QC/T 1152-2021 PDF in English
QC/T 1152-2021 (QC/T1152-2021, QCT 1152-2021, QCT1152-2021)
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Specification of DC/DC converter for electric motorcycles and electric mopeds
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QC/T 1152-2021: PDF in English (QCT 1152-2021) QC/T 1152-2021
QC
AUTOMOBILE INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 43.140
CCS T 85
Specification of DC/DC converter for electric motorcycles
and electric mopeds
ISSUED ON: AUGUST 21, 2021
IMPLEMENTED ON: FEBRUARY 01, 2022
Issued by: Ministry of Industry and Information Technology of PRC
Specification of DC/DC converter for electric motorcycles
and electric mopeds
1 Scope
This document specifies the product model compilation, requirements, test methods,
markings of DC/DC converter for electric motorcycles and electric mopeds.
This document applies to DC/DC converters for electric motorcycles and electric
mopeds.
2 Normative references
The contents of the following documents constitute essential provisions of this
document through normative references in the text. Among them, for dated references,
only the version corresponding to the date applies to this document; for undated
references, the latest version (including all amendments) is applicable to this document.
GB/T 2423.1 Environmental testing - Part 2: Test methods - Tests A: Cold
GB/T 2423.2 Environmental testing - Part 2: Test methods - Tests B: Dry heat
GB/T 2423.5 Environmental testing - Part 2: Test methods - Test Ea and guidance:
Shock
GB/T 2423.17 Environmental testing for electric and electronic products - Part 2:
Test method - Test Ka: Salt mist
GB/T 2423.34-2012 Environmental testing - Part 2: Test methods - Test Z/AD:
Composite temperature/humidity cyclic test
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB 34660 Road vehicles - Requirements and test methods of electromagnetic
compatibility
QC/T 680-2014 General technical specifications for voltage regulators for
motorcycles and mopeds
QC/T 792-2007 Motors and controllers for electric motorcycles and electric mopeds
3.6
Rated power
Under the specified environmental conditions, rated voltage, continuous operation,
the maximum power at which the DC/DC converter can work continuously, after
reaching thermal stabilization under the temperature rise limit.
3.7
Peak power
The maximum power that the DC/DC converter can work continuously, under the
specified environmental conditions and within the specified time.
3.8
Thermal equilibrium
The state under which the temperature rise of the heating part of the DC/DC
converter casing does not change by more than 1 K within 0.5 h.
Note: Thermal equilibrium can be defined by a time-temperature rise diagram, that is, the
connecting line -- between the start and end points of adjacent intervals of 0.5 h has a
gradient of 1 K or less than 1 K every 0.5 h, OR a gradient of 2 K or less than 2 K every 1
h.
3.9
Ripple factor
Ratio -- of half the difference between the peak value and the valley value of the
pulsating DC power TO the absolute value of the DC component.
3.10
Dynamic response time
The time it takes for the system to change from a stable working state to another
stable working state, after being stimulated.
4 Compilation of product model
4.1 General
The model of the DC/DC converter shall be composed of two parts: product name code
and performance parameter code.
The model nomenclature of the DC/DC converter is as shown in Figure 1:
Figure 1 -- Schematic diagram of model nomenclature
4.2 Product name code
DC/DC converter product name code is ZB; if necessary, an extended name code can
be added, after the basic name code; the two are separated by the symbol "-". The
extended name code is:
G - Isolated type.
4.3 Performance parameter code
4.3.1 The performance parameter code includes four parts: rated power code, nominal
input voltage code, rated output voltage code, one-way and two-way code. The voltage
unit indicated in the model name is V; the power unit is W.
4.3.2 The rated power, nominal input voltage, rated output voltage in the performance
parameter code are all integer digits, of which the nominal input voltage and rated
output voltage are 3 integer digits, the rated power is 4 integer digits; 0 is added in front,
if its digit is insufficient.
4.3.3 For DC/DC converters with multiple outputs, all rated output voltage values shall
be marked and separated by "/".
4.3.4 For two-way DC/DC converters, all nominal input voltage values and rated output
voltage values shall be identified and separated by "/".
4.4 Example of product model
Examples of product models are as follows:
Example 1: ZB 0120-072-012 A: Indicates a one-way non-isolated DC-DC converter,
which has a rated power of 120 W, a nominal input voltage of 72 V, a rated output
voltage of 12 V.
Example 2: ZB-G 1000-072-012/005 B: Indicates two-way isolated DC-DC converter,
which has a rated power of 1000 W, a nominal input voltage of 72 V, a rated output
voltage of 12 V/5 V, two-way, isolated.
The two letters A and B represent one-way and two-way respectively
Three Arabic numerals indicate rated output voltage
Three Arabic numerals indicate nominal input voltage
Four Arabic numerals indicate rated power
ZB-G stands for isolated DC/DC converter
5.4 Environmental adaptability
5.4.1 Low temperature
After the DC/DC converter is tested, according to the provisions of 6.5.1, under the
environment of -25 °C ± 1 °C, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.2 High temperature
After the DC/DC converter is tested according to the provisions of 6.5.2, under the
environment of 60 °C ± 1 °C, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.3 Combined temperature/humidity cycle
After the DC/DC converter is subjected to 2 cycles of combined temperature/humidity
cycle test as specified in 6.5.3, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3,
appearance rust shall not affect normal work.
5.4.4 Salt spray
The DC/DC converter shall be subjected to the salt spray test as specified in 6.5.4. After
the test is completed and allowed to stand, the electrical performance shall meet the
requirements of 5.3.2 and 5.3.3.
5.4.5 Vibration
The DC/DC converter shall be subjected to the vibration test, in accordance with the
provisions of 6.5.5. The parts shall not be loose or damaged during the test. After the
test, the electrical properties shall meet the requirements of 5.3.2 and 5.3.3.
5.4.6 Shock
The DC/DC converter shall be subjected to the shock test, in accordance with the
provisions of 6.5.6. The parts shall not be loose or damaged during the test. After the
test, the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.7 Degree of protection
The product's degree of protection of the DC/DC converter shall meet the requirements
of IP55 in GB/T 4208.
5.5 Protection function
5.5.1 Output current limit protection
The DC/DC converter shall have the output current limiting protection function. When
the output load increases to the current limiting state, which is specified in the technical
documents of the enterprise, the converter shall be able to enter the protection state. The
output current shall be limited to the current limiting value range, which is specified in
the technical documents of the enterprise, AND no longer increase.
5.5.2 Input undervoltage protection
The DC/DC converter shall have the function of input under-voltage protection. When
the input voltage is lower than the under-voltage protection value, which is specified in
the technical documents of the enterprise, the converter shall be able to enter the
protection state and no longer output. When the input voltage recovers from the under-
voltage protection value to within the normal operating voltage range, which is
specified in the enterprise's technical documents, the converter shall be able to
automatically resume normal operation OR resume normal operation after restarting.
5.5.3 Output short circuit protection
The DC/DC converter shall have output short-circuit protection function. When the
output is short-circuited, the converter shall stop the output immediately. After the fault
is removed, the converter shall be able to automatically resume normal operation OR
resume normal operation after restarting.
5.6 Enable control
For DC/DC converters, which are equipped with an enable switch, when the nominal
input voltage is provided at the input, if turning on the enable switch, the converter shall
start working; if turning off the enable switch, the converter shall enter the standby or
off state.
5.7 Electromagnetic compatibility
The electromagnetic radiation emission limit of DC/DC converter shall meet the
requirements for electrical/electronic components (ESA) in GB 34660.
The DC/DC converter is subjected to the electromagnetic radiation immunity test,
according to the provisions of GB 34660, for the electrical/electronic components
(ESA). The deviation of the rated output voltage before the test, during the test and after
the test shall not exceed ±10%.
5.8 Service life
Carry out the test according to the method of 6.9. The fault-free working time of the
DC/DC converter shall not be less than 1000 h.
During the test, when the DC/DC converter is not working, the terminals of the same
independent circuit in the DC/DC converter shall be short-circuited. Use a voltage
withstanding tester, to apply the following test voltage, between the terminals of each
independent live circuit of the DC/DC converter and (ground) enclosure, as well as
between the input circuit and the output circuit of the isolated DC/DC converter, for a
duration of 1 min. Record the leakage current during the test.
a) The frequency of the alternating current is 50 Hz ~ 60 Hz; the waveform is an
actual sine wave;
b) The capacity of the test equipment is not less than 0.5 kV·A;
c) The test voltage (effective value), for the highest working voltage below 48 V
(including 48 V), is 500 V; the test voltage (effective value) of other DC/DC
converters is 1000 V.
When mass-produced DC/DC converters are subjected to the dielectric strength test,
the test voltage is allowed to be 120% of the above specified value; the test time is
correspondingly shortened to 1 s.
6.4 Electrical performance
6.4.1 Rated power
Make the input voltage of the DC/DC converter equal to the nominal input voltage
value on the nameplate. Adjust the load output current, to make it equal to the rated
output current. Observe whether the output voltage is within the rated output voltage
range. Calculate whether the product of the output voltage multiplying the output
current reaches the rated power. After the DC/DC converter continues to operate until
the enclosure reaches a thermally stable state, the DC/DC converter continues to operate
for no less than 2 h. Then read the output power value.
6.4.2 Input voltage change test
The DC/DC converter outputs rated power within the input voltage range, which is
specified by the enterprise. Adjust the input voltage, to gradually increase it to the upper
limit of the input voltage, which is specified in the technical documents of the enterprise.
Observe whether the output voltage meets the rated output voltage, which is specified
in the technical documents of the enterprise.
The DC/DC converter outputs rated power within the input voltage range, which is
specified by the enterprise. Adjust the input voltage, to gradually reduce it to the lower
limit of the input voltage, which is specified in the technical documents of the enterprise.
Observe whether the output voltage meets the rated output voltage, which is specified
in the technical documents of the enterprise.
6.4.3 No-load test
The low temperature test of the DC/DC converter is carried out, according to the
relevant requirements of GB/T 2423.1. When the ambient temperature reaches the range
of -25 °C ± 1 °C, the DC/DC converter is kept at this temperature for 2 hours. After
that, the DC/DC converter shall be able to start normally AND continue to run for 2
hours, at the rated output power. After the test, carry out insulation resistance test, input
voltage change test, no-load test, according to the methods specified in 6.3.1, 6.4.2,
6.4.3.
6.5.2 High temperature
The high-temperature test of the DC/DC converter is carried out, according to the
relevant requirements of GB/T 2423.2. When the ambient temperature reaches the range
of 60 °C ± 1 °C, the DC/DC converter is kept at this temperature, for 2 hours. After that,
the DC/DC converter continues to run for 2 hours, at the rated output power. After the
test, carry out insulation resistance test, input voltage change test, no-load test,
according to the methods specified in 6.3.1, 6.4.2, 6.4.3.
6.5.3 Combined temperature/humidity cycle
The DC/DC converter is subjected to 2 cycles of combined temperature/humidity cycle
test, in the range of -10 °C ~ 65 °C, according to the provisions of Figure 2 in GB/T
2423.34-2012; the time of each cycle shall be 24 h. After the test, carry out insulation
resistance test, input voltage change test, no-load test, according to the methods
specified in 6.3.1, 6.4.2, 6.4.3.
6.5.4 Salt spray
The salt spray test shall be carried out, in accordance with the relevant provisions in
GB/T 2423.17. The DC/DC converter shall be in the normal installed state. The test
duration is 16 h. At the end of the test, after the DC/DC converter has been restored for
2 hours, carry out the input voltage change test and no-load test, according to the
methods specified in 6.4.2 and 6.4.3.
6.5.5 Vibration
Fix the DC/DC converter on the vibration test bench, in the normal installation position.
At the same time, install and fix the cables and other accessories, which are connected
to the DC/DC converter. Conduct the test, according to the provisions of 4.4 in QC/T
680-2014. During the test, the DC/DC converter is in a non-working state.
After the test, carry out the input voltage change test and no-load test, according to the
methods specified in 6.4.2 and 6.4.3.
6.5.6 Shock
Fix the DC/DC converter on the test bench. Carry out the test, according to the method
specified in GB/T 2423.5. The peak acceleration, pulse duration, waveform, number of
shocks are as specified in Table 4 in QC/T 792-2007. During the test, the DC/DC
converter is in a non-working state.
After the test, carry out the input voltage change test and no-load test, according to the
methods specified in 6.4.2 and 6.4.3.
6.5.7 Degree of protection
Carry out test, according to the method of IP55 in GB/T 4208.
6.6 Protection function
6.6.1 Output current limit protection
Under the nominal input voltage of the DC/DC converter, use a DC load or similar
equipment, to gradually increase the output load of the DC/DC converter to the current
limit value, which is specified in the technical documents of enterprise. Observe
whether the output current of the converter is limited within the technical documents of
enterprise AND not increase within the specified current limit value range.
6.6.2 Input undervoltage protection
The DC/DC converter first works under the nominal input voltage. When the input
voltage of the DC/DC converter is gradually adjusted to the undervoltage protection
value, which is specified in the technical documents of the enterprise, by a DC power
supply or similar equipment, observe whether the converter enters the protection state
AND no longer output. Gradually adjust the input voltage, to recover from the
undervoltage protection value to the normal operating voltage range, which is specified
by the enterprise; observe the working state of the DC/DC converter.
6.6.3 Output short-circuit protection
Short-circuit the output terminal for no more than 5 s. Observe whether the DC/DC
converter stops output immediately. After the fault is removed, observe the working
state of the DC/DC converter.
6.7 Enable control
Provide the nominal input voltage, at the input of the DC/DC converter. Turn on the
enable switch. Observe the converter by the use of a digital meter/oscilloscope (or other
instruments which have the same function and accuracy level); the converter shall be
able to work at the rated output power and rated output voltage.
Provide the nominal input voltage, at the input of the DC/DC converter; close the enable
switch. Observe the converter by the use of a digital meter/oscilloscope (or other
instruments which have the same function and accuracy level); it shall stop working.
6.8 Electromagnetic compatibility
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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