What safety risks might a power battery system face, and could it cause electric shock accidents? Questions about major power battery systems actually relate to the characteristics of their internal components and the external usage and operating environment, which constitute the main challenges in product safety design.

1) Will the battery cell catch fire or explode?

The battery cells used in power battery systems have very high energy density. Taking lithium iron phosphate cells as an example, the energy density can reach 120 Wh/kg. Converted into joules, 1 kilogram of lithium iron phosphate cells contains 120 × 3600 joules = 0.43 MJ. So how much energy does TNT release? 1 gram of TNT can release 4184 joules of energy. Converted, the energy contained in 1 kilogram of lithium iron phosphate cells is equivalent to 103 grams of TNT.

A purely electric car typically uses battery cells that weigh several hundred kilograms. Using 100 kilograms of battery cells as a reference, the total energy is equivalent to 10 kilograms of TNT. Anyone in their right mind would feel uneasy, wondering if this thing could be unstable, catch fire, or even explode.

2) Will electric shock accidents occur?

In order to improve the drive efficiency of the whole vehicle, the DC output voltage of the power battery is usually above 100V, and sometimes even exceeds 400V. Anyone with some electrical knowledge knows that a DC voltage above 60V is dangerous.

Every year, many electric shock accidents occur due to leakage from electrical appliances, wires, and power equipment, and they are often reported in the media. When I was a child, I was shocked by an exposed 220V wire, an experience I will never forget. So, people also have reason to worry: could the high-voltage live components in electric vehicles leak electricity and cause electric shock accidents?

3) Can it withstand various harsh environments?

The operation and usage environment of the vehicle is very complex. It must endure tests of high temperature and high humidity, as well as the hardships of high altitude and cold. It encounters both flat paved roads and rugged unpaved roads, extremely dry areas, and places that frequently require fording water.

During the vehicle's operation, it has to undergo cycles of high and low temperatures, endure corrosive coastal climates, be subjected to heavy rain and flooding, and withstand various impacts, vibrations, drops, and even collisions and rollovers. So, in the face of these objective environmental conditions, can the power battery system withstand the test without posing serious safety risks?

4) Can it withstand various forms of abuse?

When the sales of a product are large enough, there will inevitably be cases where the product is used beyond the specified limits or certain unexpected situations occur. Taking mobile phones as an example, when the charging protection fails, the phone battery may catch fire or explode due to overcharging. If the phone battery is punctured by a sharp metal object, an explosion may also occur.

So, can the power battery system of electric vehicles withstand similar abuse tests without causing safety incidents? These abuses are caused both by human actions and by objective environmental factors.

5) What to do if the battery management system fails?

The power battery system has a complex management and control system that constantly collects various operating parameters of the entire power battery pack, performing calculations, diagnostics, communication, and switch control. The more intelligent the system, the more serious the consequences when a failure occurs.

For example, if a certain cell inside a power battery pack overheats, the thermal management system fails, and the cell is at risk of thermal runaway, what if the temperature sensor at this time is broken? What if the software cannot properly judge and issue the cut-off command? Or what if the switch that is supposed to execute the disconnection action cannot function properly? Will the risk spread and cause a serious safety accident?

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