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Electric Drive Vehicle Systems: Suggested Changes to Large Truck and Motorcoach Regulations and Inspection Procedures

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Electric Drive Vehicle Systems: Suggested Changes to Large Truck and Motorcoach Regulations and Inspection Procedures Electric Drive Vehicle Systems: Suggested Changes to Large Truck and Motorcoach Regulations and Inspection Procedures November 2015 FOREWORD This report provides recommendations for changes to the Federal Motor Carrier Safety Regulations (FMCSRs), North American Standard (NAS) inspection procedures, and out-of- service (OOS) criteria that are needed to accommodate and facilitate the use of commercial vehicles with high-voltage electric drive systems. Such vehicles include battery-electric vehicles, vehicles with hybrid-electric drive systems, and vehicles with hydrogen fuel cell engines. In addition to providing specific recommendations for changes, this report summarizes the process used to arrive at the recommendations. NOTICE This document is disseminated under the sponsorship of the U.S. Department of Transportation (USDOT) in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The contents of this report reflect the views of the contractor, who is responsible for the accuracy of the data presented herein. The contents do not necessarily reflect the official policy of the USDOT. This report does not constitute a standard, specification, or regulation. The U.S. Government does not endorse products or manufacturers named herein. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective. QUALITY ASSURANCE STATEMENT The Federal Motor Carrier Safety Administration (FMCSA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FMCSA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FMCSA-RRT-14-007 4. Title and Subtitle 5. Report Date Electric Drive Vehicle Systems November 2015 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Lowell, Dana 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) M.J. Bradley & Associates, LLC 47 Junction Square Drive 11. Contract or Grant No. Concord, MA 01742 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered U.S. Department of Transportation Final Report Federal Motor Carrier Safety Administration Office of Analysis, Research, and Technology 1200 New Jersey Ave. SE 14. Sponsoring Agency Code Washington, DC 20590 FMCSA 15. Supplementary Notes Contracting Officer’s Representative (COR): Quon Kwan 16. Abstract This report provides recommendations for changes to the Federal Motor Carrier Safety Regulations (FMCSRs), North American Standard (NAS) inspection procedures, and Out-of-Service (OOS) criteria that are needed to accommodate and facilitate the use of commercial vehicles with high-voltage electric drive systems. Such vehicles include battery-electric vehicles, vehicles with hybrid-electric drive systems (including plug-in hybrids), and vehicles with hydrogen fuel cell engines. In addition to providing specific recommendations for changes, this report summarizes the process used to arrive at the recommendations, which included a literature review and gap analysis, industry site visits and consultations, and a formal peer review process. Because most of the commercial vehicles now in service have only low-voltage electrical systems (12/24 volts direct current [VDC]), the current FMCSRs, NAS inspection procedures, and OOS criteria do not address the unique safety aspects of high-voltage systems (less than 60 VDC or greater than 30 volts alternating current [VAC]) when present on a vehicle. The purpose of this project was to identify necessary changes to the current FMCSRs and inspection procedures, if any, to address the unique safety requirements associated with high-voltage vehicle systems, and to improve the overall safety of commercial vehicle operations by ensuring that commercial vehicles with high-voltage drive systems meet appropriate safety criteria while operating on public roads. 17. Key Words 18. Distribution Statement Commercial motor vehicle, battery vehicle, fuel cell No restrictions vehicle, high voltage, hybrid-electric vehicle, plug-in hybrid vehicle, safety 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 77 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized. SI* (MODERN METRIC) CONVERSION FACTORS Approximate Conversions to SI Units Symbol When You Know Multiply By To Find Symbol Length in inches 25.4 millimeters mm ft feet 0.305 meters m yd yards 0.914 meters m mi miles 1.61 kilometers km Area in² square inches 645.2 square millimeters mm² ft² square feet 0.093 square meters m² yd² square yards 0.836 square meters m² ac Acres 0.405 hectares ha mi² square miles 2.59 square kilometers km² Volume (volumes greater than 1,000L shall be shown in m³) fl oz fluid ounces 29.57 milliliters mL gal gallons 3.785 liters L ft³ cubic feet 0.028 cubic meters m³ yd³ cubic yards 0.765 cubic meters m³ Mass oz ounces 28.35 grams g lb pounds 0.454 kilograms kg T short tons (2,000 lb) 0.907 megagrams (or “metric ton”) Mg (or “t”) Temperature (exact degrees) °F Fahrenheit 5(F-32)/9 or (F-32)/1.8 Celsius °C Illumination fc foot-candles 10.76 lux lx fl foot-Lamberts 3.426 candela/m² cd/m² Force and Pressure or Stress lbf poundforce 4.45 newtons N lbf/in² poundforce per square inch 6.89 kilopascals kPa Approximate Conversions from SI Units Symbol When You Know Multiply By To Find Symbol Length mm millimeters 0.039 inches in m meters 3.28 feet ft m meters 1.09 yards yd km kilometers 0.621 miles mi Area mm² square millimeters 0.0016 square inches in² m² square meters 10.764 square feet ft² m² square meters 1.195 square yards yd² Ha hectares 2.47 acres ac km² square kilometers 0.386 square miles mi² Volume mL milliliters 0.034 fluid ounces fl oz L liters 0.264 gallons gal m³ cubic meters 35.314 cubic feet ft³ m³ cubic meters 1.307 cubic yards yd³ Mass g grams 0.035 ounces oz kg kilograms 2.202 pounds lb Mg (or “t”) megagrams (or “metric ton”) 1.103 short tons (2,000 lb) T Temperature (exact degrees) °C Celsius 1.8c+32 Fahrenheit °F Illumination lx lux 0.0929 foot-candles fc cd/m² candela/m² 0.2919 foot-Lamberts fl Force and Pressure or Stress N newtons 0.225 poundforce lbf kPa kilopascals 0.145 poundforce per square inch lbf/in² * SI is the symbol for the International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003, Section 508-accessible version September 2009.) ii TABLE OF CONTENTS LIST OF ACRONYMS, ABBREVIATIONS AND SYMBOLS............................................. vii EXECUTIVE SUMMARY ......................................................................................................... ix 1. INTRODUCTION.................................................................................................................1 1.1 PURPOSE ......................................................................................................................1 1.2 PROCESS ......................................................................................................................3 2. SUMMARY OF FMCSA REQUIREMENTS FOR VEHICLES WITH HIGH- VOLTAGE ELECTRICAL SYSTEMS .............................................................................5 2.1 FEDERAL MOTOR CARRIER SAFETY REGULATIONS .......................................5 2.1.1 Electrical System Requirements ....................................................................... 5 2.1.2 Inspection, Repair, and Maintenance Requirements......................................... 6 2.1.3 Inspection Standards and OOS Criteria ............................................................ 6 2.2 NAS INSPECTION PROCEDURES AND OOS CRITERIA ......................................7 3. SUMMARY OF LITERATURE REVIEW......................................................................11 3.1 CODES, STANDARDS, AND BEST PRACTICES ..................................................11 3.2 USDOT GUIDANCE AND RESEARCH ...................................................................16 3.3 FMVSS ........................................................................................................................17 3.4 NEW YORK STATE, CANADA, AND EUROPEAN UNION REGULATIONS ....18 3.4.1 New York State ............................................................................................... 18 3.4.2 Canada............................................................................................................. 20 3.4.3 European Union .............................................................................................. 20 3.5 OPERATIONAL SAFETY FOCUS FOR ELECTRIC DRIVE VEHICLES .............21 3.6 GAP ANALYSIS .........................................................................................................22 3.6.1 Federal Motor Carrier Safety Regulations ...................................................... 22 3.6.2 NAS Inspection Procedures ............................................................................ 23 3.6.3 OOS Criteria ................................................................................................... 23 4. SITE VISITS AND INDUSTRY CONSULTATIONS ....................................................25
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