Design of Automatic Fire Extinguisher System for Electric Vehicles
Milan Sonnad
1 a
, Mohammed Saqhib
1 b
, Mohammed Hussain Khan
1 c
, Himanshu Jha
1 d
and P. Sudhakar
1 e
1
Department of Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore,India
iamhimanshhh@gmail.com, Sudhakar-me@dayanandasagar.edu
Keywords: Electric Vehicle, Battery, Fire, Safety Factors, Explosions and Prevention.
Abstract: Electric vehicles are best alternatives for the internal combustion engine powered vehicles but there is
increased concern among people about safety in electric vehicles due to increased number of EV battery fire
reports. The growing popularity and adoption of electric vehicles (EVs) have led to an increased need for
advanced safety systems, especially in fire prevention and extinguishing. Electric vehicle fires present unique
challenges due to the high energy density of their battery packs and the potential for thermal runaway. This
study introduces an automated fire extinguisher system specifically designed for electric vehicles, aiming to
enhance safety and mitigate fire-related risks.In this work, an automatic fire extinguishing system is designed
using CATIA software and a program coding to detect battery temperature using Arduino software was carried
out. This system helps in minimizing huge property damage, injuries, losses and also system to alert rider
about the fire so rider can reach safe distance from the vehicle and escape from fatal injuries. This study also
aims to minimize the chances of battery explosion and save the vehicle from destruction in case of battery
fire.
1 INTRODUCTION
The rise in air pollution from fossil fuel-driven
vehicles and the depletion of fossil fuel reserves have
led to a growing demand for alternative energy
sources in the automobile industry. Electric vehicles
(EVs) are emerging as one of the prominent
alternatives to traditional fossil fuel vehicles and have
been gaining popularity in recent years. In 2015,
approximately 380,000 EVs were produced, and the
demand for electric vehicles growing rapidly more
than the expected rate.
As the automobile sector in India experiences
significant growth in EV adoption, the reliability and
safety of battery-powered electric vehicles present
additional challenges for focus on safety and security
becomes increasingly vital. Studies conducted by
various organizations indicate a
a
https://orcid.org/ 0009-0007-4409-0692
b
https://orcid.org/ 0009-0001-4439-7682
c
https://orcid.org/ 0009-0004-2129-6311
d
https://orcid.org/ 0009-0007-6877-1900
e
https://orcid.org/ 0000-0002-6381-2490
noticeable increase in the number of reported electric
vehicle fire accidents. These incidents have caused
considerable property damage, injuries, and even
casualties due to thermal self-ignition, battery
explosions, and fires caused by vehicle batteries. The
concerns surrounding the firefighting and emergency
rescue operations. Consequently, numerous research
efforts have been undertaken to address the
technology of lithium battery fire prevention and
control prevention and control the disturbances in
battery can cause fire (David, 2018).
The objective of this study is to design an
automatic fire extinguishing system using CATIA
software and a program coding to detect battery
temperature using Arduino software was carried out.
With considering all the reasons mentioned in fig1.,
the were conducted. The fig 1. shows different
reasons why Electric Vehicles catch fire. It can be
seen that many electric bikes catch fire during
charging and many incidents occur at charging
stations. There are also many other reasons for this as
mentioned improper wiring can also result in this. It
can also consider accidents as main reason during
collision study aims that it can prevent from property
damage, injuries and improve safety.
Sonnad, M., Saqhib, M., Khan, M., Jha, H. and Sudhakar, P.
Design of Automatic Fire Extinguisher System for Electric Vehicles.
DOI: 10.5220/0012525900003808
Paper published under CC license (CC BY-NC-ND 4.0)
In Proceedings of the 1st International Conference on Intelligent and Sustainable Power and Energy Systems (ISPES 2023), pages 125-130
ISBN: 978-989-758-689-7
Proceedings Copyright © 2024 by SCITEPRESS – Science and Technology Publications, Lda.
125
Fig. 1: Parts of Arduino UNO.
In consideration of fire in battery of EV, two types
of fire namely Class B and C are present in this fire
detection in lithium batteries and their brief
information of each fire is listed below:
Table 1: TVS bike details.
Why EVs Catch Fire
Short circuit
A short circuit brought about from a wiring
fault to even a puncture in the cells can
cause a rise in temperature and
subsequently a fire.
Faulty charging
Using incorrect and/or faulty cables or wall
outlets can also trigger a fire with an
incorrect amount of electricity
Cell quality
Even a single contaminated cell can spark a
massive fire, igniting itself and then leading
to the dreaded thermal runway igniting
subsequent cells thanks to the temperature
rise.
BMS issues
The key safety task in any battery
management system (BMS) is temperature
control. This entails carefully managing
both charge and discharge speed and
cycles, any fault here can raise the battery
temperature sufficient enough to combust
and high ambient temperatures exacerbate
the issue.
Accidental damage
Though protected very well, a battery
getting punctured or even dented in an
accident can lead to cell ruptures and thus
ignition. An accident can also spill oil - yes
EVs have oil for lubrication and cooling -
onto hot electrical components which can
ignite and lead to a bigger blaze
Class B Fire:
Class B fires are ignited by flammable liquids or
gases such as alcohol, kerosene, paint, gasoline,
methane, oil-based coolants, or propane. Water is
ineffective for extinguishing Class B fires. Instead,
Carbon Dioxide (CO
2
) or dry chemical agents are
typically used to combat these fires.
Class C Fire:
Class C fires are characterized by live electrical
currents or electrical equipment as their source of
fuel. These could include electric tools, appliances,
motors, and transformers. Such fires are prevalent in
industrial settings dealing with energy or electrically
powered quipment, such as wind turbines. Water is
unsuitable for fighting electrical fires and can worsen
the situation. Non-conductive chemical agents,
including clean agents, are recommended for
extinguishing the flames (Yang, 2018).
In this case, the study deals with an Iqube (TVS
make) bike battery with a capacity of 24Ah and
battery details are stated in table 1.
1.1 Fire Suppression Agents for
Battery Fire
Table 2 shows some of the fire suppression agents and
its effectiveness to the fire. This indicates that various
compounds have various suppressing effects and that
various agents are effective for various battery kinds.
In some agents the re-ignition which might be danger
sometimes. So, careful consideration of parameters
related to selection of agent which is used in the
system (Yang, 2018).
Table 2: Battery specification.
Nominal Capacity
24 Ah
Capacity
24 Ah
Nominal Voltage
60 V
Maximum Charging Current
5 Amp
Warranty
2 yrs.
Model Name/Number
IQube
Minimum Order Quantity
1
Table 3: Different fire suppression agents for different
batteries.
Agent
Battery type
Release
moment
CO
2
LiNi
03
Co
0.2
Mn
0.3
O
2
/Grap
hite
Safety valve is
opened
HFC-
227ea
LiNi
03
Co-
0.2
Mn
0.3
O
2
/Gr
aphite
Safety valve is
opened
ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems
126
Water
mist
LiNi
03
Co-
0.2
Mn
0.3
O
2
/Gr
aphite
Safety valve is
opened
Water
Ni
oxide/graphit
e
Temperature of
battery up
to 650 "C
CO
2
Ni
oxide/graphit
e
Temperature of
battery up
to 650 "C
Foam
Ni
oxide/graphit
e
Temperature of
battery up
to 650 "C
Water
mist
Ni
oxide/graphit
e
Temperature of
battery up
to 650 "C
Dry
power
Ni
oxide/graphit
e
Temperature of
battery up
to 650 "C
CO
2
LFP
Battery occurs
fire
HFC-
227ea
LFP
Battery occurs
fire
Super
fine
power
LFP
Battery occurs
fire
CO
2
13S5P
18650-TYPE
LiCoO
2
Cell
15 s after fire
occurred
Dry
powder
13S5P
18650-TYPE
LiCoO
2
Cell
15 s after fire
occurred
3% AFFF
13S5P
18650-TYPE
LiCoO
2
Cell
15 s after fire
occurred
Aqueous
agent
5 18650-type
UBs
First battery
occur TR
Gaseous
agent
5 18650-typ e
UBs
First battery
occur TR
2 MATERIALS AND METHODS
The Automatic fire extinguisher system for EVs has
following components:
• Arduino UNO
• MQ 2 sensor
• RTD Sensor (temperature sensor)
• Solenoid valve
• Pressure cylinder for CO
2
• IR flame sensor
2.1 Arduino Uno
The Arduino Uno is a microcontroller board based on
the Microchip ATmega328P microcontroller (MCU)
and it is an open-source platform equipped with sets
of digital and analog input/output (I/O) pins, enabling
connections to various expansion boards (shields) and
circuits. The board features 14 digital I/O pins, with
six of them capable of PWM
(Pulse Width Modulation) output, and 6 analog I/O
pins. For programming the Arduino Uno, Arduino
IDE (Integrated Development Environment) with a
type B USB cable is used in this study. Power can be
supplied through either a USB cable or a barrel
connector that supports voltages between 7 and 20
volts, like a rectangular cross section 9-volt battery.
Fig. 2: MQ2 smoke sensor.
2.2 MQ2 Smoke Sensor
The Fig. 3 shows MQ2 smoke sensor, belonging to
the family of MQ sensors, operates based on Metal
Oxide Semiconductor (MOS) technology. It requires
a 5V DC supply and consumes approximately
800mW of power. This sensor can detect various
gases, including smoke, hydrogen, alcohol and
carbon monoxide with concentrations ranging from
200 to 10,000 parts per million.
Fig. 3: RTD Sensor.
Design of Automatic Fire Extinguisher System for Electric Vehicles
127
2.3 RTD Sensor
A RTD (Resistance Temperature Detector) is a
temperature sensor that exhibits a change in
resistance corresponding to fluctuations in
temperature. Fig. 4 shows the sensor used here. This
resistance-temperature relationship is widely
understood and remains consistent over time,
ensuring repeatability. It's important to note that an
RTD functions as a passive device (Wang, 2015).
Fig. 4: 160 Bar High pressure stainless-steel solenoid valve.
2.4 Solenoid Valve
Application of the solenoid valve maintains flow of
CO
2
, the valve product name is BRANDO SH as
shown in fig. 5 and the details are mentioned
below.Specifications of valve:Make/manufacturer:
BRANDO
1. Model no: SH
2. Working medium: air, water, gas, liquid, etc
3. Max Working Pressure: 160 bar
4. Seal Material: PTFE
5. Body Material: Stainless Steel 304
6. Port Size: 3/8'', 1/2'', 3/4'', 1''
7. Orifice Size: 1mm to 25mm
8. Operation: Direct Acting (DN1 to 5),
Piston Pilot Operated (DN10 to 25)
9. Voltage: 12VDC, 24VDC, 24VAC,
110VAC, 220VAC (50/60Hz)
Fig. 5: Technical Data of valve.
2.5 Pressure Cylinder for CO
2
Fig. 6: Pressure cylinder for CO2.
Fig. 7 shows bulk low-pressure carbon dioxide and
high-pressure canister CO
2
(Liu, 2003). Material and
Weight: CO
2
bulk tanks and cylinders are available in
various sizes depending on their intended use, and the
two most common materials used are aluminum and
steel. The weight of these tanks differs based on their
material and whether it is empty or filled. Bulk tanks
are stationary and typically constructed from 100%
stainless steel, and are prepared in various sizes to suit
specific requirements. The size and capacity offer
increased distribution flexibility and reduce the need
for frequent refilled cylinders. On the other hand, CO
2
canisters or cylinders are high-pressure tanks
designed for exchange of fluid. It is weighed over 100
lbs when empty and up to 200 lbs when filled.
Fig. 7: Prototype design.
Fig. 8: Working principle.
ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems
128
Fig. 9: Circuit diagram.
2.5 Prototype Design for Fire
Extinguishing System
Various components, such as the flame sensor, gas
sensor, buzzer, and water pump, are connected to the
Arduino using jumper cables (fig. 10). These sensors
and components are linked to their respective pins, as
specified in the program that was uploaded to
Arduino. Power for the Arduino board comes from a
laptop, while the other components receive power
from the 5V pin on the Arduino.
Fig. 10: Temperature sensor output readings.
The IR flame sensor and MQ2 gas sensors
continuously monitor for the presence of flames or
smoke near the battery. If either sensor detects flame
or smoke, it sends a value of 1 to the Arduino,
indicating the presence of fire or smoke. The
Arduino, in turn, triggers the buzzer, and the water
pump floods the battery compartment with water until
the fire is extinguished.
The design of the automatic fire extinguisher
system is intended for the “IQube”, which features a
3.04kWh Lithium-Ion battery with a curved shape.
The structure is constructed using materials capable
of withstanding higher temperatures and is less prone
to catching fire, unlike steel. The design incorporates
breathing holes to facilitate battery cooling. The
flame sensor has an effective range of 30cm, and
smoke sensors are strategically placed in each corner,
approximately 50cm apart from one another, mainly
oriented towards the terminals to cover the entire
battery area as seen in fig. 8. In the event of flame or
smoke detection, the buzzer and solenoid valve are
activated as seen in fig 9, allowing the flow of AVD
(Automatic Vapor Dispenser) stored in the boot
space. Within 25 seconds of detection, the curved
structure is flooded with AVD, preventing further
damage to components, and avoiding battery
explosions (Roy, 1970).
3 RESULTS AND DISCUSSION
Results are discussed in this section.
3.1 Results
Outputs of sensors are discussed.
3.1.1 IR Sensor Output
The output of an IR (infrared) sensor can vary
significantly depending on its specific type. It will
manifest in various forms, such as digital signals that
signify the presence or absence of an object. Analog
signals that correspond to the intensity of detected
infrared radiation, pulse width modulation (PWM)
signals that change based on proximity or intensity,
or serial communication protocols that offer detailed
information, including calibrated values or distance
measurements. To successfully integrate an IR sensor
with microcontrollers or other electronic components
for further processing and decision-making, it is
crucial to consult the sensor's datasheet or relevant
literature. Fig. 10 shows the temperature variation for
the given period of time. The reference value for
initiation of flame considered is 1500 C, it is seen in
the fig. 10 the designed system detects in 20 seconds.
Maximum upper limit and minimum upper limit is
160 and 1060 C in the temperature management of
fire detection is considered.
3.1.2 MQ2 Sensor Output
The MQ2 smoke sensor will detect the presence of
smoke or flammable gases within a range of 300 ppm
to 10000 ppm. Its output typically takes the form of
an analog signal, with variations in voltage or current
proportional to the quantity of smoke or flammable
Design of Automatic Fire Extinguisher System for Electric Vehicles
129
gases detected. Higher concentrations of smoke or
gas leads to an increase in the output signal, while
lower concentrations result in a decrease in signal
strength. In areas where there is a potential risk of
smoke or combustible gases, this analog output can
be further processed or utilized in conjunction with
microcontrollers or other electronic devices to trigger
alarms, activate safety features, or assess the air
quality.
3.2 Discussions
In the realm of fire suppression, innovative solutions
tailored specifically for electric vehicles (EVs) are
emerging. These solutions encompass various
methods such as foam, inert gases, water mist, and
even solid-state extinguishing substances. In
comparison to traditional fire suppression systems,
these cutting-edge technologies offer numerous
advantages, including enhanced effectiveness in
extinguishing battery fires, reduced environmental
impact, and simplified installation and maintenance
processes. The integration of fire suppression
systems with other vehicle safety features is a
possibility in the future. This could involve
combining them with existing safety mechanisms like
airbags and battery management systems. Such
connectivity would enable the fire suppression
system to activate automatically in the event of a fire
or be manually triggered by the driver or passenger
during emergency situation (Wang, 2002).
As EV technology continues to gain wider
adoption, it becomes imperative to establish new
criteria for EV fire safety. These standards must
account for the diverse range of fire suppression
devices available and consider the unique
characteristics of EV batteries. By doing so, it is
ensured the utmost safety and protection as electric
vehicles become more prevalent on the roads.
4 CONCLUSION
After conducting an extensive review of various
literature papers and developing an automatic fire
extinguisher system for electric vehicles, the study
arrives the conclusion that the designed model
exhibits excellent capabilities in detecting and
extinguishing fires. Moreover, it can be seamlessly
integrated into production electric vehicles, thereby
significantly reducing the occurrence of electric
vehicle fire accidents. The inclusion of infra-red
flame sensors and MQ2 smoke sensors ensures a
swift response to battery fires. In the event of a fire,
these sensors will promptly trigger the fire
extinguisher system and alarm, effectively containing
the fire's spread, minimizing component damage, and
reducing the risk of explosions. The alarm system
serves as a crucial warning mechanism, alerting riders
and bystanders to evacuate to a safe distance before
any potential dangers escalate. To ensure continuous
monitoring of battery temperature, a temperature
sensor module is incorporated. In situation where
battery's temperature exceeds a certain threshold,
indicating a high likelihood of fire or explosion, the
system takes preventive measures. It immediately
disconnects the battery from circuits and charging to
prevent any potential fire, and the cooling system is
activated to mitigate temperature rise (Yang, 2018).
In the literature, Advanced vehicle diagnostics
(AVD) was mentioned as the most efficient fire
extinguishing agents for lithium-ion battery fires,
though a complexion in design, intended not to
include them in this field of study. Also, several
reasons integrated for excluding AVD in design for
eliminating increasing complexity, programming
requirements, and associated component costs.
Nonetheless, the designed system with its array of
sensors and fire extinguishing mechanisms is proven
to be highly effective and addresses the critical need
for enhanced fire safety in electric vehicles.
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