OEM documentation package¶
What is this: the three-report structure (Table C.1) the manufacturer must submit for the thermal propagation analysis and verification. Two reports come from the OEM, one from the test agency.
The three reports¶
"The thermal propagation analysis and verification report should include the three reports listed in Table C.1. The first and second reports should be provided by the manufacturer, and the third report should be issued by the testing agency. The verification tests described in C.3.5 d) and C.4 can be the same test conducted at the same testing agency." (C.4.2)
Reproducing Table C.1:
| # | Report title | Corresponding sections |
|---|---|---|
| 1 | Manufacturer-defined thermal event alarm signal description | C.2.1, C.2.2 |
| 2 | Technical documentation on the safety of the battery pack or system | C.3.2, C.3.3, C.3.4, C.3.5 |
| 3 | Test report for results verification based on manufacturer's technical documents and test procedures | (issued by the test agency, per C.4) |
Report 1 — Alarm signal description (C.2)¶
Two parts:
- C.2.1 Triggering parameters — which signals the alarm uses (temperature, temperature rise rate, SOC, voltage drop, current, etc.) and the threshold levels. The thresholds must be clearly distinct from the manufacturer's specified normal operational state.
- C.2.2 Alarm signal description — describes the sensors and how the BMS / pack control responds during a thermal event.
This is the document that defines what "thermal event warning signal" means for this specific pack. The 5-minute clock in 5.2.7 b) 2) measures from TR trigger to the moment this signal is issued.
Report 2 — Pack/system safety documentation (C.3)¶
Four sub-sections. The manufacturer must show, on paper, that the pack design achieves the C.1 outcome (no fire, no explosion, warning, smoke condition).
- C.3.2 Risk reduction analysis — fault analysis using GB/T 34590, ISO 26262, GB/T 20438, IEC 61508, or equivalent. Identifies the risks from single-cell TR and the design features that mitigate them.
- C.3.3 System diagrams — for the physical systems and components that contribute to meeting C.1.
- C.3.4 Functional operation diagrams — confirming all risk-mitigation features.
- C.3.5 Test procedure and results document — with the following parts spelled out in the standard:
- a) Description of the operating strategy.
- b) Identification of the physical systems / components implementing the function.
- c) Technical documentation of the risk-mitigation function from analysis or simulation.
- d) Technical documentation from verification tests, including:
- Test time, location, product technical parameters
- Test procedure: methods, test object, triggering object, monitoring point layout, TR trigger conditions, list of modifications to the test object. The manufacturer may use their own procedure or refer to C.5.
- Test results: photos, data, and time of key events (TR trigger, TR occurrence, trigger stop, alarm signal, external smoke, fire, explosion, etc.).
- e) The smoke clause for pack/system tests: if the OEM uses the pack/system as the test object, the documentation must describe that, before the alarm signal and within 5 minutes after it, smoke does not endanger the occupant compartment. (See smoke and passenger compartment.)
Report 3 — Test agency verification report (C.4)¶
"The testing agency will verify the results based on the technical documentation and test procedures provided by the manufacturer and provide a test report." (C.4.1)
The test agency may run the verification test using the OEM's procedure or the C.5 reference procedure (which spells out the trigger methods, sensor placement, and TR confirmation). The verification tests in C.3.5 d) and C.4 may be the same test performed at the same agency (C.4.2).
Engineering note (non-normative): The C.3.5 d) → C.4 collapse is the practical path most OEMs take: one bench test, witnessed by the test agency, generates both the OEM's C.3.5 d) data and the agency's C.4 report. Treating them as separate test campaigns is permitted but expensive.
Engineering note (non-normative): Report 1 (C.2) is small but load-bearing. The thresholds defined there determine when the 5-minute warning clock can stop. If the alarm thresholds are looser than the (a OR b) AND c TR-confirmation rule, the BMS may detect TR but issue the warning too late to satisfy 5.2.7 b) 2). Tune the alarm to fire on precursor signals.
Source: GB 38031-2025, Appendix C sections C.2–C.4 and Table C.1 (PDF p. 34–35).