GB 38031-2025 English PDF

GB 38031-2025: Electric vehicles traction battery safety requirements
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GB 38031-2025
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.120
CCS T 47
Replacing GB 38031-2020
Electric vehicles traction battery safety requirements
ISSUED ON. 2025-03-28
IMPLEMENTED ON. 2026-07-01
Issued by. State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword... 3
Introduction... 6
1 Scope... 7
2 Normative references... 7
3 Terms and definitions... 7
4 Symbols and abbreviations... 11
4.1 Symbols... 11
4.2 Abbreviations... 11
5 Safety requirements... 12
5.1 Safety requirements for battery cells... 12
5.2 Safety requirements for battery pack or system... 12
6 Test conditions... 14
6.1 General conditions... 14
6.2 Accuracy of measuring instruments and meters... 16
6.3 Test process error... 16
6.4 Data recording and recording interval... 17
7 Test preparation... 17
7.1 Preparation for battery cell test... 17
7.2 Preparation for battery pack or system test... 18
8 Test methods... 19
8.1 Test methods for battery cell safety... 19
8.2 Battery pack or system safety test method... 22
9 Determination of the same type... 40
10 Implementation of the standard... 43
Appendix A (Informative) Examples of typical structures of battery packs and systems
... 44
Appendix B (Normative) Test method for battery pack or system insulation resistance
... 47
Appendix C (Normative) Thermal diffusion analysis and verification report... 49
References... 57
Foreword
This document was drafted in accordance with the provisions of GB/T 1.1-2020
"Directives for standardization - Part 1.Rules for the structure and drafting of
standardizing documents".
This document replaces GB 38031-2020 "Electric vehicles traction battery safety
requirements". Compared with GB 38031-2020, in addition to structural adjustments
and editorial changes, the main technical changes are as follows.
- CHANGE the scope (see Chapter 1; Chapter 1 of the 2020 edition);
- ADD the definition of battery subsystem (see 3.5);
- CHANGE the definition of leakage (see 3.14; 3.13 of the 2020 edition);
- ADD the definition of thermal events (see 3.15);
- ADD the safety requirements and test methods for battery cells after fast charging
cycles (see 5.1.7 and 8.1.8);
- CHANGE the safety requirements and test methods for battery pack or system
vibration (see 5.2.1 and 8.2.1; 5.2.1 and 8.2.1 of the 2020 edition);
- CHANGE the safety requirements for mechanical shock of battery packs or
systems (see 5.2.2; 5.2.2 of the 2020 edition);
- CHANGE the safety requirements for simulated collision of battery packs or
systems (see 5.2.3; 5.2.3 of the 2020 edition);
- CHANGE the safety requirements and test methods for extrusion of battery packs
or systems (see 5.2.4 and 8.2.4; 5.2.4 and 8.2.4 of the 2020 edition);
- CHANGE the safety requirements for damp heat cycling of battery packs or
systems (see 5.2.5; 5.2.5 of the 2020 edition);
- CHANGE the safety requirements for water immersion of battery packs or systems
(see 5.2.6; 5.2.6 of the 2020 edition);
- CHANGE the safety requirements and test methods for thermal stability of battery
packs or systems (see 5.2.7, 8.2.7 and Appendix C; 5.2.7, 8.2.7 and Appendix C of
the 2020 edition);
- CHANGE the safety requirements and test methods for temperature shock of
battery packs or systems (see 5.2.8 and 8.2.8; 5.2.8 and 8.2.8 of the 2020 edition);
- CHANGE the safety requirements and test methods for battery pack or system salt
Electric vehicles traction battery safety requirements
1 Scope
This document specifies the safety requirements and test methods for power batteries
(hereinafter referred to as batteries) for electric vehicles, battery packs or systems.
This document applies to power batteries for electric vehicles.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB/T 2423.4 Environmental testing for electric and electronic products - Part 2.Test
method - Test Db. Damp heat, cyclic (12 h + 12 h cycle)
GB/T 2423.17-2024 Environmental testing - Part 2.Test methods - Test Ka. Salt
mist
GB/T 2423.43 Environmental testing for electric and electronic products - Part 2.
Test methods - Mounting of specimens for vibration, impact and similar dynamic
tests
GB/T 2423.56 Environmental testing - Part 2.Test methods - Test Fh. Vibration,
broadband random and guidance
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB/T 19596 Terminology of electric vehicles
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for
electrical and electronic equipment - Part 4.Climatic loads
3 Terms and definitions
The terms and definitions defined in GB/T 19596, as well as the following terms and
definitions, apply to this document.
3.1
5 Safety requirements
5.1 Safety requirements for battery cells
5.1.1 The battery cells shall not catch fire or explode, when subjected to the over-
discharge test in accordance with 8.1.2.
5.1.2 The battery cells shall not catch fire or explode, when subjected to the over-charge
test in accordance with 8.1.3.
5.1.3 The battery cells shall not catch fire or explode, when subjected to the external
short-circuit test in accordance with 8.1.4.
5.1.4 The battery cells shall not catch fire or explode, when subjected to the heating test
in accordance with 8.1.5.
5.1.5 The battery cell shall not catch fire or explode, when subjected to temperature
cycle test in accordance with 8.1.6.
5.1.6 The battery cell shall not catch fire or explode, when subjected to extrusion test
in accordance with 8.1.7.
5.1.7 The battery cell shall not catch fire or explode, when subjected to fast charge cycle
in accordance with 8.1.8.
5.2 Safety requirements for battery pack or system
5.2.1 The battery pack or system shall be subjected to vibration test in accordance with
8.2.1; it shall not have leakage, housing crack, fire or explosion. The insulation
resistance after the test shall be not less than 100 Ω/V. If there is an AC circuit, the
insulation resistance shall be not less than 500 Ω/V.
5.2.2 The battery pack or system shall be subjected to mechanical impact test in
accordance with 8.2.2; it shall not have leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be not less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be not less than 500 Ω/V.
5.2.3 The battery pack or system shall be subjected to a simulated collision test in
accordance with 8.2.3; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be no less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be no less than 500 Ω/V.
5.2.4 The battery pack or system shall be subjected to an extrusion test in accordance
with 8.2.4; there shall be no fire or explosion. The insulation resistance after the test
shall be no less than 100 Ω/V. If there is an AC circuit, the insulation resistance shall be
no less than 500 Ω/V.
5.2.5 The battery pack or system shall be subjected to a damp heat cycle test in
accordance with 8.2.5; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance within 30 minutes after the test shall be no less than 100 Ω/V. If
there is an AC circuit, the insulation resistance shall be no less than 500 Ω/V.
5.2.6 The battery pack or system shall be subjected to water immersion test in
accordance with 8.2.6; it shall meet one of the following requirements.
a) According to method 1, no fire or explosion shall occur;
b) According to method 2, after the test, it shall meet the IPX7 requirements of GB/T
4208-2017, and there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall not be less than 100 Ω/V. If there is an AC
circuit, the insulation resistance shall not be less than 500 Ω/V.
5.2.7 Thermal stability test shall be carried out in accordance with 8.2.7 (except for
nickel-metal hydride battery packs or systems). The requirements are as follows.
a) The battery pack or system shall be subjected to external fire test in accordance
with 8.2.7.1 and shall not explode;
b) The battery pack or system or the whole vehicle shall be subjected to thermal
diffusion analysis and verification in accordance with 8.2.7.2; it shall.
1) Be no fire or explosion;
2) Provide a thermal event alarm signal, meanwhile the alarm signal shall be
issued no later than 5 minutes after the thermal runaway of the battery cell is
triggered;
3) For battery pack or system level tests, provide technical description documents
that smoke does not cause danger to the passenger compartment before and
within 5 minutes after the thermal event alarm signal is issued; for vehicle level
tests, no smoke enters the passenger compartment before and within 5 minutes
after the thermal event alarm signal is issued.
5.2.8 The battery pack or system shall be subjected to temperature shock test in
accordance with 8.2.8; there shall be no leakage, housing crack, fire or explosion. The
insulation resistance after the test shall be no less than 100 Ω/V. If there is an AC circuit,
the insulation resistance shall be no less than 500 Ω/V.
5.2.9 The battery pack or system shall be subjected to salt spray test in accordance with
8.2.9; there shall be no leakage, housing crack, fire or explosion. The insulation
resistance after the test shall be no less than 100 Ω/V. If there is an AC circuit, the
3% of the rated capacity for 3 consecutive times, the battery cell is deemed to have
completed the pretreatment; the pretreatment cycle can be terminated; the average of
the last 3 test results is taken as the actual capacity.
7.2 Preparation for battery pack or system test
7.2.1 Confirmation of working status
Before the formal test begins, the battery electronic components or BCU shall be in
normal working condition.
7.2.2 Pretreatment
7.2.2.1 Before the formal test begins, the battery pack or system shall be preconditioned.
The steps are as follows.
a) Charge at a current of not less than 1 I3 or according to the charging method
recommended by the manufacturer to the end-of-charge condition specified by
the manufacturer;
b) Let it stand for 30 min or the time specified by the manufacturer;
c) Discharge at a current specified by the manufacturer and not less than 1 I3 to the
end-of-discharge condition specified by the manufacturer;
d) Let it stand for 30 min or the time specified by the manufacturer;
e) Repeat steps a) ~ d) no more than 5 cycles.
7.2.2.2 If the discharge capacity change of the battery pack or system for 2 consecutive
times is not higher than 3% of the rated capacity, the battery pack or system is
considered to have completed the pretreatment; the pretreatment cycle can be
terminated; the average of the last 2 test results is taken as the actual capacity.
7.2.2.3 Unless otherwise specified, if the time interval between the completion of the
pretreatment cycle and adjustment to the highest working state of charge and a new test
item is greater than 24 h, a supplementary charge shall be performed. charge at a current
of not less than 1 I3 to the end-of-charge condition specified by the manufacturer or
charge according to the charging method recommended by the manufacturer; let it stand
for 30 min or the time specified by the manufacturer.
8.1.8.2 Test according to the following steps.
a) Adjust to 20% SOC according to the method provided by the manufacturer;
b) Let it stand for 30 minutes or the time specified by the manufacturer;
c) Charge to 80% SOC according to the charging method provided by the
manufacturer; the charging time shall not exceed 15 minutes;
d) Let it stand for 30 minutes or the time specified by the manufacturer;
e) Repeat steps a) ~ d) 300 times;
f) Perform external short-circuit test according to 8.1.4.
8.2 Battery pack or system safety test method
8.2.1 Vibration
8.2.1.1 The test object is a battery pack or system.
8.2.1.2 Install the test object on the vibration table according to the installation position
and fixing method of the test object vehicle and the requirements of GB/T 2423.43.
Random and fixed frequency vibration loads are applied in each direction; the loading
sequence shall be z-axis random, z-axis fixed frequency, y-axis random, y-axis fixed
frequency, x-axis random, x-axis fixed frequency (the direction of vehicle travel is the
x-axis direction; the other horizontal direction perpendicular to the travel direction is
the y-axis direction). The testing agency can also choose the sequence by itself to
shorten the conversion time. The test process is carried out in accordance with GB/T
2423.56.
8.2.1.3 For battery packs or systems loaded on vehicles other than categories M1 and
N1, the vibration test parameters are set according to Table 2 and Figure 2, where the
RMS of the x-axis, y-axis, z-axis are 0.52 g, 0.57 g, 0.73 g, respectively. Where there
are multiple installation directions (x/y/z) for the test object, the test is carried out in
the installation direction with the largest RMS. For battery packs or systems installed
on the top of the vehicle, vibration tests shall be carried out according to the vibration
test parameters provided by the manufacturer that are not less than those in Table 2 and
Figure 2.
8.2.1.4 For battery packs or systems installed on categories M1 and N1 vehicles, the
vibration test parameters shall be set according to Table 3 and Figure 3, where the RMS
of the x-axis, y-axis, z-axis are 0.50 g, 0.45 g, and 0.64 g, respectively.
temperature determined according to a) or b) (as applicable) is reached; then maintained
at or above this temperature until the end of the test.
a) If the battery ...