RELEASE DATE:2021-01-13 16:00
ABSTRACT: India Automotive Industry Standards Commission AISC released draft AIS-038 Rev.2 / D1 for electric vehicle power systems and AIS-156 / D1 for electric two-wheelers power systems on September 30, 2019 for public comment and it is expired on October 29, 2019. Recently. ATIC had completed Indian AIS-038 electric vehicle traction battery test witness for several top manufacturers domestically. These manufacturers were the frsts to test since this standard was released, and would obtain the certification report soon.

Compared with the previous regulation AIS-048, the new regulations AIS-038 / AIS-156 were changed greatly in terms of regulatory framework, technical requirements, and test methods. The previous regulation AIS-048 could test at the cell module, and battery pack levels, and no environmental test item was included. The new regulations AIS-038 / AIS-156 got closer to EU standrds,  and were added with environmental tests and thermal propagation. Test objects became mainly the battery system, subsystem and even the entire vehicle. Besides, nail penetration was removed which was the most concerming test item before.In the process of the Indian AIS-038 electric vehicle traction battery test witness, the following tests have a high non-conformance rate, which should be paid special attention to:

1. Four protections
The four protections refer to over-temperature protection, over-current protection, over-discharge protection and over-charge protection. These four protection tests are in line with the new China national standard (GB 38031-2020) and the EU (R100 Rev 2) requirements, with the following key points to note:
Over-temperature protection tests require removal of the cooling system;
Over-current protection needs to confirm the test parameters;
Over-charge protection and over-discharge protection need to confirm the charge and discharge strategy.

At the same time, attention should be paid to avoid fault signals of non-test items being alarmed in the test process, which will affect the observation of the under-testing items.

The common cases like during the over-temperature protection test, because the battery pack internal temperature difference is too large, the battery management system BMS reported a fault signal for the temperature difference is too large, which affects the test of the over-temperature protection error signal detection; and during the over-current protection test, due to the improper charging current setting, the BMS did not report a error signal. The setting of these parameters will affect the detection and judgment of test witness to a certain extent.

2. Fire resistance
The specific test process of fire resistance test is: preheat for 60 seconds; direct exposure to flame for 70 seconds; then indirect exposure to flame for 60 seconds (or continue direct exposure to flame for 60 seconds); Leave the fire at last.

The main non-conformance in the test was the battery pack caught fire or ignited during combustion (endangering the safety of the occupant). A small area of fire occurred in some parts of the battery pack shell during the test, which can be judged to meet the test requirements under the condition that the safety of the passengers is not endangered.

3. Thermal propagation test
Referring to the test method of UN GTR 20 Phase 1, the recommended initiation method for thermal propagation test of AIS-038 includes nail penetration, heating and overcharging initiation method.

India AIS - 038 thermal propagation test to determine the standard of battery pack has the following two kinds: no thermal runaway occurs; in case of thermal propagation of the battery pack, the battery management system BMS shall send out an error signal in time to remind the passenger to leave the vehicle, and within five minutes the battery pack will not appear fire, explosion and other hazards to the safety of the passenger.

The thermal propagation test is a test with the highest non-conformance rate in the whole AIS-038 certification in India. The main problems include: when thermal propagation occurs, the error signal is delayed; when the thermal propagation does not occur, the error signal is false; within five minutes after the error signal reported, the battery pack smoke and there is a risk of entering the cabin which endangering the safety of passengers; These are all common non-conformances in the testing process.

Test items
CHINA(GB 38031-2020)
EU(R100 Rev 2)
Mechanical integrity
Crush plate (Type 1, Type 2)
Crush plate (Type 1, Type 2)
Crush plate (Type 2)
Thermal shock and cycling test
Storage in the lowest and highest temperature for at least 8 hours
Storage in the lowest and highest temperature for at least 6 hours
Storage in the lowest and highest temperature for at least 6 hours
Warning in the event of operational failure
Low-temperature protection
Vibration test
X/Y/Z 3 axles,total for 39h
X/Y 2 axles,total for 3h
X/Y 2 axles,total for 3h

1. Testing and trial-testing of IS and AIS standards
2. India CMVR (whole vehicles and components), BIS (consumer products, automotive components and electronic information products), WPC/TEC (wireless communication products) certification services
3. Preparation and translation of a complete set of application materials
4. Factory audit guidance, accompanied by translation throughout
5. Direct co-operation with authorities and certification bodies without communication barriers
6. Local representative available

ATIC is a young technical service company from China, established in 2015. ATIC is committed to integrate domestic and international regulations, testing and certification resources with a global perspective in the context of globalization, and establish a new, specialized regulation research, testing and certification platform. With innovative Digital Reporting System (DRS), Customer Service Platform (CSP) and self-developed Global Vehicle Regulation Database (GVRD), ATIC’s compliance service covers more than 54 countries/regions globally, testing and certification service covers more than 30 countries/regions worldwide. ATIC serve more than 3,300 manufactures each year.


Jimmy Liang
Asia Homologation Department
Jimmy graduated from South China Normal University and has experience in internationally renowned testing and certification organizations.In ATIC he is focused on Asian automotive and consumer product regulation and homologation system research.
Phone: +86 15521437139