GB 38032-2020 English PDF (GB38032-2020)

This Standard specifies the safety requirements and test methods for electric buses. This Standard applies to M2 and M3 electric buses, including battery electric buses and hybrid electric buses. This Standard does not apply to fuel cell electric buses.

GB 38032-2020
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.080.20
T 47
Electric buses safety requirements
ISSUED ON: MAY 12, 2020
IMPLEMENTED ON: JANUARY 01, 2021
Issued by: General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China;
Standardization Administration of the People's Republic of
China.
Table of Contents
Foreword ... 3
Introduction ... 4
1 Scope ... 5
2 Normative references ... 5
3 Terms and definitions ... 6
4 Safety requirements ... 6
4.1 General safety requirements ... 6
4.2 Requirements for waterproof and dustproof performance ... 6
4.3 Requirements for fireproof performance ... 7
4.4 Safety requirements for rechargeable energy storage system ... 8
4.5 Control system safety requirements ... 9
4.6 Charging safety requirements ... 9
4.7 Safety requirements after vehicle crash and rollover ... 10
5 Test methods ... 11
5.1 Waterproof and dustproof ... 11
5.2 Fireproof performance ... 11
5.3 Rechargeable energy storage system safety ... 12
5.4 Functional safety protection ... 12
5.5 Vehicle crash and rollover safety ... 12
6 Implementation date ... 12
Annex A (normative) Thermal runaway test method ... 13
Annex B (normative) Crash test method ... 15
Bibliography ... 17
Electric buses safety requirements
1 Scope
This Standard specifies the safety requirements and test methods for electric buses.
This Standard applies to M2 and M3 electric buses, including battery electric buses and hybrid electric buses.
This Standard does not apply to fuel cell electric buses.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2408-2008 Plastics - Determination of burning characteristics -
Horizontal and vertical test
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB 8624-2012 Classification for burning behavior of building materials and products
GB/T 10295 Thermal insulation - Determination of steady-state thermal
resistance and related properties - Heat flow meter apparatus
GB 13094 The safety requirements for bus construction
GB/T 15089 Classification of power-driven vehicles and trailers
GB 17578 Requirements and test methods of strength for the superstructure of bus
GB 18384 Electrically propelled road vehicles - Safety specifications
GB/T 19596 Terminology of electric vehicles
GB 20071-2006 The protection of the occupants in the event of a lateral crash
GB/T 31498-2015 The safety requirement of electric vehicle post crash
3 Terms and definitions
For the purpose of this document, the terms and definitions defined in GB 13094, GB/T 15089, GB/T 19596 and the following apply.
3.1
minimum management unit of battery system
The minimum unit of battery that the battery management system can monitor. 4 Safety requirements
4.1 General safety requirements
The general safety of electric buses shall meet the requirements of GB 18384. 4.2 Requirements for waterproof and dustproof performance
4.2.1 Vehicle wading requirements
Carry out the vehicle wading test according to the test method specified in 5.1.1. Within 10 min after the test is completed, the insulation resistance of the vehicle shall be greater than 1 MΩ.
4.2.2 Requirements for degrees of protection provided by Class B voltage components
Carry out the degrees of protection test according to the test method specified in 5.1.2. The insulation resistance of the vehicle shall be greater than 1 MΩ. The degrees of protection provided by the following components shall not be less than IP67:
a) Class B voltage electrical equipment and connectors connected to Class B voltage components, of which the lowest point is below the passenger
cabin floor and 500 mm under the ground;
b) Class B voltage electrical equipment (excluding powered devices) that are installed on the roof of the vehicle without protective devices.
4.2.3 Vehicle soaking requirements
Carry out the vehicle soaking test according to the test method specified in 5.1.3. Within 2 h after the test is completed, the vehicle shall not be fired or 19 Bellows
Bellows
(all size
specifications)
√ √
Note: “—” means that this component does not need to meet this requirement. 4.3.2 Requirements for flame retardant and thermal insulation
performance between rechargeable energy storage system (or
installation cabin) and passenger cabin
Flame retardant and thermal insulation materials shall be used between the rechargeable energy storage system (or installation cabin) and the passenger cabin. The test of flame retardant and thermal insulation performance between the rechargeable energy storage system (or installation cabin) and the
passenger cabin shall be carried out according to the test method specified in 5.2.2. The burning characteristics of flame retardant and thermal insulation materials shall meet the requirements of Class A specified in GB 8624-2012. The thermal conductivity at 300 °C shall not be greater than 0.04 W/(m · K). 4.4 Safety requirements for rechargeable energy storage system
4.4.1 Thermal runaway requirements for the minimum management unit
of battery system
Carry out the thermal runaway test for the minimum management unit of battery system according to the test method specified in 5.3.1. The test object shall not be fired or exploded.
4.4.2 Flame retardant requirements for materials of parts in rechargeable energy storage system
Except for secondary cells, other non-metallic parts in the rechargeable energy storage system are subjected to the flame retardant test of the materials of parts in the rechargeable energy storage system according to the test method
specified in 5.3.2, which shall meet the following flame retardant requirements: a) The materials of parts that meet any of the following conditions must meet the requirements of horizontal burning HB level and vertical burning V-0 level:
- The mass of an individual part is ≥ 50 g;
- The total mass of an individual part of the same model in the
rechargeable energy storage system is > 200 g.
b) The materials of other non-metallic parts meet the requirements of
horizontal burning HB75 level and vertical burning V-2 level.
interface that does not perform charging shall be electrically neutral. 4.6.2 Temperature monitoring requirements for charging sockets
The charging sockets of the vehicle shall be provided with a temperature monitoring device, which shall be able to transmit the corresponding signal to the vehicle according to the temperature change, used to realize the
temperature monitoring and over-temperature protection functions of vehicle charging interfaces.
4.7 Safety requirements after vehicle crash and rollover
4.7.1 Safety requirements after vehicle crash
If there is a rechargeable energy storage system of which the lowest point is not more than 1 m above the ground (the vehicle is at no-load state), the crash test shall be carried out according to the test method specified in 5.5.1. After the crash test, the vehicle shall comply with the requirements of 4.2 ~ 4.4 in GB/T 31498-2015.
4.7.2 Safety requirements after vehicle rollover
If an electric bus needs to be subjected to the superstructure strength test according to the test method specified in 5.5.2, the test shall be carried out with the charge capacity (SOC) of the rechargeable energy storage system
maintained at 30 % ~ 50 % and in the Class B voltage power-up state. After the test, it shall meet the requirements of 4.2 ~ 4.4 in GB/T 31498-2015.
4.7.3 Exemption clauses for vehicle crash and rollover tests
When a vehicle model that requires the assessment of vehicle crash safety requirements meets one of the following two conditions, it is deemed to meet the requirements of 4.7.1.
a) Compared with the model that has passed the crash test, if the following five conditions are met at the same time:
- The production enterprise and type of rechargeable energy storage
system (single or assembly) are the same;
- The energy of the rechargeable energy storage system is the same or
reduced;
- The cabinet structure is the same or strengthened;
- The cabinet installation structure is the same or strengthened;
- The body structure of the battery pack installation area remains
The burning characteristics are tested according to the provisions of GB 8624- 2012. The thermal conductivity is tested according to the provisions of GB/T 10295.
5.3 Rechargeable energy storage system safety
5.3.1 Thermal runaway test of minimum management unit of battery
system
Carry out the thermal runaway test according to the provisions of Annex A. 5.3.2 Flame retardant test of materials of components in rechargeable
energy storage system
The horizontal burning and vertical burning shall be tested according to the provisions of GB/T 2408-2008.
5.4 Functional safety protection
The manufacturer provides specific program descriptions according to the functional protection requirements specified in 4.4.3, 4.4.4, 4.4.5, 4.5, and 4.6. The testing organization tests and verifies on the parts or the actual vehicle according to the descriptions, and carries out the compliance judgment. 5.5 Vehicle crash and rollover safety
5.5.1 Vehicle crash safety test
Carry out the vehicle crash safety test according to the provisions of Annex B. 5.5.2 Vehicle rollover safety test
Carry out the superstructure strength test according to the provisions of GB 17578.
6 Implementation date
Models that newly apply for the type approval will be implemented from the date of implementation of this Standard, and models that have obtained the type approval will be implemented from the 13th month of the implementation of this Standard.
Annex B
(Normative)
Crash test method
B.1 Test site
The test site shall be able to accommodate the mobile barrier drive system, the movement of vehicle being hit after crash and the installation of test equipment. The site where vehicles crash and move shall be level and flat, and the coefficient of friction of the road shall not be less than 0.5.
B.2 Vehicle preparation before the test
B.2.1 The charge capacity of the rechargeable energy storage system shall be adjusted to 30 % ~ 50 % SOC. For battery electric buses, the whole vehicle shall be powered on, and for hybrid electric buses, the whole vehicle can be powered on at low voltage.
B.2.2 The test vehicle shall be in the state of curb weight.
B.2.3 The window shall be closed, and the door is closed but not locked. B.2.4 The gear shall be in neutral position, and the parking brake shall be released.
B.2.5 The tyre pressure shall be adjusted to the pressure value specified by the manufacturer.
B.2.6 The test vehicle is placed so that the axle is level.
B.3 Test conditions
B.3.1 The test vehicle shall remain stationary.
B.3.2 The characteristics of the mobile deformable barrier shall comply with the characteristics specified in Annex C of GB 20071-2006. Appropriate devices shall be installed on the mobile deformation barrier to avoid secondary crash with the test vehicle.
B.3.3 During the test, the mobile deformable barrier hits the weakest position of the test vehicle. (For the weakest position, it mainly considers the installation of traction batteries and the protection conditions of the whole vehicle. If a traction battery is installed on the side of the vehicle, the side of the vehicle is preferred for crash. The details are determined by the testing organization and