electric vehicles type approval

The final type approval of a 100% electric vehicle follows a path similar to that of internal combustion engine vehicles in many general aspects (passive safety, braking, lighting, etc.), but it includes specific and additional requirements related to the nature of its electric powertrain.

In Europe, the general reference legislation for vehicle type approval is Regulation (EU) 2018/858 (which replaced the former Directive 2007/46/EC). This regulation establishes the framework for the type approval of vehicles in categories M, N and O (passenger transport, goods transport and trailers).

However, for electric vehicles, the most specific and fundamental regulation is UN/ECE Regulation No. 100. This regulation lays down the “Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric powertrain.”

Below are the key points and specific requirements for the type approval of a 100% electric vehicle, in accordance with UN/ECE Regulation No. 100 and other relevant regulations:

Electrical Safety (UN/ECE Regulation No. 100)

This is the core of type approval for electric vehicles and covers several critical aspects:

Protection against electric shock:

  • Insulation: Adequate insulation must be ensured between live parts and exposed conductive parts.

  • High-voltage circuit protection: High-voltage components (generally defined as circuits with voltages above 60 V DC or 30 V AC RMS) must be protected against direct or indirect contact.

  • IP protection rating: Specific protection ratings (e.g., IPXXB for parts outside the passenger compartment, IPXXD for the passenger compartment) must be achieved to prevent access to live parts.

  • Insulation resistance: Minimum requirements are set for the insulation resistance of the high-voltage system, measured in ohms/volt.

  • Grounding: All exposed conductive parts must be effectively connected to the vehicle’s electrical chassis, with a resistance below 0.1 Ohm.

  • Functional Safety (ISO 26262): Although not directly part of Regulation 100, functional safety is crucial for electric vehicles. It concerns the prevention of systematic or random malfunctions in electronic and electrical systems that could lead to hazards.

  • Marking and labeling: High-voltage components and cables must be clearly identified (e.g., orange color for high-voltage cables) and marked with appropriate hazard symbols.

Safety in case of accident/collision:

  • Structural integrity of the high-voltage system: The high-voltage system (battery, inverter, motor, etc.) must maintain integrity after crash tests (e.g., frontal, side, rear).

  • Automatic deactivation: The high-voltage system must automatically shut down in the event of an accident to prevent risks of electric shock or fire.

  • Protection against electric leakage: Current leakage after an impact must remain within safe limits.

Batteries (REESS – Rechargeable Electric Energy Storage System)

Batteries are a critical component and are subject to rigorous safety testing:

UN/ECE Regulation No. 100 (Part II): This part of the regulation focuses on the specific requirements for rechargeable electric energy storage systems (REESS). The tests include:

  • Vibration: Resistance tests to simulate driving conditions.

  • Thermal shock and cycling: Resilience to extreme temperature variations.

  • Mechanical impact: Resistance to impact forces.

  • Overcharge, overdischarge, and short-circuit tests: Verification of safety under abnormal operating conditions.

  • Flame propagation test (fire resistance): The battery pack’s ability to resist fire or limit flame propagation.

  • Overcurrent protection: Systems to prevent excessive currents.

  • Penetration test: Simulation of impacts with sharp objects.

  • Thermal runaway prevention: Prevention of thermal runaway, a critical phenomenon for lithium-ion batteries.

Electromagnetic Compatibility (EMC)

UN/ECE Regulation No. 10: This regulation defines the requirements for electromagnetic compatibility (EMC) of vehicles, ensuring that electrical and electronic components do not generate interference that could affect the operation of other vehicle systems or external devices, and that they are immune to external interference. This is particularly relevant for electric vehicles due to the presence of high-power systems that can generate electromagnetic fields.

sound emissions

Although electric vehicles are inherently quieter, they must still comply with noise limits, especially at low speeds where the noise from an internal combustion engine does not mask other sounds (e.g., tire rolling, aerodynamics, or the AVAS – Acoustic Vehicle Alerting System), a mandatory system for electric and hybrid vehicles at low speeds to alert pedestrians and cyclists.

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of Inspections, Certifications and Type Approvals in the Automotive sector.

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type approval of whole vehicles

ATS Group, through its companies designated by e24 and e5 marks, is able to issue the type approval of complete vehicles.

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The test laboratories affiliated with ATS Group are ISO 17025 accredited, ensuring reliability, accuracy, and compliance with international standards.

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Our proprietary online platform can manage the whole approval process, fron the quotation till the direct download on the final Type Approval Certificate.

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