SAFETY SYSTEM ANALYSIS STUDY OF ELECTRIC CAR CONVERSION BATTERIES

Abstract

Electric vehicle conversion in Indonesia has become an effective strategy for transportation decarbonization. However, battery system safety remains a major challenge, particularly in non-factory converted vehicles. This study analyzes the safety aspects of LiFePO4 battery systems in converted electric cars using a 10 kW PMSM motor, 180A peak current, and 72V 220Ah battery with Smart BMS 24S 500A. Test results show voltage deviation between cells of ±3.0V and battery temperature increases up to 49.2°C during full load. Overcurrent protection by BMS functions well, but the thermal system is still passive and not optimal. This study recommends integration of active cooling and real-time temperature monitoring systems as thermal runaway mitigation efforts as well as standardization of battery mounting design and high-protection cable routes to improve the electrical safety of conversion vehicle systems..