Safety Protection for Light Electric Vehicle Batteries SETsafe | SETfuse Solutions and Products 

This article primarily introduces safety protection for light electric vehicle batteries, covering:

|  Lead-Acid Battery: Over-Temperature Protection

|  Battery Management System (BMS): Active Protection

|  Battery Management System (BMS): Overvoltage Protection

Overview

Light electric vehicles (LEVs) encompass electric bicycles, electric scooters, light electric motorcycles, and low-speed electric vehicles (e.g., community vehicles and electric tricycles). According to market trends, the global LEV market is projected to reach tens of billions of USD by 2025, with the Battery Management System (BMS) market valued at approximately USD 2.3 billion (around CNY 16 billion). By 2030, the overall market is expected to exceed USD 100 billion, with the BMS market reaching USD 40 billion (approximately CNY 276.7 billion), reflecting a compound annual growth rate of about 30.1%. (Data sourced from the internet for reference only.)

Why Light Electric Vehicle Batteries Require Safety Protection

The primary reasons include:

Thermal Runaway Risk:

Overcharging, over-discharging, high temperatures, or short circuits may lead to battery fires or explosions.

Overcharge/Over-discharge Damage:

Overcharging can cause electrolyte decomposition or structural damage, while over-discharging may result in permanent capacity loss.

External Impact and Vibration:

Collisions or vibrations during operation may cause short circuits or leakage.

Lifespan and Performance:

Protection mechanisms extend battery lifespan and improve efficiency through balancing and monitoring.

User Safety:

Ensuring consumer safety by preventing battery-related incidents.

Certifications and Mandatory Standards

Chinese National Standards

GB 38031-2025:

Requires batteries to be free from fire or explosion risks, with additional tests for bottom impact, fast-charging cycle safety, and revised thermal propagation testing.

GB/T 31467.3-2015:

Covers tests for over-temperature, overvoltage, and short circuits.

GB 17761-2018:

Specifies requirements for electrical safety, overcharge protection, and thermal management.

GB/T 36972-2018:

Defines requirements for over-temperature, overvoltage, overcurrent protection, and cycle life.

International Standards

IEC 62133:

Safety standard for secondary batteries in portable devices, covering overcharge, over-discharge, short-circuit, and thermal abuse tests.

UN 38.3:

Lithium battery transportation safety standard, including tests for vibration, impact, overcharge, and over-temperature.

ISO 26262:

Automotive functional safety standard, ensuring the reliability of BMS over-temperature and overvoltage protection (e.g., ASIL C level).

UL 2271:

Safety standard for LEV batteries, covering electrical, mechanical, and environmental tests.

EN 15194:

European standard for electric bicycles, requiring BMS with over-temperature, overvoltage, and short-circuit protection.

Battery Safety Protection Mechanisms

Safety protection mechanisms for LEV batteries, designed for lithium-ion and lead-acid batteries, aim to prevent risks such as thermal runaway, overcharge/over-discharge, and short circuits. These include:

|  Lead-Acid Battery Over-Temperature Protection

|  Battery Management System (BMS) Active Protection

|  Battery Management System (BMS) Overvoltage Protection

|  Overcurrent and Short-Circuit Protection

|  Mechanical and Environmental Protection

These mechanisms are typically integrated, combining intelligent BMS management with hardware components (e.g., fuses, MOSFETs, thermistors) to ensure battery safety and reliability under various operating conditions.

Importance of Safety Protection for LEV Batteries

LEV batteries require safety protection due to risks such as thermal runaway, overcharge/over-discharge, external impacts, and vibrations, which may lead to fires, explosions, capacity loss, or user safety hazards. Protection mechanisms monitor temperature, voltage, and current to prevent electrolyte decomposition or short circuits, extend battery lifespan, and ensure safe operation. Key measures include lead-acid battery over-temperature protection, BMS active protection (e.g., cell balancing and thermal management), and overvoltage protection, compliant with Chinese standards (e.g., GB 38031-2025) and international standards (e.g., IEC 62133, UL 2271).

SETsafe | SETfuse Solutions, Products

Protection Type:

Lead-Acid Battery – Over-Temperature Protection

Product Name:

Thermal Link– Alloy Type (ATCO)

Series: For more details, contact sales@SETfuse.com

Protection Type:

Battery Management System (BMS) – Active Protection

Product Name:

Heat CutOff (HCO), also known as Three-Terminal Fuse

Series:

SMD Type: SHP  Learn more

SMD Type: SHL  Learn more

Protection Type: 

Battery Management System (BMS) – Overvoltage Protection

Product Name: 

Transient Voltage Suppression Diode (TVS)

Series:

SMD Type: ASMA  Learn more

SMD Type: ASMB  Learn more

SMD Type: ASMC  Learn more

SMD Type: SM8SxxA  Learn more

SMD Type: SM8TxxA  Learn more

Product Name:

ESD TVS Diode Arrays (ESD TVS)

Series:

SMD Type: GSM24CCAN  Learn more

Common Circuit Protection Components for Light Electric Vehicles

Fuse

MOSFET

Thermistor (NTC/PTC)

TVS Diode (Transient Voltage Suppression Diode)

Relay

Inductor/Capacitor Filter

Schottky Diode

Partner with SETsafe | SETfuse to Transform Technical Challenges into Reliable Solutions

When you encounter technical challenges in selecting circuit protection components or designing system solutions, the professional engineering team at SETsafe | SETfuse is your trusted partner. Specializing in over-temperature, over-current, over-voltage, and active protection technologies, SETsafe | SETfuse offers comprehensive technical expertise and rapid response to meet your needs. Whether you require precise product parameter guidance or comprehensive system-level protection solutions, SETsafe | SETfuse delivers professional, practical, and efficient recommendations and support.

From initial design consultation and solution implementation to post-sales product assurance, we provide end-to-end collaboration, ensuring your project progresses seamlessly and reliably. For any inquiries or requirements, please contact us at: sales@SETfuse.com

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