECE’s Global Technical Regulation (GTR) No 20, Electric Vehicle Safety.

The new mandatory standards are:
- GB 18384-2020, which addresses safety requirements for xEVs;
- GB 38032-2020, which addresses safety requirements for electric buses;
- GB 38031-2020, which addresses traction battery safety requirements for xEV batteries and battery systems, exclusively focusing on battery cells and packs.
In China, the xEV battery homologation process requires the use of a third-party testing laboratory that has been recognised by the MIIT. We support you here.
Traction battery type approval for other major automotive markets

South Korea

South Korea, which formerly relied on self-certification for automotive components, adopted a more rigorous regulatory process in 2011 to help ensure component safety. As a result, the country now requires OEMs of xEV batteries and battery systems to test their products to verify compliance with the battery pack testing requirements of the relevant Korean Motor Vehicle Safety Standard (KMVSS). The resulting test report is then used to support the certification of the xEV by Korea Transportation Safety Authority (KOTSA).

Thailand

Thailand had adopted a type approval process for the review and approval of automotive components. The country’s Department of Land Transport (DLT) has adopted UNECE Regulations as the standard that manufacturers and importers must meet to order to obtain the DLT Automotive Certification T-Mark. This is required to legally market and sell automotive components in Thailand. However, at the time of writing, no timetable has been established for mandatory compliance with this requirement.