GB/T 44500-2024 English PDF (GB/T44500-2024)

GB/T 44500-2024: Code of practice for new energy vehicles safety operation inspection
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GB/T 44500-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.180
CCS R 80
Code of practice for new energy vehicles safety operation
inspection
ISSUED ON: AUGUST 23, 2024
IMPLEMENTED ON: MARCH 01, 2025
Issued by: State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword ... 3
Introduction ... 4
1 Scope ... 5
2 Normative references ... 5
3 Terms, definitions, abbreviations ... 6
3.1 Terms and definitions ... 6
3.2 Abbreviations ... 6
4 Inspection procedure ... 6
5 Inspection items ... 7
6 Inspection requirements ... 8
6.1 Basic requirements for inspected vehicles ... 8
6.2 Inspection environment ... 8
6.3 Inspection equipment ... 8
6.4 Inspection method ... 10
6.5 Test results ... 17
Appendix A (Normative) Communication protocol for diagnostic terminal to collect
inspection data ... 18
Appendix B (Informative) Reference thresholds for new energy vehicle operation safety
test items ... 26
Appendix C (Informative) New energy vehicle operation safety inspection report
(sample) ... 27
References ... 28
Code of practice for new energy vehicles safety operation
inspection
Important tips: Users of this document shall wear insulating shoes and insulating
gloves when inspecting electrical safety-related items to protect personnel safety.
1 Scope
This document specifies the inspection procedures, inspection items, inspection
requirements for the operation safety inspection of new energy vehicles.
This document is applicable to the operation safety inspection of pure electric vehicles
and plug-in hybrid (including extended-range) vehicles in use; other types of new
energy vehicles in use can use it as a reference.
2 Normative references
The contents of the following documents constitute the essential terms of this document
through normative references in the text. Among them, for referenced documents with
dates, only the version corresponding to that date applies to this document; for
referenced documents without dates, the latest version (including all amendments)
applies to this document.
GB 3847 Limits and measurement methods for emissions from diesel vehicles under
free acceleration and lugdown cycle
GB/T 18487.1 Electric vehicle conductive charging system - Part 1: General
requirements
GB/T 19596 Terminology of electric vehicles
GB/T 27930 Digital communication protocols between off-board conductive
charger and electric vehicle
GB/T 32960.3 Technical specifications of remote service and management system
for electric vehicles - Part 3: Communication protocol and data format
GB/T 34014 Coding regulation for automotive traction battery
GB/T 40822 Road vehicles - Unified diagnostic services
ISO 27145⁃2 Road vehicles - Implementation of World-Wide Harmonized On-
Board Diagnostics (WWH-OBD) communication requirements - Part 2: Common
data dictionary
ISO 27145-4 Road vehicles - Implementation of World-Wide Harmonized On-
Board Diagnostics (WWH-OBD) communication requirements - Part 4: Connection
between vehicle and test equipment
3 Terms, definitions, abbreviations
3.1 Terms and definitions
The terms and definitions defined in GB/T 19596, as well as the following terms and
definitions, apply to this document.
3.1.1
New energy vehicles safety operation inspection
Inspection of the technical performance of components/devices related to operation
safety such as power batteries, drive motors, electronic control systems, electrical
safety of new energy vehicles.
3.2 Abbreviations
The following abbreviations apply to this document.
DID: Data Identifier
SOC: State⁃Of⁃Charge
UDSonCAN: Unified Diagnostic Services on Controller Area Network
UDSonIP: Unified Diagnostic Services on Internet Protocol
4 Inspection procedure
4.1 The operation safety inspection of new energy vehicles should be carried out in
combination with the data monitoring and analysis results transmitted in GB/T 32960.3
(hereinafter referred to as "online monitoring and analysis results").
4.2 The operation safety inspection process of new energy vehicles is shown in Figure
1. During the inspection process, if the vehicle has alarm signals related to power
batteries, drive motors, electronic control systems, electrical safety, the inspection shall
be stopped.
6.3.2.1 Charging safety test equipment
Charging safety test equipment shall meet the following requirements:
a) The charging interface shall comply with the relevant provisions of GB/T 18487.1;
b) The communication transmission protocol shall comply with the relevant
provisions of GB/T 27930;
c) The maximum DC charging power shall be greater than or equal to 60 kW;
d) It shall have the function of automatically recording and transmitting the test
process data.
6.3.2.2 Automobile chassis dynamometer
6.3.2.2.1 The drum and power absorption unit of the automobile chassis dynamometer
shall comply with the requirements of GB 3847.
6.3.2.2.2 The chassis dynamometer used for testing small and micro passenger cars
shall also meet the following requirements:
a) It shall consist of two platforms with adjustable spacing; the spacing adjustment
range shall be greater than or equal to 1 m;
b) The front and rear platform roller speeds shall be synchronized; the roller surface
linear speed synchronization error shall be less than or equal to 2 km/h.
6.3.2.3 Diagnostic terminal
The diagnostic terminal shall meet the following requirements:
a) It shall be able to read the operating data of the vehicle power battery, drive motor,
electronic control system, and other information, as well as fault data, through the
vehicle service end interface;
b) The communication protocol for the diagnostic terminal to collect inspection data
shall comply with the requirements of Appendix A.
Note: The vehicle service end interface refers to the interface on the vehicle used to collect
inspection data and diagnose vehicle faults.
6.3.2.4 Electrical safety test equipment
6.3.2.4.1 Megaohmmeter
The megohmmeter shall meet the following requirements:
a) The range is greater than or equal to 100 MΩ;
b) Indication error: ±3%;
c) Resolution is less than or equal to 0.1 MΩ.
6.3.2.4.2 Milliohmmeter
The milliohmmeter shall meet the following requirements:
a) The measuring current is adjustable; the measuring current is greater than or equal
to 0.2 A;
b) Indication error: ±3%;
c) Resolution is less than or equal to 0.01 Ω.
6.3.2.4.3 Electrical safety automatic test equipment
The electrical safety automatic test equipment shall meet the following requirements:
a) Meet the provisions of 6.3.2.4.1 and 6.3.2.4.2;
b) Have the function of automatic recording and transmission of test data.
6.4 Inspection method
6.4.1 Power battery safety
6.4.1.1 Charging
When inspecting the safety (charging) of power batteries:
a) According to the instructions for use of the instrument and equipment, connect the
DC charging plug of the charging safety inspection equipment and the DC
charging socket of the vehicle to charge the vehicle; the continuous charging time
shall not be less than 180 s;
b) During the charging stage, collect the maximum temperature of the power battery
and the maximum voltage of the single battery. The time interval between the
collection points shall not exceed 250 ms; record the maximum temperature and
maximum voltage during the charging process;
c) At the end of charging, collect the maximum voltage of the single battery and the
minimum voltage of the single battery. The time interval between the collection
points shall not exceed 250 ms; calculate the voltage range of the single battery
(the difference between the maximum voltage of the single battery and the
minimum voltage of the single battery).
end interface and other methods. The highest temperature and the lowest voltage
of the single battery during the test are recorded.
d) During the test, if the loading force or vehicle speed exceeds the allowable range
for 8 consecutive s or 20 s cumulatively, the test shall be repeated.
6.4.2 Drive motor safety and electronic control system safety
During the power battery safety (discharge) inspection:
a) Use the diagnostic terminal to read the drive motor temperature and motor
controller temperature; record the maximum drive motor temperature and motor
controller temperature during the test;
b) Use the diagnostic terminal to read the vehicle DC/DC converter temperature and
record the maximum DC/DC converter temperature during the test.
6.4.3 Electrical safety
6.4.3.1 Charging socket insulation resistance
6.4.3.1.1 The insulation resistance of the charging socket can be measured manually or
automatically.
6.4.3.1.2 The manual measurement method of the charging socket insulation resistance
is as follows.
a) Turn off the power of the vehicle and make all power and electronic switches on
the vehicle inactive.
b) For the DC charging socket, connect the two probes of the megohmmeter to the
positive and negative terminals of the DC charging socket (as shown in DC+ and
DC- in Figure 2) and the PE terminal, respectively. The detection voltage set by
the megohmmeter shall be greater than the maximum charging voltage until the
reading is stable (3 s ~ 5 s). Manually read the insulation resistance between the
DC+ terminal and the PE terminal, the insulation resistance between the DC-
terminal and the PE terminal; calculate the insulation resistance of the DC
charging socket according to formula (3).
Where:
Ri - DC charging socket insulation resistance, in ohms per volt (Ω/V);
R1 - Insulation resistance between DC+ and PE, in ohms (Ω);
6.4.3.1.3 The automatic measurement method of the insulation resistance of the
charging socket is as follows:
a) Turn off the power of the vehicle and make all power and electronic switches on
the vehicle in an inactive state;
b) Connect the DC charging detection probe of the electrical safety automatic test
equipment to the DC charging socket of the vehicle; start the electrical safety
automatic test equipment; the detection voltage set by the electrical safety
automatic test equipment shall be greater than the maximum charging voltage of
the vehicle until the indication is stable (3 s ~ 5 s); display and record the
insulation resistance Ri of the DC charging socket;
c) Connect the AC charging detection probe of the electrical safety automatic test
equipment to the AC charging socket of the vehicle; start the electrical safety
automatic test equipment; the detection voltage set by the electrical safety
automatic test equipment shall be greater than the maximum charging voltage of
the vehicle until the indication is stable (3 s ~ 5 s); display and record the
insulation resistance Rj of the AC charging socket;
d) The insulation resistance of the DC charging socket and the insulation resistance
of the AC charging socket can be measured simultaneously.
6.4.3.2 Potential equalization
6.4.3.2.1 Potential equalization measurement can be carried out by manual
measurement or automatic measurement.
6.4.3.2.2 The manual measurement method for potential equalization is as follows:
a) Turn off the power of the vehicle; make all electrical and electronic switches on
the vehicle in an inactive state;
b) When measuring potential equalization (conductive parts and electrical platform),
connect the two probes of the milliohmmeter to the PE terminal of the AC
charging socket (or DC charging socket) and the conductive part of the vehicle
frame or the conductive parts connected to it (such as door frames, door locks,
etc.); increase the test current to at least 0.2 A; read the measurement results, as
shown in Figure 4;
c) When measuring potential equalization (between conductive parts), connect the
two probes of the milliohmmeter to the PE terminal of the DC charging socket
and the PE terminal of the AC charging socket (for vehicles with only two DC
charging sockets, the DC charging socket); increase the test current to at least 0.2
A; read the measurement results, as shown in Figure 5.
GB/T 44500-2024
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.180
CCS R 80
Code of practice for new energy vehicles safety operation
inspection
ISSUED ON: AUGUST 23, 2024
IMPLEMENTED ON: MARCH 01, 2025
Issued by: State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword ... 3
Introduction ... 4
1 Scope ... 5
2 Normative references ... 5
3 Terms, definitions, abbreviations ... 6
3.1 Terms and definitions ... 6
3.2 Abbreviations ... 6
4 Inspection procedure ... 6
5 Inspection items ... 7
6 Inspection requirements ... 8
6.1 Basic requirements for inspected vehicles ... 8
6.2 Inspection environment ... 8
6.3 Inspection equipment ... 8
6.4 Inspection method ... 10
6.5 Test results ... 17
Appendix A (Normative) Communication protocol for diagnostic terminal to collect
inspection data ... 18
Appendix B (Informative) Reference thresholds for new energy vehicle operation safety
test items ... 26
Appendix C (Informative) New energy vehicle operation safety inspection report
(sample) ... 27
References ... 28
Code of practice for new energy vehicles safety operation
inspection
Important tips: Users of this document shall wear insulating shoes and insulating
gloves when inspecting electrical safety-related items to protect personnel safety.
1 Scope
This document specifies the inspection procedures, inspection items, inspection
requirements for the operation safety inspection of new energy vehicles.
This document is applicable to the operation safety inspection of pure electric vehicles
and plug-in hybrid (including extended-range) vehicles in use; other types of new
energy vehicles in use can use it as a reference.
2 Normative references
The contents of the following docume...