Honeywell Drives Innovation To Make EVs Safer

In the backdrop of adoption of electric vehicles in a large number, American multinational Honeywell has come up with lithium-ion battery safety sensors which can help in detecting potential battery fires.

Speaking to Opportunity India, company’s spokesperson said that one of the main safety risks associated with the use of lithium-ion batteries is thermal runaway, a phenomenon in which lithium-ion cells enter an uncontrollable heating state that can result in extremely high temperatures within the battery cell where it no longer functions properly and may eventually lead to battery failure, smoke and possibly, fire.

Following are the excerpts from the conversation:

Honeywell has come up with a solution for Electric Vehicles (EV) in India that helps to avoid EV fire incidents from its batteries. Could you explain more about it?

Spokesperson: One of the main safety risks associated with the use of lithium-ion batteries is thermal runaway, a phenomenon in which lithium-ion cells enter an uncontrollable heating state that can result in extremely high temperatures within the battery cell where it no longer functions properly and may eventually lead to battery failure, smoke and possibly, fire.

Thermal runaway is a chain of events that typically starts with the gradual breakdown of EV battery cells, causing pre-heating of the EV battery cells and pack. The elevated temperature within the EV battery cells causes the organic solvents to breakdown, resulting in the release of gases, increased pressure, and temperature beyond its flashpoint. As different materials within the EV battery pack breakdown—such as the metal-oxide cathode—oxygen is released, which can cause an ignition. The electrolyte used in EV LIBs is flammable and spreads the fire. Thermal Runaway may occur over a prolonged period of time before an actual fire starts, or the fire could be instantaneous.

It can be caused by a variety of factors, including internal defects, over-heating or over-charging, etc. If thermal runaway is not properly managed and addressed, it impacts the overall drivability and safety of electric vehicles (EVs). EV batteries can go into thermal runaway while the vehicle is being operated or when a car is parked and unattended, which is why proper battery safety sensing technology is critical. Without it, the vehicle becomes at risk for fire hazards.

How this battery fire detection solution works in the vehicle?

Spokesperson: Fires from lithium-ion batteries are dangerous and difficult to contain after they begin, which is why detecting the battery conditions leading up to thermal runaway sooner is critical. Our sensor-based, advanced gas detection solutions in EV battery packs will allow for early intervention, helping avoid costly property damage and safety issues. We have a proprietary solution that can detect conditions that lead to thermal runaway and help solve safety challenges.

As EVs continue to gain popularity, new regulatory guidelines have been introduced by the Indian government to ensure vehicle and passenger safety. The Ministry of Road Transport and Highways (MoRTH) in India set a new safety requirement, mandating electric vehicles to provide a signal to activate the advance warning indication in the vehicle to allow egress or 5 minutes prior to the presence of a hazardous situation inside the cabin, passenger area and seating area caused by thermal propagation. Honeywell’s Battery Safety Aerosol Sensors (BAS) Series has been shown to alert to thermal runaway events at very early stages, allowing exceed the five-minute warning requirement.

How it costs to the manufacturer and adds to the overall cost of EVs. To what percentage will it reduce the risk of fire in electric vehicles?

Spokesperson: Honeywell has ready-now solutions in India for the EV safety market, specifically addressing safety concerns associated with thermal runaway in lithium-ion batteries. These solutions incorporate advanced gas detection and battery monitoring sensors to enable early intervention and mitigate potential property damage and safety concerns. These solutions can be tailored to exact specifications for improved time to market, lower total system costs and enhanced reliability.

In January, we announced a partnership with Nexceris to provide cutting-edge automotive sensing technology aimed at mitigating and preventing conditions that lead to thermal runaway in EV batteries. Through collaboration with Nexceris, we are actively working on developing an enhanced suite of battery monitoring sensors. Our sensor-based solutions, incorporating advanced gas detection, enable early intervention and effectively mitigate potential property damage and safety concerns, thus avoiding costly consequences.

How Honeywell is contributing to the EV industry in India and what other solutions the company is looking at for the manufacturers?

Spokesperson: India’s EV market is estimated to grow rapidly at a compounded annual growth rate (CAGR) of 90 per cent in this decade to touch USD 150 billion by 2030 according to a report by RBSA Advisors. India’s COP27 strategy also highlights plans for increasing electric vehicle penetration.

To facilitate this growing need for EVs in the country, protecting against thermal runaway in electric vehicle batteries is crucial to helping keep people safe. Through this sensing technology, we are offering our vehicle manufacturing customers a more advanced safety solution that they can integrate into their Battery Management Systems, to help protect drivers on the road, homeowners who may have EVs parked in their garages and shipping handlers transporting EVs to their final destinations.

Could you elaborate on the company’s battery safety portfolio?

Spokesperson: Honeywell’s existing battery safety portfolio includes automotive-grade pressure and aerosol sensors that detect thermal runaway. We also produce High Amperage Current sensors used in Battery Management Systems (BMS), which monitor conditions related to the state of charge and state of health of the EV battery. These sensors enable the safe operation of EVs and improve battery life and vehicle performance, thereby allowing vehicle manufacturers to optimize driving range. We also have a wide portfolio of gas detection devices for use in EV battery manufacturing sites to protect workers from exposure to harmful, toxic, and flammable gases.

Honeywell offers a wide range of lithium-ion battery safety and performance solutions, including sensors used in battery management systems to monitor the health of EV batteries, gas detection solutions used throughout the manufacturing process and electrical safety personal protective equipment, providing protection to workers and allowing them to operate safely in hazardous conditions. 

Since India is moving rapidly towards a greener and sustainable future and charging infrastructure is a huge concern about EVs, how do you see the opportunity of the energy storage system in India for rapid and smooth transition to electric vehicles from ICE vehicles?

Spokesperson: Electric vehicles (EVs) are the future, and a critical step to reducing greenhouse gas (GHG) emissions and creating a more sustainable world. According to the US Environmental Protection Agency (EPA), GHG emissions from the transportation sector are larger than any other sector, accounting for approximately 27 per cent of total greenhouse gas emissions in the US.

The road ahead for EV safety in India involves a multifaceted approach that includes promoting the use of safer battery technologies, implementing proper charging infrastructure, increasing awareness and education on safe EV handling and maintenance, and ensuring proper training and certification for EV technicians and emergency responders. Additionally, it is important for manufacturers to prioritize safety in the design and production of EVs.

Honeywell plays a key role in enabling EV safety by providing safety equipment and solutions such as sensors, control systems, and safety switches. Honeywell’s solutions can help enhance the overall safety of EVs in India and contribute to the growth of the EV industry in the country.