Summary Report. OPTIMORE Optimised Modular Range Extender for every day customer usage

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Jewel Nicholson
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1 EUROPEAN COMMISSION DG RTD SEVENTH FRAMEWORK PROGRAMME THEME 7 TRANSPORT - SST GC.SST : Integration and optimisation of range extenders on Electric Vehicles GA No Summary Report OPTIMORE Optimised Modular Range Extender for every day customer usage Deliverable No. OPTIMORE D5.2 Deliverable Title Functional Safety Development Hazard and Risk Analysis Dissemination level CO - This document is a summary of the original deliverable report as the extended information is restricted. If you require any more information on the content please contact the author, contact details can be found on the last page. Written By M. Baum (AVL SCHRICK) June 2013 Checked by J. Grether (AVL SCHRICK) June 2013 Approved by Theodor Sams (AVL) July 2013 Issue date 14 August 2013

2 Executive summary The deliverable Hazard and Risk Analysis (HRA) was created to evaluate and review the development of powertrain system designs of RE-EVs (Range Extender Electric Vehicles). The primary objective of the hazard analysis and risk assessment is to identify and classify the hazards that may arise due to potential faulty behavior during the operational modes of the vehicle associated with the existing concept. The classification is done according to the ISO26262 and includes critically levels from ASIL A to ASIL D, as well as QM ratings for errors not rated to be safety relevant. The focus is set on the hybrid powertrain control system, as listed in the item definition document. The RE-EV architecture taken into account in this HRA is a compromise of all RE-EVs of the OPTIMORE partners and has been jointly agreed with the project partners. It has been developed in such a way, that it can be applied to all range extender systems of the OPTIMORE project partners, as defined in the item definition. A verification review of the HRA has been performed by the OPTIMORE partners. For the execution of the HRA, two assumptions of the system have been made concerning the HV battery safety level and the intrinsic warm up of the HV battery. These assumptions have to be proven by the HV battery supplier and can be found in Chapter 5. For the whole RE-EV concept, the following numbers of hazardous situations have been identified: ASIL A: 17 issues ASIL B: 11 issues ASIL C: 2 issues ASIL D: 3 issues For each of these hazardous situations, a safety goal and top level safety requirement have been defined, associated with the criticality level of the hazardous situation. In case those hazardous situations are identical, the safety goals have been grouped. For a detailed analysis of the related functions please refer to Chapter 6 of this document. 2/49

3 Contents 1 Introduction Purpose of the document References Abbreviations & Definitions Item overview on system level Main operating modes and states of the item Environmental conditions Temperature Humidity Air Pressure Sunlight Atrocious Weather Electromagnetic Altitude Height Roads / Field surface Water ingress protection Operational conditions Road conditions Traffic situations Drive situations Environment / specific description of the environment Overview of relevant situations HRA methodology Hazard identification Hazard classification Severity Table Exposure Table Controllability Table Determination of the ASIL Definition of safety goal and safe state HRA Assumptions EUCAR hazard classification Cooling system and battery temperature HRA classification table /49

4 6.1 Driving function (Creep, Stopping, Parking) Driving function (Constant driving, Acceleration) Braking, Coast-down and recuperation functions Driver Misuse and Accident LV Boardnet supply (DC/DC) function HV-Charging (RE and Plug-In charging) function System power-up function System Power-Down function HV Battery cooling function HRA - Relevant legal requirements Agreement Risk Register Acknowledgment List of Figures Figure 1: Hazard and Risk Analysis steps Figure 2: Temperature / Voltage Behavior of a Lithium-ion Cell /49

5 List of Tables Table 1: Reference Table... 6 Table 2: Abbreviations... 6 Table 3: Main operating modes & states of the item... 9 Table 4: Environmental temperatures Table 5: Environmental Air Pressure Table 6: Overview of relevant safety situations Table 7: Severity Table Table 8: Exposure Table Table 9: Controllability Table Table 10: ASIL determination Table 11: ASIL descriptions Table 12: HRA Assumptions Table 13: EUCAR hazard classification Table 14: List of driving functions (Creep, Stopping, Parking) Table 15: List of identified hazards and Safety Goals for the Driving functions (Constant driving, Acceleration) Table 16: List of Braking, Coast-down and recuperation functions Table 17: List of Misuse and Accident functions Table 18: List of LV Boardnet supply (DC/DC) functions Table 19: List of HV-Charging (RE and Plug-In charging) functions Table 20: List of identified hazards for the system power-up functions Table 21: List of identified hazards for system power down functions Table 22: List of identified hazards for HV Battery cooling functions Table 23: HRA legal requirements Table 24: Risk Register /49

10 Acknowledgment This project is co-funded by the 7th FP (Seventh Framework Programme) of the EC - European Commission DG Research http://cordis.europa.eu/fp7/cooperation/home_en.html http://ec.

6 10 Acknowledgment This project is co-funded by the 7th FP (Seventh Framework Programme) of the EC - European Commission DG Research Disclaimer The FP7 project has been made possible by a financial contribution by the European Commission under Framework Programme 7. The Publication as provided reflects only the authors view. Every effort has been made to ensure complete and accurate information concerning this document. However, the author(s) and members of the consortium cannot be held legally responsible for any mistake in printing or faulty instructions. The authors and consortium members retrieve the right not to be responsible for the topicality, correctness, completeness or quality of the information provided. Liability claims regarding damage caused by the use of any information provided, including any kind of information that is incomplete or incorrect, will therefore be rejected. The information contained on this website is based on author s experience and on information received from the project partners. 49/49

7 This document is a summary of the original Deliverable report as the extended information is restricted. If you require any more information on the content please contact the author/wp Leader: AVL Schrick- Mr Johannes Grether Contact details WP5 Leader: AVL Schrick Mr. Johannes Grether johannes.grether@avl-schrick.com

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