Electric Vehicle Safety Protection Technology: A Systematic Solution from Battery Protection to Active Safety

Keywords: electric vehicle safety protection, battery protection, active safety, collision testing

abstract

Safety is the core demand of electric vehicle users. This article analyzes the technical system and engineering practice of battery pack protection, active safety system, and collision testing.

4.1 Battery Pack Structure Protection Technology

CTP (Cell to Pack) technology: BYD blade batteries are directly integrated into the battery pack, increasing the volume utilization rate by 50%. Through needle testing (5mm steel needle, 50 ℃ environment), it does not ignite.

Explosion proof valve and pressure relief design: The Ningde Times 811 battery pack is equipped with an explosion-proof valve (opening pressure of 0.5MPa), which can release pressure within 30 seconds in case of thermal runaway to avoid explosion.

4.2 Active Safety System Upgrade

AEB automatic emergency braking: The Mobileye EyeQ6 chip supports an 8-megapixel camera, which can recognize pedestrians and brake at a speed of 80km/h with a false triggering rate of less than 0.1%.

ESC electronic stability control: Bosch iBooster 3.0 line control dynamic system response time is shortened to 90ms, which is three times faster than traditional vacuum booster pumps.

4.3 Collision Testing and Safety Standards

Euro NCAP 2025: Added side pole impact test (speed 32km/h), requiring battery pack deformation to be less than 5mm to avoid electrolyte leakage.

C-NCAP five-star standard: The 2023 version requires electric vehicles to have a high-voltage system power outage time of less than 100ms in a 40% offset collision at 64km/h.

4.4 Network Security and Data Privacy

In car firewall: Tesla uses Palo Alto Networks firewall to intercept 99% of external attacks (such as blocking DDoS attacks against in car entertainment systems in 2021).

GDPR compliance: The EU requires car companies to encrypt and store user location data, and access requires user authorization (such as Volkswagen ID. series supporting anonymous data upload).

4.5 Fire Protection and Emergency Rescue

Perfluorohexane fire extinguishing device: A 2L perfluorohexane tank is integrated into the battery pack, with a spraying time of less than 5 seconds, and the fire extinguishing efficiency is twice that of heptafluoropropane.

Emergency power-off switch: The national mandatory standard requires electric vehicles to be equipped with a red emergency power-off switch, which can cut off high-voltage power within 3 seconds.

conclusion

Security protection needs to shift from "passive protection" to "active prevention". By optimizing the battery pack structure, coordinating active safety systems with network security, a full lifecycle safety system can be constructed.