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What every Quality Professional should consider about EV Safety

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On the cutting edge of 21st-century automotive innovation are Electric Vehicles (EVs). Their ability to reduce emissions and decrease dependence on fossil fuels has propelled them to the forefront of the industry. At the heart of this revolution are lithium-ion batteries—compact, powerful devices crucial to the operation of EVs. However, these critical components present significant challenges in terms of safety and quality, especially during final inspection. 

The Importance of Safety in Lithium-Ion Batteries
 
Lithium-ion batteries are known for their high energy density, making them extremely efficient for storing and releasing energy. However, this same density makes them prone to heat generation and, in extreme cases, to ignition or explosion. Historical incidents of dramatic lithium battery failures highlight the need for rigorous safety and protection measures.

According to the National Highway Traffic Safety Administration (NHTSA), fires in electric vehicles with lithium-ion batteries are considerably more difficult to extinguish than fires in conventional vehicles. This fact underscores the need for swift and effective responses to protect both occupants and product quality.

Battery Architecture
 
Engineers must meticulously consider every aspect, from the insulation of individual cells to thermal management. Management systems continuously monitor the temperature and voltage of each cell. In case of a failure, these systems can isolate the problematic cell to prevent the issue from spreading.

Tesla has developed an advanced battery architecture that maximizes safety. Their batteries feature thousands of individual cells that are isolated and monitored—a design proven effective over millions of miles traveled.

Testing and Audits
 
Commitment to safety doesn’t stop at design. Battery production requires comprehensive testing and stringent audits. Each component undergoes stress tests, and management systems are audited to verify the integrity of individual cells.

The Swedish Civil Contingencies Agency (Myndigheten för Samhällsskydd och Beredskap, MSB) reported that advancements in technology, improvements in quality processes, and rigorous testing have made EVs safer than at their inception.

The Future of Battery Safety
 
Advances in materials, management systems, and testing techniques continue to enhance safety. For SQA (Supplier Quality Assurance) and SQE (Supplier Quality Engineering) professionals, staying updated with these developments is essential as lithium-ion battery safety evolves.
 
Battery safety not only protects lives but also ensures the quality and reliability of electric vehicles. This commitment to safety is crucial for the future of electric mobility.
 
While the likelihood of an electric vehicle catching fire is now lower compared to a thermal vehicle, it is important to note that the future of electric mobility depends on the ability to provide safe, reliable, and high-quality vehicles. Every battery, every test, and every audit is a link in this chain of safety.
 
PTI QCS has built a path of quality and trust over its twenty years of experience in the automotive industry with leading OEMs and their suppliers, ensuring excellence in components through inspection, rework, launch support, yard management, and supply chain services.
 
Contact us at janava@ptiqcs.com for Mexico and Brazil, sales@ptiqcs.com for the United States, and tiqbal@ptiqcs.com for Canada