Experimental Investigations on the Repeatability of the Fire-Resistance Testing of Electric Vehicle Post-Crash Safety...

The widespread adoption of electric vehicles (EVs) has elevated the importance of rigorous safety standards, particularly for fire resistance in post-crash scenarios. Existing testing protocols, such as Regulation No. 100, utilize petrol pool fires to simulate real-world fire hazards but lack comprehensive analysis regarding their repeatability and reliability. This study addresses this critical gap by evaluating the variability and consistency of fire-resistance tests performed on multiple battery energy storage systems (BESSs) under standardized conditions. A custom-built measurement system incorporating thermocouples, anemometers, and hygrometers provided high-resolution data on flame dynamics, ambient conditions, and pool fire efficiency. Statistical evaluations following ISO 5725 series guidelines revealed substantial inconsistencies, including unstable exposure temperatures and sensitivity to local turbulence. These findings call into question the robustness of current testing methods, and we propose an alternative approach employing LPG burners for improved precision and repeatability. By identifying significant flaws in existing standards and offering scientifically grounded enhancements, this work contributes a novel perspective to the field of EV safety, advancing global fire-resistance testing protocols.