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GB/T 40433-2021 English PDF (GBT40433-2021)

GB/T 40433-2021 English PDF (GBT40433-2021)

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GB/T 40433-2021: Technical specifications of combined power source for electric vehicles

This Document specifies the technical requirements and test methods for combined power source system for electric vehicle. This Document is applied to combined power source system with a maximum DC working voltage of less than 60V.
GB/T 40433-2021
GB
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 43.080
CCS T 47
Technical Specifications of Combined Power Source
for Electric Vehicles
ISSUED ON: AUGUST 20, 2021
IMPLEMENTED ON: MARCH 01, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of PRC.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative References ... 4
3 Terms and Definitions ... 4
4 Signs and Abbreviations ... 5
5 Technical Requirements ... 5
6 Test Methods ... 8
Appendix A (Informative) Combined Power Source System Structure and
Application ... 18
Appendix B (Informative) Exhaust Safety Test ... 20
Technical Specifications of Combined Power Source
for Electric Vehicles
1 Scope
This Document specifies the technical requirements and test methods for combined power source system for electric vehicle.
This Document is applied to combined power source system with a maximum DC working voltage of less than 60V.
2 Normative References
The following documents are essential to the application of this document. For the dated documents, only the versions with the dates indicated are applicable to this document; for the undated documents, only the latest version (including all the amendments) is applicable to this document.
GB/T 2408-2008 Plastics - Determination of Burning Characteristics - Horizontal and Vertical Test
GB/T 19596 Terminology of Electric Vehicles
GB/T 31467.1-2015 Lithium-Ion Traction Battery Pack and System for Electric Vehicles -Part 1: Test Specification for High Power Applications
GB 38031-2020 Electric Vehicles Traction Battery Safety Requirements
3 Terms and Definitions
For the purposes of this Document, the terms and definitions given in GB/T 19596 and the following apply.
3.1 Combined power source system
An electric energy supply system that is composed of two or more rechargeable energy storage units of different types or voltage levels.
NOTE: Usually, it includes rechargeable energy storage unit, control unit, battery management 5.1.2 Unless otherwise required, the combined power source system shall be able to work normally under the following environmental conditions:
a) Ambient temperature: -30??C ~50??C;
b) Relative humidity: 10%~95%;
c) Air pressure: 61.6kPa~106kPa.
5.1.3 There shall be no obvious scratches, burrs, deformation, rust, cracks and other defects in the shell of each component of the combined power source system. 5.1.4 The product information shall be clearly and firmly marked on the shell of each component of the combined power source system.
5.2 Functional requirements
5.2.1 The combined power source system shall have charging- and discharging- functions, which can be used to store the electric energy fed back during the braking process of the whole vehicle and provide auxiliary electric energy for the power output of the whole vehicle.
5.2.2 The main power source should have an independent battery management system for monitoring the power supply voltage, current, temperature and other parameters, and realize the functions of fault diagnosis, information recording and fault handling.
5.3 Safety requirements
5.3.1 Working voltage
The combined power source system shall meet the maximum operating voltage requirements of Class A voltage circuits.
5.3.2 Electrical connection
5.3.2.1 The electrical interface shall adopt the error-proof design to ensure that the components can be connected correctly.
5.3.2.2 The electrical connection shall be firm and reliable, and there should be no problems such as deformation, looseness, or falling off.
5.3.3 Mechanical connection
5.3.3.1 The components of the combined power source supply system should be arranged in locations that are not susceptible to collision or other mechanical damage. 5.3.3.2 The mechanical connection shall be firm and reliable, and there should be no problems such as deformation, looseness, falling off, etc.
5.3.4 Flame retardant properties
The shell of each component of the combined power source system shall meet the Level V-0 requirements specified in GB/T 2408-2008. For combined power source systems containing 12V lead-acid batteries, the shells of components other than 12V lead-acid batteries shall meet the Level V-0 requirements specified in GB/T 2408-2008. 5.3.5 Power safety
5.3.5.1 The safety of the main power source that provides energy to the vehicle power system shall meet the requirements of GB 38031-2020.
5.3.5.2 For the main power supply arranged in the passenger compartment, at least one of the following requirements shall be met:
a) The main power source shall be equipped with an exhaust device, and when exhaust occurs, the gas is exported to the outside of the passenger compartment through the exhaust pipe of the whole vehicle;
b) Carry out exhaust safety test in accordance with 6.4.2.2, and the exhaust composition and concentration shall not cause harm to passengers;
c) The manufacturer shall provide safety documentation to prove that the main power exhaust shall not cause harm to passengers.
5.4 Electrical performance requirements
5.4.1 Capacity
The combined power source system or main power source shall be tested in accordance with 6.5.1. The discharge capacity at -20??C shall be no less than 70% discharge capacity at the room temperature; the discharge capacity at 0??C shall be no less than 90% discharge capacity at the room temperature; and the discharge capacity at 40??C shall be no less than 95% discharge capacity at room temperature. 5.4.2 Power performance
The combined power source system or main power source is tested in accordance with 6.5.2; and its maximum pulse charge and discharge rate for 10s at room temperature shall be no less than 20C; and the charge and discharge power density for 10s at room temperature shall be no less than 1kW/kg.
5.4.3 No load capacity loss
The combined power source system or main power supply is tested in accordance with 6.5.3; and the no load capacity loss shall be no lower than the requirements in Table 6.1.1 General conditions
6.1.1.1 Unless otherwise required, the test shall be carried out under the following environmental conditions:
a) Ambient temperature: 22??C??5??C;
b) Relative humidity: 10%~90%;
c) Atmospheric pressure: 86kPa~106kPa.
6.1.1.2 The room temperature mentioned in this Document refers to 25??C ?? 2??C. 6.1.1.3 When the combined power source system is delivered, it is required to attach the necessary operating documents and the interface components (such as connectors, plugs) connected to the test equipment. The manufacturer needs to provide the safe operating limits (such as voltage, current, temperature) of the combined power source system.
6.1.1.4 When the target environmental temperature of the test changes, the test object needs to complete the environmental adaptation process before the test: stand still at low temperature for no less than 24h; stand still at high temperature for no less than 16h. If the test sample contains a hybrid power system control unit, it needs to be shut down during the environmental adaptation process.
6.1.1.5 The method of adjusting the SOC to the test target value m%: Fully charge the main power source according to the charging method provided by the manufacturer; stand for 1h; and discharge at a constant current of 1C for (100-m)/100 h. After each SOC adjustment, the test subjects need to stand for 30 min before the new test starts. 6.1.1.6 The discharge rate during the test shall be implemented in accordance with the provisions of this Document; and the charging mechanism and discharge cut-off conditions shall be provided by the manufacturer.
6.1.1.7 If the absolute value of the difference between the actual available capacity and the rated capacity of the main power source exceeds 5% of the rated capacity, it shall be clearly stated in the test report; and the actual available capacity shall be used instead of the rated capacity as the basis for the calculation of charge and discharge current and SOC.
6.1.1.8 The sign of the discharge current of the main power supply is positive, and the sign of the charging current is negative.
6.1.2 Test instrument and meter accuracy
6.1.2.1 The accuracy of test instruments and meters shall be no lower than the following requirements:
a) Voltage measuring device: ??0.5% FS;
b) Current measuring device: ??0.5% FS;
c) Temperature measuring device: ??0.5??C;
d) Time measuring device: ??0.1% FS;
e) Dimension measuring device: ??0.1% FS;
f) Mass measuring device: ??0.1% FS.
6.1.2.2 During the test, the control accuracy of the charging and discharging device, temperature control box and other control instruments shall be no lower than the following requirements:
a) Voltage: ??1%;
b) Current: ??1%;
c) Temperature: ??2??C.
6.2 Data recording
Unless otherwise required, the recording interval of test data (such as time, temperature, current and voltage, etc.) shall be no greater than 100s.
6.3 Test preparation
6.3.1 The low-voltage interface, charge-discharge interface, cooling device, and battery management system of the combined power source system shall be connected to the test platform equipment; and the active and passive protection of the combined power source system shall be turned on. Normal communication is realized between the test platform and the battery management system. The test platform ensures that the test parameters and conditions are consistent with the requirements of the test procedures; and that the battery system works within reasonable limits. These limits are transmitted by the battery management system to the test platform via the bus. The program of the battery management system can be changed by the manufacturer of the combined power source system according to the test procedure when necessary. Active protection also needs to be guaranteed by the test platform, which can be realized by disconnecting the main contactor of the combined power source system when necessary.
6.3.2 During the test of the combined power source system, the combined power source system communicates with the test platform through the bus; and transmits the state parameters and operating limits of the combined power source system to the test platform in real time; and the test platform controls the test procedures according to 3 - test sample;
4 - pressure sensor;
5 - thermocouple;
6 - trigger device;
7 - DC power source.
Figure B.1 ?€? Schematic Diagram of Test Platform
B.3.2 Trigger exhaust
B.3.2.1 When the heating method is used to trigger the exhaust of a single cell, the test can be carried out in accordance with the provisions of C.5.3 in GB 38031-2020. B.3.2.2 When the overcharge method is used to trigger the exhaust of a single cell, the battery must be charged to 200% SOC at a constant current specified by the manufacturer and not less than 1C or after reaching the exhaust voltage threshold of the cell specified by the manufacturer, then stop charging.
B.3.3 Gas collection
B.3.3.1 When the gas temperature in the gas collection device returns to the ambient temperature and the pressure reaches a steady state (the temperature reduction rate is less than 5??C/h, and lasts for more than 2h), calculate the gas production: a) Calculate the amount of initial gas substance in the gas collection device before the test according to Formula (B.1):
Where:
n1 ?€? the amount of initial gas substance in the gas collection device, in mol; p1 ?€? initial pressure in the gas collection device, in Pa;
V ?€? volume of the gas collection device, in L;
R ?€? ideal gas constant, the value of which is 8.314, in [J/(mol ?€? K)];
T1 ?€? initial ambient temperature, in K.
b) Calculate the amount of gas substance after exhaust according to Formulas (B.2) and (B.3):

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