# 電池設計相關規則
> 以下照著FSAE 2023 Rule 中相關編列順序
[FSAE rule 2023 download](https://www.fsaeonline.com/cdsweb/gen/DownloadDocument.aspx?DocumentID=d2404288-c121-4242-9944-90aa0b1d6a5f)

## definition
- EV.1.3 Accumulator
>All the battery cells or super capacitors that store the electrical energy to be used by the
Tractive System

## Limitations
- EV.4.1.1 The maximum power drawn from the Accumulator must not exceed 80 kW.
- EV.4.1.2 The maximum permitted voltage that may occur between any two points must not exceed 600 V DC
>電池箱出來的功率不能超過80kW
>任兩點最大電壓不能超過600VDC
>判斷標準會由能量計量到的數據( EV4.3.1、4.3.4 )作為依據

- EV.4.1.3 The powertrain must not regenerate energy when vehicle speed is between 0 and 5 km/hr
>今年規則有修改→不能倒車也合併進去了

- EV.4.3.1 All Electric Vehicles must run with the Energy Meter provided by the organizer.
- EV.4.3.4 Power and Voltage limits will be checked by the Energy Meter data. Energy is calculated as the time integrated value of the measured voltage multiplied by the measured current logged by the Energy Meter.
> 上面兩則定義了能量計以及輸出上限會由能量計量到的為主

## Components

- EV.5.3 Accumulator Container
- EV.5.3.1 Accumulator Containers must meet F.10
- EV.5.3.2 The Accumulator Container(s) must be removable from the vehicle while still remaining rules compliant.
> 電池箱必須可以在符合規則的狀況下拆卸
- EV.5.3.3 The Accumulator Container(s) must be completely closed at all times (when mounted to the vehicle and when removed from the vehicle) without the need to install extra protective covers.
>電池箱必須處於不需額外加裝遮罩的封閉狀態
- EV.5.3.4 The Accumulator Container(s) may contain Holes or Openings.
- a. Only the wiring harness, ventilation, cooling and fasteners may pass through holes in the Accumulator Container(s)
- b. Holes and Openings in the Accumulator Container must meet F.10.4
- c. External holes must meet EV.7.1
> 電池箱可以在以上狀況開孔
- EV.5.3.5 Any Accumulators that may vent an explosive gas must have a ventilation system or pressure relief valve to prevent the vented gas from reaching an explosive concentration.
- EV.5.3.6 Completely sealed Accumulator Containers must have a pressure relief valve to prevent high pressure in the container.
> 對於完全密閉/會產生易爆炸氣體的箱體必須具有洩壓裝置
- EV.5.3.7 Each Accumulator Container must be labeled with the:
- a. Symbol specified in [ISO 7010-W012](https://www.iso.org/obp/ui#iso:grs:7010:W012) (triangle with black lightning bolt on yellow background) with triangle side length of 100 mm minimum
- b. Text “Always Energized”
- c. Text “High Voltage” if the voltage meets T.9.1.1
> 電池箱標示限制

- EV.5.10 Accumulator Hand Cart
- EV.5.10.1 Teams must have a Hand Cart to transport their Accumulator Container(s).
- EV.5.10.2 The Hand Cart must be used when the Accumulator Container(s) are transported on the competition site.
> 每支隊伍都必須要有自己的電池箱推車，並且只能用電池箱推車來移動電池箱
- EV.5.10.3 Accumulator Container(s) must be securely attached to the Hand Cart
- EV.5.10.4 The Hand Cart must:
- a. Be able to carry the load of the Accumulator Container(s) without tipping over
- b. Contain a minimum of two wheels
- c. Have a brake that must be:
- Released only using a dead man type switch (where the brake is always on except when released by pushing and holding a handle)
- Able to stop the Hand Cart with a fully loaded Accumulator Container

## ENERGY STORAGE
- EV.6.1 Accumulator
- EV.6.1.1 All cells or super capacitors which store the Tractive System energy are built into Accumulator Segments and must be enclosed in (an) Accumulator Container(s).
- EV.6.1.2 Each Accumulator Segment must contain:
- Maximum static voltage of less than 120 V DC
- Maximum energy of 6 MJ

>The contained energy of a stack is calculated by multiplying the maximum stack voltage with the nominal capacity of the used cell(s).
>> 單一電池包含有電壓不能超過 120VDC 6MJ
> 能量計算方式是將最大電壓乘以電池容量

- EV.6.1.3 No further energy storage except for reasonably sized intermediate circuit capacitors are allowed after the Energy Meter EV.4.2

- EV.6.1.4 All Accumulator Segments and/or Accumulator Containers (including spares and replacement parts) must be identical to the design documented in the ESF and SES

- EV.6.3 Maintenance Plugs
- EV.6.3.1 Maintenance Plugs must allow electrical separation of the Accumulator Segments to meet:
- a. The separated Segments meet voltage and energy limits of EV.6.1.2
- b. The separation must affect both poles of the Segment
- EV.6.3.2 Maintenance Plugs must:
- a. Require the physical removal or separation of a component. Contactors or switches are not acceptable Maintenance Plugs
- b. Not be physically possible to connect in any configuration other than the design intended configuration
- c. Not require tools to install or remove
- d. Include a positive locking feature which prevents the plug from unintentionally becoming loose
- e. Be nonconductive on surfaces that do not provide any electrical connection
- EV.6.3.3 When the Accumulator Containers are opened or Segments are removed, the Accumulator Segments must be separated by using the Maintenance Plugs. See EV.10.2.1

## Protection
- EV.7.6 Overcurrent Protection
- EV.7.6.1 All electrical systems (both Low Voltage and High Voltage) must have appropriate Overcurrent Protection/Fusing.
- EV.7.6.2 Unless otherwise allowed in the Rules, all Overcurrent Protection devices must:
- a. Be rated for the highest voltage in the systems they protect. Overcurrent Protection devices used for DC must be rated for DC and must carry a DC rating equal to or greater than the system voltage.
- b. Have a continuous current rating less than or equal to the continuous current rating of any electrical component that it protects.
- c. Have an interrupt current rating higher than the theoretical short circuit current of the system that it protects.
- EV.7.6.3 Each parallel element of multiple parallel battery cells, capacitors, strings of battery cells, strings of capacitors, or conductors must have individual Overcurrent Protection.
- EV.7.6.4 Any conductors (wires, busbars, etc) conducting the entire pack current must meet one of:
- a. Be appropriately sized for the total current that the individual Overcurrent Protection devices could transmit
- b. Contain additional Overcurrent Protection to protect the conductors
- EV.7.6.5 Battery packs with Low Voltage or non voltage rated fusible links for cell connections may be used when all three conditions are met:
- An Overcurrent Protection device rated at less than or equal to one third the sum of the parallel fusible links and complying with EV.7.6.2.b above is connected in series.
- The AMS can detect an open fusible link and will Open the Shutdown Circuit EV.8.2.2 if a fault is detected.
- Fusible link current rating is specified in manufacturer’s data or suitable test data is provided.
- EV.7.6.6 Cells with internal Overcurrent Protection may be used without external Overcurrent Protection if suitably rated. Most cell internal Overcurrent Protection devices are Low Voltage or non voltage rated and conditions of EV.7.6.5 above will apply

## BMS

- EV.8.3 Accumulator Management System - AMS
- EV.8.3.1 An Accumulator Management System must monitor the Accumulator(s) Voltage EV.8.4 and Temperature EV.8.5 when the:
- a. Tractive System is Active EV.10.1
- b. Accumulator is connected to a Charger EV.9.3

- EV.8.3.2 The AMS must have galvanic isolation at every segment to segment boundary, as approved in the ESF
- EV.8.3.3 Cell balancing is not permitted when the Shutdown Circuit is Open ( EV.8.2, EV.9.4 )
- EV.8.3.4 The AMS must monitor for:
- a. Voltage values outside the allowable range EV.8.4.2
- b. Voltage sense Overcurrent Protection device(s) blown or tripped
- c. Temperature values outside the allowable range EV.8.5.2
- d. Missing or interrupted voltage or temperature measurements
- e. A fault in the AMS
- EV.8.3.5 If the AMS detects one or more of the conditions of EV.8.3.4 above, the AMS must:
- a. Open the Shutdown Circuit EV.8.2.2
- b. Turn on the AMS Indicator Light
- EV.8.3.6 The AMS Indicator Light must be:
- a. Color: Red
- b. Clearly visible to the seated driver in bright sunlight
- c. Clearly marked with the lettering “AMS”

- EV.8.4 Accumulator Voltage
- EV.8.4.1 The AMS must measure the cell voltage of every cell When single cells are directly connected in parallel, only one voltage measurement is needed
- EV.8.4.2 Cell Voltage levels must remain inside the allowed minimum and maximum cell voltage levels stated in the cell data sheet. Measurement accuracy must be considered.
- EV.8.4.3 All voltage sense wires to the AMS must meet one of:
- a. Have Overcurrent Protection EV.8.4.4 below
- b. Meet requirements for no Overcurrent Protection listed in EV.8.4.5 below
- EV.8.4.4 When used, Overcurrent Protection for the AMS voltage sense wires must meet the following.
- a. The Overcurrent Protection must occur in the conductor, wire or PCB trace which is directly connected to the cell tab.
- b. The voltage rating of the Overcurrent Protection must be equal to or greater than the smaller of:
- The sum of the cell voltages sensed by the AMS board
- The sum of the cell voltages sensed between galvanic isolation boundaries on the cell board/AMS
- EV.8.4.5 Overcurrent Protection is not required on a voltage sense wire if all three of the following conditions are met:
- AMS is a distributed AMS system (one cell measurement per board)
- Sense wire length is < 25 mm
- AMS board has Overcurrent Protection
- EV.8.5 Accumulator Temperature
- EV.8.5.1 The AMS must measure the temperatures of critical points of the Accumulator
- EV.8.5.2 Temperatures (considering measurement accuracy) must remain below the lower of the two:
- The maximum cell temperature limit stated in the cell data sheet
- 60°C
- EV.8.5.3 Cell temperatures must be measured at the negative terminal of the respective cell
- EV.8.5.4 The temperature sensor used must be in direct contact with one of:
- The negative terminal itself
- The negative terminal busbar less than 10 mm away from the cell terminal
- EV.8.5.5 For lithium based cells,
- a. The temperature of a minimum of 20% of the cells must be monitored by the AMS
- b. The monitored cells must be equally distributed inside the Accumulator Container(s) Every cell temperature should be monitored
- EV.8.5.6 Multiple cells may be monitored with one temperature sensor, if EV.8.5 is met for all cells sensed by the sensor.
- EV.8.5.7 Temperature sensors must have appropriate electrical isolation that meets one of the two:
- Between the sensor and cell
- In the sensing circuit
The isolation must consider both GLV/TS isolation as well as common mode voltages between
sense locations.

## Charge
- EV.9.1 Charger Requirements
- EV.9.1.1 All features and functions of the Charger and Charging Shutdown Circuit must be demonstrated at Electrical Technical Inspection. IN.4.1
- EV.9.1.2 Chargers will be sealed after approval. IN.4.7.1

- EV.9.2 Charger Features
- EV.9.2.1 The Charger must be galvanically isolated (AC) input to (DC) output.
- EV.9.2.2 If the Charger housing is conductive it must be connected to the earth ground of the AC input.
- EV.9.2.3 All connections of the Charger(s) must be isolated and covered.
- EV.9.2.4 The Charger connector(s) must incorporate a feature to let the connector become live only when correctly connected to the Accumulator.
- EV.9.2.5 High Voltage charging leads must be orange
- EV.9.2.6 The Charger must have two TSMPs installed, see EV.6.8.2
- EV.9.2.7 The Charger must include a Charger Shutdown Button which is:
- a. A push-pull or push-rotate emergency switch
- b. Minimum diameter of 25 mm
- c. Labelled with the international electrical symbol (a red spark on a white edged blue triangle)
- EV.9.3 Charging Shutdown Circuit
- EV.9.3.1 The Charging Shutdown Circuit consists of:
- a. Charger Shutdown Button EV.9.2.7
- b. Accumulator Management System (AMS) EV.8.3
- c. Insulation Monitoring Device (IMD) EV.8.6
- EV.9.3.2 The AMS and IMD parts of the Charging Shutdown Circuit must:
- a. Be designed as Normally Open contacts
- b. Have completely independent circuits to Open the Charging Shutdown Circuit.
Design of the respective circuits must ensure that a failure cannot result in electrical
power being fed back into the Charging Shutdown Circuit.
- EV.9.4 Charging Shutdown Circuit Operation
- EV.9.4.1 When Charging, the AMS and IMD must:
- a. Monitor the Accumulator
- b. Open the Charging Shutdown Circuit if a fault is detected.
- EV.9.4.2 When the Charging Shutdown Circuit Opens:
- a. All current flow to the Accumulator must stop immediately
- b. The voltage in the Tractive System must be Low Voltage T.9.1.2 in five seconds or less
- c. The Charger must be turned off
- d. The Charger must remain disabled until manually reset

## Operations

- EV.10.2 Accumulator
- EV.10.2.1 The following work activities at competition are allowed only in the designated area and during Electrical Technical Inspection IN.4 See EV.6.3.3
- a. Opening Accumulator Containers
- b. Any work on Accumulators, cells, or Segments
- c. Energized electrical work
- EV.10.2.2 Moving Accumulator cells and/or Accumulator Segment(s) at the competition site is only allowed inside a completely closed Accumulator Container. See EV.5.10.2

- EV.10.3 Charging
- EV.10.3.1 Accumulators must be removed from the vehicle inside the Accumulator Container and placed on the Accumulator Container Hand Cart EV.5.10 for Charging.
- EV.10.3.2 Accumulator Charging must occur only inside the designated area.
- EV.10.3.3 A team member(s) who has knowledge of the Charging process must stay with the Accumulator(s) during Charging.
- EV.10.3.4 Each Accumulator Container(s) must have a label with the following data during Charging:
Team name and Electrical System Officer phone number(s).
- EV.10.3.5 Additional site specific rules or policies may apply.

## Appendix - ACC Container( F.10 )
- F.10 ACCUMULATOR CONTAINER (EV ONLY)
- F.10.1 General Requirements
- F.10.1.1 All Accumulator Containers must be:
- a. Designed to withstand forces from deceleration in all directions
- b. Made from a Nonflammable Material ( F.1.18 )
- F.10.1.2 Design of the Accumulator Container must be documented in the SES. Documentation includes materials used, drawings/images, fastener locations, cell/segment weight and cell/segment position.
- F.10.1.3 The Accumulator Containers and mounting systems are subject to approval during SES review and Technical Inspection.
- F.10.2 External Structure
- F.10.2.1 The Floor or Bottom must be made from one of the three:
- a. Steel 1.25 mm minimum thickness
- b. Aluminum 3.2 mm minimum thickness
- c. Equivalent Alternate / Composite materials ( F.4.1, F.4.3 )
- F.10.2.2 Vertical Walls, Covers and Lids must be made from one of the three:
- a. Steel 0.9 mm minimum thickness
- b. Aluminum 2.3 mm minimum thickness
- c. Equivalent Alternate / Composite materials ( F.4.1, F.4.3 )
- F.10.2.3 The accepted methods of joining walls to walls and walls to floor are:
- a. Welding
- Welds may be continuous or interrupted.
- If interrupted, the weld/space ratio must be 1:1 or greater
- All weld lengths must be greater than 25 mm
- b. Fasteners Combined strength of the fasteners must be Equivalent to the strength of the welded joint ( F.10.2.3.a above )
- c. Bonding
- Bonding must meet F.5.5
- Strength of the bonded joint must be Equivalent to the strength of the welded joint ( F.10.2.3.a above )
- Bonds must run the entire length of the joint
- F.10.2.4 Covers and Lids must be attached with a minimum of one fastener for each external vertical wall per section.
- F.10.3 Internal Structure
- F.10.3.1 Walls
- a. Construction of Internal walls (vertical or horizontal) separating cells and/or segments must meet F.10.2.2
- b. Internal vertical walls separating cells and/or segments must have minimum height of the full height of the Accumulator Segments
- c. Fastened connections between the floor and any vertical wall of each Section must have minimum of two fasteners.
- d. Removable horizontal interior walls must be fastened with a minimum of one fastener for each external vertical wall per section. Folding or bending plate material to create flanges or to eliminate joints between walls is recommended.
- F.10.3.2 Sections
- a. Internal vertical walls divide the Accumulator Container into “Sections”
- b. A maximum of 12 kg is allowed in any Section
- c. Fastened connections between vertical walls around Sections containing 8kg or less must have a minimum of two fasteners
- d. Fastened connections between vertical walls around sections containing between 8 kg and 12 kg must have a minimum of three fasteners Example: An Accumulator Container with 2 internal walls has 3 Sections. Each Section contains less than 8 kg. Therefore 18 floor to wall joints are required in total with minimum two fasteners per joint.
- F.10.3.3 If segments are arranged vertically above other segments, each layer of segments must have a load path to the Chassis attachments that does not pass through another layer of segments
- F.10.3.4 Cells and Segments
- a. The cells and/or segments must be appropriately secured against moving inside the Container.
- b. This mounting system design must withstand the following accelerations: 40 g in the longitudinal direction (forward/aft) 40 g in the lateral direction (left/right) 20 g in the vertical direction (up/down)
- c. Calculations and/or tests proving these requirements are met must be included in the SES.
- d. Any fasteners must be 6 mm or 1/4” minimum diameter
- F.10.4 Holes and Openings
- F.10.4.1 The Accumulator Container(s) exterior or interior walls may contain holes or openings, see EV.5.3.4
- F.10.4.2 Any Holes and Openings must be the minimum area necessary
- F.10.4.3 Exterior and interior walls must cover a minimum of 75% of each face of the battery segments
- F.10.4.4 Holes and Openings for airflow:
- a. Must be round. Slots are prohibited
- b. Should be maximum 10 mm diameter
- c. Must not have line of sight to the driver, with the Firewall installed or removed
- F.10.5 Attachment
- F.10.5.1 Attachment of the Accumulator Container must be documented in the SES
- F.10.5.2 Accumulator Containers must:
- a. Attach to the Major Structure of the chassis A maximum of two attachment points may be on a chassis tube between two triangulated nodes.
- b. Not attach to the Shoulder Harness Mounting
- F.10.5.3 Any fasteners used to attach Accumulator Container(s) are Critical Fasteners, see T.8.2
- F.10.5.4 Each attachment point to a composite Accumulator Container requires backing plates that are one of the two:
- a. Steel with a thickness of 2 mm minimum
- b. Alternate materials Equivalent to 2 mm thickness steel
- F.10.5.5 Teams may justify the Accumulator Container attachment using one of:
- Corner Attachments and Analysis per F.10.5.6
- Load Based Analysis per F.10.5.7
- F.10.5.6 Accumulator Attachment – Corner Attachments
- a. Eight or more attachments are required for any configuration.
- One attachment for each corner of a rectangular structure of multiple Accumulator Segments
- More than the minimum number of fasteners may be required for non rectangular arrangements Examples: If not filled in with additional structure, an extruded L shape would require attachments at 10 convex corners (the corners at the inside of the L are not convex); an extruded hexagon would require 12 attachments
- b. The mechanical connections at each corner must be:
- 50 mm or less from the corner of the Segment
- Spaced minimum 50 mm from the mechanical connection of any other corner
- The same fastener diameter and grade
- c. Each attachment point must be able to withstand a Test Load.
- The Test Load is equal to 1/4 of total mass of the container accelerating at 40 g
- Every fastener must withstand the Test Load in pure shear, using the minor diameter if any threads are in shear.
- Every Accumulator bracket, chassis bracket, or monocoque attachment point must withstand the Test Load in bending, in pure tearout, pure pullout, pure weld shear if welded, and pure bond shear and pure bond tensile if bonded.
- F.10.5.7 Accumulator Attachment – Load Based
- a. The minimum number of attachment points depends on the total mass of the container: Accumulator Weight Minimum Attachment Points
- < 20 kg 4
- 20–30 kg 6
- 30–40 kg 8
- \> 40 kg 10
- b. Any brackets which attach the Accumulator Container to the chassis must:
- Be made of steel 1.6 mm minimum thickness or aluminum 4 mm minimum thickness
- Have gussets to carry bending loads.
- c. Each attachment point, including any brackets, backing plates and inserts, must be able to withstand 15 kN in any direction
- d. Fasteners must spaced minimum 50 mm apart to be counted as separate attachment points.