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GB/T 24347-2021 English PDF (GBT24347-2021)

GB/T 24347-2021 English PDF (GBT24347-2021)

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GB/T 24347-2021: DC/DC converter for electric vehicles

This Standard specifies the technical requirements and test methods of DC/DC converter for electric vehicles. This Standard is applicable to DC/DC converter for electric vehicles. Other circuits with DC/DC conversion function may take this document as a reference.
GB/T 24347-2021
GB
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 43.080.01
CCS T 47
Replacing GB/T 24347-2009
DC/DC Converter for Electric Vehicles
ISSUED ON: AUGUST 20, 2021
IMPLEMENTED ON: MARCH 1, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of the PEOPLE Republic of
China.
Table of Contents
Foreword ... 3
1 Scope ... 5
2 Normative References ... 5
3 Terms and Definitions ... 6
4 Technical Requirements ... 7
4.1 Appearance Requirements ... 7
4.2 Input and Output Performance ... 8
4.3 Protective Functions ... 9
4.4 Environmental Adaptability ... 10
4.5 Electromagnetic Compatibility ... 11
4.6 Electrical Safety ... 14
5 Test Methods ... 15
5.1 Test Requirements ... 15
5.2 Appearance Test ... 16
5.3 Input and Output Performance Test ... 16
5.4 Protective Functions Test ... 21
5.5 Environmental Adaptability Test ... 24
5.6 Electromagnetic Compatibility Test ... 25
5.7 Electrical Safety Test ... 26
Bibliography ... 28
DC/DC Converter for Electric Vehicles
1 Scope
This Standard specifies the technical requirements and test methods of DC/DC converter for electric vehicles.
This Standard is applicable to DC/DC converter for electric vehicles. Other circuits with DC/DC conversion function may take this document as a reference.
2 Normative References
The contents of the following documents constitute indispensable clauses of this document through normative references in the text. In terms of references with a specified date, only versions with a specified date are applicable to this document. In terms of references without a specified date, the latest version (including all the modifications) is applicable to this document.
GB/T 18655-2018 Vehicles, Boats and Internal Combustion Engines - Radio Disturbance Characteristics - Limits and Methods of Measurement for the Protection of On-board Receivers
GB/T 19596 Terminology of Electric Vehicles
GB/T 19951 Road Vehicles - Disturbances Test Methods for Electrical / Electronic Component from Electrostatic Discharge
GB/T 28046.3-2011 Road Vehicles - Environmental Conditions and Testing for Electrical and Electronic Equipment - Part 3: Mechanical Loads
GB/T 28046.4-2011 Road Vehicles - Environmental Conditions and Testing for Electrical and Electronic Equipment - Part 4: Climatic Loads
GB/T 29259 Road Vehicle - Electromagnetic Compatibility Terminology
ISO 7637-2:2011 Road Vehicles - Electrical Disturbances from Conduction and Coupling - Part 2: Electrical Transient Conduction along Supply Lines Only ISO 7637-3:2016 Road Vehicles - Electrical Disturbances from Conduction and Coupling - Part 3: Electrical Transient Transmission by Capacitive and Inductive Coupling via Lines Other Than Supply Lines
ISO 11452-2 Road Vehicles - Component Test Methods for Electrical Disturbances from Narrowband Radiated Electromagnetic Energy - Part 2: Absorber-lined Shielded Figure 1 -- Schematic Diagram of Overshoot and Response Time
3.3 Quiescent Current
Quiescent current refers to the current of the low-voltage battery consumed by the DC/DC converter in the dormant state.
3.4 Weighted Efficiency
Weighted efficiency refers to the weighted average value of each efficiency of the load spectrum corresponding to the DC/DC converter.
3.5 DC/DC for High Voltage Output
DC/DC for high voltage output refers to DC/DC converter with rated output voltage level greater than 60 V and not greater than 1,500 V.
3.6 DC/DC for Low Voltage Output
DC/DC for low voltage output refers to DC/DC converter with rated output voltage level not greater than 60 V.
3.7 Ripple Factor
Ripple factor refers to the ratio of the half of the difference between the peak value and the valley value of the pulsating DC power to the absolute value of its DC component. [source: GB/T 19826-2014, 3.8]
4 Technical Requirements
4.1 Appearance Requirements
4.1.1 The outer surface of the DC/DC converter for electric vehicles (hereinafter referred to as ?€?DC/DC?€?) shall manifest no obvious defects, for example, damage or deformation.
4.1.2 The terminals or lead wires of the DC/DC shall be intact and undamaged; the fastener connections shall not be loose.
4.1.3 The accessible surface of the DC/DC shall be free of rust, burrs, trimmings and similar sharp edges.
4.1.4 The installation of the marks containing product information shall be upright and firm, and the handwriting shall be clear.
4.2.5 Quiescent current
When the DC/DC does not have output, for the port that has a fixed electrical connection with the low-voltage battery (cannot be controlled to disconnect), the quiescent current shall not be greater than 3 mA.
4.2.6 Ripple factor of output voltage
The ripple factor of the DC/DC output voltage shall not be greater than 5%. 4.3 Protective Functions
4.3.1 Input overvoltage and undervoltage protection
When the DC/DC input voltage is greater than or equal to the overvoltage protection value, or less than or equal to the undervoltage protection value, the output shall be turned off or limited. After troubleshooting, the output can be automatically restored, or after necessary human intervention.
The input overvoltage protection value and input undervoltage protection value shall comply with the stipulations of the product technical documents.
4.3.2 Output overvoltage and undervoltage protection
When the DC/DC output voltage is greater than or equal to the overvoltage protection value, or less than or equal to the undervoltage protection value, the output shall be turned off or limited. After troubleshooting, the output can be automatically restored, or after necessary human intervention.
The output overvoltage protection value and output undervoltage protection value shall comply with the stipulations of the product technical documents.
4.3.3 Output short-circuit protection
For the DC/DC with short-circuit protection function, when a short-circuit occurs at the DC/DC output terminal, the power output shall be turned off or limited. After troubleshooting, the output can be automatically restored, or after necessary human intervention.
4.3.4 Over-temperature protection
The DC/DC shall have over-temperature protection function. When the temperature of the DC/DC temperature sampling point reaches the set value of the over-temperature protection, the output shall be turned off or limited. After troubleshooting, the output can be automatically restored, or after necessary human intervention.
The over-temperature protection value shall comply with the product technical documents.
The high-temperature operation resistance of the DC/DC shall comply with the requirements of 5.1.2.2 in GB/T 28046.4-2011.
4.4.4 Damp heat
4.4.4.1 Damp heat cycle
The damp heat cycle resistance of the DC/DC shall comply with the requirements of 5.6 in GB/T 28046.4-2011.
4.4.4.2 Steady-state damp heat
The steady-state damp heat resistance of the DC/DC shall comply with the requirements of 5.7 in GB/T 28046.4-2011.
4.4.5 Salt spray
The salt spray resistance of the DC/DC shall comply with the requirements of 5.5 in GB/T 28046.4-2011.
4.4.6 Vibration resistance
The vibration resistance of the DC/DC shall comply with the requirements of 4.1 in GB/T 28046.3-2011.
4.4.7 Mechanical shock
The mechanical shock resistance of the DC/DC shall comply with the requirements of 4.2 in GB/T 28046.3-2011.
4.5 Electromagnetic Compatibility
4.5.1 Functional feature status
Functional feature status, which defines the expected target of functional features of the device under test (DUT) in the test environment, is applicable to each independent function of the DUT. It describes the working status of the expected function during and after the test. Four functional feature statuses are provided below:
---Status I: the design function can be completed during and after the test; ---Status II: the design function cannot be completed during the test, but it can automatically return to the normal status after the test;
---Status III: the design function cannot be completed during the test, but after the test, through the simple operation of the testing personnel, it can return to the normal status, for example, by turning on / off the DUT, or restarting; ---Status IV: the design function cannot be completed during the test, and more 4.5.3.1.1 For the measurement of unshielded systems and low-voltage artificial network radio frequency ports through the conducted emission voltage method, the limits shall comply with the limit requirements of Level-3 in Table 5 of GB/T 18655-2018, or the stipulations of the product technical documents.
4.5.3.1.2 The measurement through the conducted voltage method by the shielded power supply device shall comply with the limit requirements of Level-3 in Table I.1 of GB/T 18655-2018, or the stipulations of the product technical documents. 4.5.3.1.3 The limits of the DC/DC conducted emission current probe method shall comply with the limit requirements of Level-3 in Table 6 of GB/T 18655-2018, or the stipulations of the product technical documents.
4.5.3.2 Radiated emission disturbance
The DC/DC radiated emission disturbance shall comply with the limit requirements of Level-3 in Table 7 of GB/T 18655-2018, or the stipulations of the product technical documents.
4.5.3.3 Electrical transient conduction disturbance along the power line The electrical transient conduction disturbance of DC/DC along the power line shall satisfy the requirements of Level III in Appendix B of ISO 7637-2:2011. 4.6 Electrical Safety
4.6.1 Insulation resistance
The insulation resistance of DC/DC shall satisfy the following requirements, or the stipulations of the product technical documents.
a) The insulation resistance between each independent live circuit and the ground (enclosure) shall be not less than 10 M???;
b) The insulation resistance between the circuits without electrical connection shall be not less than 10 M???.
4.6.2 Voltage resistance
The voltage resistance between each independent circuit and the ground (enclosure) and between the circuits without electrical connection shall comply with the stipulations of Table 6. The duration of the voltage resistance test is 1 min; there shall be no breakdown or arcing, and the leakage current limits shall comply with the stipulations of the product technical documents.
??????---the DC/DC weighted efficiency, expressed in (%);
i---working condition No.;
n---total number of working conditions;
???i---the efficiency of the DC/DC converter under i working condition, expressed in (%); Pouti---the output power of the DC/DC converter under i working condition; Pini---the input power of the DC/DC converter under i working condition; wi---the load weight of the DC/DC converter under i working condition.
5.3.3 Rated power test
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit. Make the DC/DC working voltage value equal to the rated voltage value. Set the
electronic load to constant-current (or constant-resistance) load mode; b) Adjust the load current, so that the product with the rated voltage is not less than the rated power;
c) Continuously work for no less than 2 h. Every 0.5 h, record the output voltage and the output current value; calculate the output power value.
5.3.4 Control error test
5.3.4.1 Voltage control error test
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit. Set the electronic load to constant-current (or constant-resistance) load mode; b) Under the conditions of rated input and rated output, turn on the DC/DC; make it work in a constant-voltage output state. The voltage is a certain set value Uzo within the controlled range of the DC/DC;
c) Respectively adjust the input voltage to the minimum input voltage, the rated input voltage and the maximum input voltage. Respectively adjust the output load to 20% (or the minimum load given in the product technical documents), 50% and 100% of the load capacity under the current conditions. At this moment, respectively measure the actual voltage Uz of the DC/DC. In
accordance with Formula (2), calculate the output voltage error:
b) Under the conditions of rated input, turn on the DC/DC; make it work under the minimum load (load current is greater than zero);
c) Gradually adjust the DC input voltage to the overvoltage protection value or the undervoltage protection value, until the DC/DC is turned off or the output is limited;
d) Gradually adjust the DC input voltage from the overvoltage protection value or the undervoltage protection value to the normal operating voltage range and observe the DC/DC output status; or re-start the DC/DC under rated
conditions and observe its output status.
5.4.2 Output overvoltage and undervoltage protection test
5.4.2.1 Output overvoltage protection test
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit. The output terminal is connected to a DC voltage source;
b) Under the conditions of rated input, turn on the DC/DC. Set the output voltage to the rated output voltage value;
c) Turn on the DC source at the output terminal; adjust the voltage source at the output terminal to the output overvoltage protection value, until the DC/DC is turned off or the output is limited;
d) Turn off the DC source at the output terminal and observe the DC/DC output status; or re-start the DC/DC under rated conditions and observe its output status.
5.4.2.2 DC output undervoltage protection test
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit. Set the electronic load to constant-resistance (or constant-voltage) load mode; b) Under the conditions of rated input, turn on the DC/DC; make it work in the output current limit state;
c) Reduce the resistance value of the electronic load (or reduce the voltage setting value of the electronic load), so that the output voltage gradually reaches the undervoltage protection value; observe the DC/DC output status; d) Restore the electronic load resistance value to the rated load state (or set the constant-voltage setting value to the DC/DC rated output voltage) and
observe the DC/DC output status; or re-start the DC/DC under rated
conditions and observe its output status.
5.4.3 Output short-circuit protection test
5.4.3.1 Short-circuit protection test before starting
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit. Short-circuit the DC/DC output DC positive and negative poles;
b) Under the conditions of rated input, turn on the DC/DC; check the DC/DC status;
c) After the output short circuit is removed, observe its output status; or re-start the DC/DC under rated conditions and observe its output status.
5.4.3.2 Short-circuit protection test during operation
The test methods and steps are as follows:
a) In accordance with Figure 2, properly connect the test circuit;
b) Under the conditions of rated input, turn on the DC/DC; make it in the rated working state;
c) Short-circuit the output DC positive and negative poles; check the DC/DC working status;
d) After the output short circuit is removed, observe its output status; or re-start the DC/DC under rated conditions and observe its output status.
5.4.4 Overtemperature protection test
The DC/DC overtemperature protection test shall be performed in accordance with the following methods:
---For air-cooled DC/DC, after the high-temperature operation test, continue to gradually increase the temperature of test chamber to the over-temperature protection value, observe and record the DC/DC working status. Restore the test chamber to the temperature range, in which, the rated operation of the DC/DC is possible, and the DC/DC can automatically restore the output or restore the output after necessary human intervention.
---For liquid-cooled DC/DC, after the high-temperature operation test, gradually increase the temperature of the coolant to the over-temperature protection value, observe and record the DC/DC working status. Restore the temperature 5.5.4 Salt spray test
The salt spray test of the DC/DC shall be performed in accordance with the stipulations of 5.5 in GB/T 28046.4-2011.
5.5.5 Vibration test
In accordance with the installation location, the vibration test of the DC/DC shall be performed in accordance with the stipulations of 4.1 in GB/T 28046.3-2011. NOTE: vibration test requires power-on test, which can be tested with small load. 5.5.6 Mechanical shock test
The mechanical shock test of the DC/DC under the non-working status shall be performed in accordance with 4.2 in GB/T 28046.3-2011.
5.6 Electromagnetic Compatibility Test
5.6.1 Working status
When the DC/DC receives the electromagnetic compatibility test under the working status, if there are no special requirements, the DC/DC works under the rated input voltage and the rated output voltage, and the output power reaches 30% of the rated power.
5.6.2 Electromagnetic immunity test
5.6.2.1 Electrostatic discharge immunity test
The test arrangement and test method shall comply with GB/T 19951.
5.6.2.2 Low-voltage electrical transient conduction immunity test along the power line
The test arrangement and test method shall comply with the requirements of different impulse tests on the low-voltage input power line in Chapter 4 of ISO 7637-2:2011. 5.6.2.3 Low-voltage conduction immunity test along the non-power line
The test arrangement and test method shall comply with the requirements of ISO 7637- 3:2016.
5.6.2.4 Anechoic chamber immunity test
The test arrangement and test method shall comply with the requirements of ISO 11452-2.
5.6.2.5 Bulk current injection (BCI) method immunity test
The test arrangement and test method shall comply with the requirements of ISO 11452-4.
5.6.2.6 Magnetic field immunity test
The test arrangement and test method shall comply with the requirements of ISO 11452-8:2015.
5.6.3 Electromagnetic emission disturbance test
5.6.3.1 Conducted emission disturbance test
The test arrangement and test method shall comply with the requirements of GB/T 18655-2018. The test shall be performed at the input port.
The voltage method is used to assess the characteristics of disturbance signals transmitting along low-voltage power lines and high-voltage wiring harnesses. The current probe method is used to assess the characteristics of disturbance signals transmitting along low-voltage wiring harnesses.
5.6.3.2 Radiated emission disturbance test
The test arrangement and test method shall comply with the requirements of GB/T 18655-2018.
5.6.3.3 Low-voltage electrical transient conduction disturbance test along the power line
The test arrangement and test method shall comply with the requirements of ISO 7637- 2:2011.
5.7 Electrical Safety Test
5.7.1 Insulation resistance test
When the DC/DC is not working, use an insulation resistance tester to measure the insulation resistance of the DC/DC; apply a DC test voltage of 500 V and maintain a steady-state value for 60 s, then, determine the insulation resistance....

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