Summary of A123 Systems Hymotion™ L5 PCM Crash Testing
BACKGROUND
Among other features, the Hymotion L5 Plug-In Conversion Module (PCM) for the Toyota Prius was designed to ensure safety and reliability. With these goals in mind, focus was placed on ensuring that the Prius converted with the L5 PCM would meet federally mandated new vehicle safety tests from the NHTSA. Our testing to these standards are summarized in this paper.
NHTSA TEST PROCEDURES
FMVSS 305, Electric Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection, is a testing standard created by the NHTSA. The vehicle must undergo a series of crash tests and must pass the following requirements:
- Minimal battery electrolyte spillage
- The battery cannot enter the passenger compartment
- Both the OEM Prius battery and Hymotion L5 PCM must maintain electrical isolation from the vehicle.
The crash tests specified include a front, side, and rear impact test. To fully comply with NHTSA standards, all three tests must be completed. To pass the crash tests, the above criteria must be met with clear visual evidence that the battery system does not enter the passenger compartment and with measurements taken to ensure electrical isolation.
REAR IMPACT TEST PROCEDURE
The rear impact test was referenced from FMVSS 301R, Fuel System Integrity – Rear Impact. For the Gen II Prius, the test specifies a moving barrier with a mass of 3778lbs impact the test vehicle at a speed of 30mph. After the impact test is completed, a rollover test is performed where the vehicle is rotated in 90º increments.
SIDE IMPACT TEST PROCEDURE
The side impact test was referenced from FMVSS214, Side impact protection. The test specifies a moving barrier with a mass of 3000lbs affixed with a deformable impact surface constructed of honeycomb aluminum. The impact speed of the moving barrier must be 33.5mph at impact. The side of the vehicle with the fuel filler cap must be impacted. Similar to the Rear Impact test, a rollover test is performed directly after the impact test is completed.
FRONT IMPACT TEST PROCEDURE
The front impact test was referenced from FMVSS208, Occupant Crash Protection. The test specified propelling the test vehicle into a wall at 30mph using a mechanical tow system. Again, after the test is completed, a rollover test is performed.
TEST FACILITY
The tests were conducted at the Calspan Transportation Sciences Center in Buffalo, NY. Calspan has more than 50 years of conducting crash testing and analysis with government and industry. The test vehicle Toyota Priuses were prepared two weeks in advance at the Calspan facility.
The test Priuses were converted with production prototype L5 PCMs. These production prototypes are fully representative of the L5 PCM mass-produced systems now being sold to customers.
TEST RESULTS
The following impact tests were completed:
| Rear Impact Test at 30mph | 04/02/2008 |
| Side Impact Test at 33.5mph | 05/13/2008 |
| Front Impact Test at 30mph | 05/15/2008 |
All tests were successfully completed with the following results:
- No smoke or fire was created during the impact
- The L5 PCM maintained electrical isolation from the rest of the vehicle
- No electrolyte spilled from the L5 PCM
- The L5 PCM remained in place after impact and rollover tests
- No damage to the OEM battery pack.
- Photographic evidence from the testing program can be found in the Appendix.
- From these results, according to the regulatory requirements, the installation of the L5 PCM into the Toyota Prius meets all compliance requirements for FMVSS 305.
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