QC/T 792-2022 PDF English
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| Standard ID | Contents [version] | USD | STEP2 | [PDF] delivery | Name of Chinese Standard | Status |
| QC/T 792-2022 | English | 305 |
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Motors and controllers for electric motorcycles and electric mopeds
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| QC/T 792-2007 | English | 160 |
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Motors and controllers for electric motorcycles and electric mopeds
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QC/T 792-2022: Motors and controllers for electric motorcycles and electric mopeds---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/QCT792-2022
QC
AUTOMOBILE INDUSTRY STANDARD
ICS 43.140
CCS T 85
Replacing QC/T 792-2007
Motors and controllers for electric motorcycles and electric
mopeds
Issued on. APRIL 08, 2022
Implemented on. OCTOBER 01, 2022
Issued by. Ministry of Industry and Information Technology of PRC
Table of Contents
Foreword... 6
1 Scope... 9
2 Normative references... 9
3 Terms and definitions... 10
4 Product model compilation... 12
5 Requirements... 14
6 Test method... 23
7 Inspection rules... 34
1 Scope
This document specifies the product model compilation, requirements, test methods,
inspection rules for motors (including motors including reducers) and controllers for
electric motorcycles and electric mopeds.
This document applies to the motors for electric motorcycles and electric mopeds
(hereinafter referred to as motors) and controllers.
2 Normative references
The contents of the following documents constitute the essential provisions of this
document through normative references in the text. Among them, for dated reference
documents, only the version corresponding to the H issue is applicable to this document;
for undated reference documents, the latest version (including all amendments) is
applicable to this document.
GB/T 755 Rotating electrical machines - Rating and performance
GB/T 1184-1996 Geometrical tolerancing - Geometrical tolerance for features
without individual tolerance indications
GB/T 2423.5-2019 Environmental testing - Part 2.Test methods - Test Ea and
guidance. Shock (IEC 60068-2-27.2008; IDT)
GB/T 2423.17-2008 Environmental testing for electric and electronic products - Part
2.Test method - Test Ka. Salt mist (IEC 60068-2-11.1981, IDT)
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB/T 4942-2021 Degrees of protection provided by the integral design of rotating
electrical machines (IP code) - Classification
GB/T 5171.21-2016 Small power motors - Part 21.General test methods
GB/T 10069.1-2006 Measurement of airborne noise emitted by rotating electrical
machines and the noise limits - Part 1.Method for the measurement of airborne
noise emitted by rotating electrical machines (ISO 1680.1999, MOD)
GB/T 10069.3-2008 Measurement of airborne noise emitted by rotating electrical
machines and the noise limits - Part 3.Noise limits
GB/T 13202-2015 Series of motorcycle rims (ISO 4249-3.2010, ISO 5995-2.1988,
ISO 6054-2.1990, MOD)
GB/T 18387 Limits and test method of magnetic and electric field strength from
electric vehicles
3 Terms and definitions
The following terms and definitions apply to this document.
3.1
Wheel with the outer shell of motor integrated
The motorcycle driving wheel, whose wheel hub and motor casing are made into an
integral part.
3.2
Continuous torque
The specified maximum torque that can work continuously for 30 minutes.
3.3
Continuous power
The specified maximum power that can work continuously for 30 minutes.
3.4
Rated speed
The motor speed at which the specified continuous power is output.
3.5
Peak torque
The maximum torque, that can be used for short periods of time.
3.6
Peak power
The maximum power, that can be used for short periods of time.
4 Product model compilation
4.1 Motor model
The model of the motor shall consist of four parts. Frame number, product name code,
performance parameter code, derivative code.
Marking example.
4.1.1 Frame No.
The frame number of the wheel with the outer shell of motor integrated is the nominal
diameter code of the wheel hub, which is specified in GB/T 13202-2015.The frame
number of the outer rotor's wheel without the outer shell of motor integrated. The frame
number of the inner rotor's motor is the outer diameter of the stator core of the motor
(in millimeters).
4.2 Controller model
The model of the controller consists of 4 parts. Product name code, voltage level,
current level code, derivative code.
Marking example.
4.2.1 Product name code
The controller's product name code is.
4.2.2 Voltage level
The controller adopts DC voltage input. The voltage level is indicated by the nominal
voltage value of the DC bus of the controller. If it is less than three digits, add a 0 in
front.
4.2.3 Current level code
The current level of the controller is indicated by the integer value (three Arabic
numerals) of the maximum DC input current of the controller. If there are less than three
digits, add a 0 in front.
5 Requirements
5.1 General requirements
The motor shall be idling flexibly, without fixed-rotor friction or abnormal noises (such
as periodic abnormal noises, abnormal noises caused by damaged bearings, or abnormal
noises caused by foreign objects stuck in the rotating parts, etc.).
5.2 Environmental conditions for use
The motor and controller shall be able to work normally under the following conditions.
5.3 Rated voltage
5.4 Appearance
The surface of the motor and controller shall be free of rust, bruises, cracks, peeling of
the coating. The fasteners shall be firmly connected. The lead wires shall be intact. The
contents of nameplate of the motor and controller shall be correct; the words shall be
clear; the background color shall not fade.
5.5 External dimensions and installation dimensions
The external dimensions and installation dimensions of the motor and controller shall
comply with the provisions of the technical documents of the enterprise.
5.6 Assembly requirements
5.7 Sealing performance of cooling circuit in liquid cooling system
For liquid-cooled motors and controllers, there shall be no leakage, when subjected to
a pressure not lower than 200 kPa.
5.8 Lead wires and connectors
5.13 Phase deviation of position sensor
The phase deviation of the motor position sensor shall be within the range, which is
stipulated in the technical documents of the enterprise.
5.14 Direction of rotation of the motor rotor
The direction of rotation of the motor rotor shall comply with the provisions of the
product technical documentation.
5.15 No-load current
The motor runs at the rated voltage and at the speed specified in the technical documents
of the enterprise, for 5 minutes without load. The bus current shall not be greater than
the limit value, which is specified in the technical documents of the enterprise.
5.16 Motor performance parameters and efficiency
5.17 Speed control accuracy, torque control accuracy
For the motor system, which has speed control function and torque control function, the
control accuracy of speed and torque shall meet the requirements of product technical
documents.
5.22 Controller efficiency
The maximum efficiency of the controller, under rated voltage and rated input current
conditions, shall not be less than 95%.
5.24 Controller's adjustment function
The controller for open-loop control shall have the function of motor terminal voltage
regulation. The controller, whose outer loop is speed closed-loop control, shall have the
function of speed regulation. The controller, whose outer loop is torque closed-loop
control, shall have the function of torque regulation.
5.30 Motor and controller mass
The mass of the motor and the controller shall be within the scope, which is stipulated
in the technical documents of the enterprise.
5.31 Temperature rise
The working temperature rise of the armature winding of the motor shall comply with
the temperature rise limit, which is specified in GB/T 755.
5.32 Low temperature
After placed in cold power-off state at the ambient temperature range of -25 ��C �� 1 ��C
for 2 hours, the insulation resistance of the motor and controller shall meet the low
temperature requirements, which are specified in Clause 5.9.The motor and controller
shall be able to start in cold state without load. The performance of the motor and
controller, after standing still to room temperature, shall meet the requirements of 5.16.2.
6 Test method
6.1 General conditions of the test
6.2 Appearance
visual inspection.
6.3 External dimensions and installation dimensions
It is detected by general gauge.
6.4 Assembly requirements
6.5 Sealing performance of cooling circuit of liquid cooling system
Fill the cooling circuit with cooling medium. Make the cooling medium fill the cooling
circuit. Empty the air in the cooling circuit. Block one end of the cooling circuit of the
sample under test. No deformation affecting the sealing performance can occur. Then
gradually increase the pressure to the value specified in 5.7.
6.6 Lead wires and connectors
6.7 Insulation resistance
Use a megohmmeter, for measurement.
6.8 Withstanding voltage
Use a withstanding voltage tester, to perform withstanding voltage test.
6.9 Stator resistance
Use a DC bridge or other instruments, that meet the accuracy requirements, to measure
the resistance of the stator windings of each phase of the motor.
6.10 Stator inductance
Use an inductance bridge, to measure inductance of the stator windings of each phase
of the motor, at a frequency of 1000 Hz.
6.11 Phase deviation of position sensor
Use an oscilloscope to simultaneously measure the phase deviation of the back EMF of
the motor and the signal of the corresponding position sensor. The phase deviation shall
be within the range, which is specified in the technical documents of the enterprise.
6.12 Direction of rotation
Correctly connect the motor and controller. Visually observe the rotation direction of
the motor, after power on.
6.13 Motor no-load current
After the motor runs at rated voltage for 5 minutes without load, measure the bus current
of the controller, which is the no-load current of the motor.
6.14 Motor performance parameters and efficiency
6.17 Motor overspeed
Fix the motor on the test bench. Use the motor method (motor no-load method) or
external power equipment dragging method, to make the motor run at 1.2 times the
maximum operating speed for 2 minutes without load; there shall be no abnormal sound
during the test. After the test, carefully inspect the rotating parts of the drive motor for
damage or unwanted deformation, or loose fasteners.
6.19 Rated input current of controller
Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply
the rated voltage to the controller. Adjust the adjustment command, to make the motor
run at the rated speed without load. After the operation is stable, the steering torque
tester gradually increases the motor torque, until the input current of the DC bus of the
controller reaches the rated input current of the controller, which is specified in the
technical documents of the enterprise, for a duration of 2 hours. Visually inspect the
controller for normal operation.
6.20 Controller efficiency
Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply
the rated voltage to the controller. Adjust the adjustment command, to make the motor
run at the rated speed without load. After the operation is stable, the steering torque
tester gradually increases the motor torque, until the input current of the DC bus of the
controller reaches the rated input current of the controller, which is specified in the
technical documents of the enterprise.
6.21 Short-term overload of controller
Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply
the rated voltage to the controller. Adjust the adjustment command, to make the motor
run without load in the speed range, which is corresponding to the peak torque. After
the operation is stable, the steering torque tester gradually increases the motor torque,
until it reaches the peak torque, which is specified in the technical documents of the
enterprise. The overload duration of the controller of the electric motorcycle's drive
motor is 60 s.
6.22 Main functions of controller
6.24 Temperature rise
Install the motor on the bracket. Place it at room temperature. After temperature balance,
measure the DC resistance of the armature winding. Record the room temperature at
that time. Then make the motor run stably, at rated speed and continuous power, for a
certain period of time, under rated voltage.
6.25 Low temperature
Install the motor and controller on the test stand. Without power, place them in the test
box. Gradually lower the box temperature to -25 ��C �� 1 ��C. Keep it for 2 h. Then
measure the insulation resistance of the motor and controller in the box. Check whether
the motor and controller can be started without load. Test the rated performance of the
motor and controller, after standing at room temperature.
6.26 High temperature
Install the motor and controller on the test stand. Put them into the test box. Make the
motor run under rated voltage without load. Gradually raise the temperature of the box
to 60 ��C �� 2 ��C. Keep it for 2 hours. Monitor the operation of the motor and controller.
After that, measure the insulation resistance of the motor and controller in the box. Test
the rated performance of the motor and controller, after they are allowed to stand at
room temperature.
6.27 Temperature cycle test
Install the motor and controller on the test stand. Without power, place them in the test
box. Control the temperature in the test box, according to the conditions in 5.34.
6.28 Constant damp heat
After the installation mating surfaces of the controller and the motor are coated with
anti-rust grease, put them in a test box (chamber) at 40 ��C �� 2 ��C and a relative humidity
of 90% ~ 95%. After 48 hours, measure the no-load current and insulation resistance.
Visually inspect the appearance of the motor and controller.
6.29 Electromagnetic compatibility
7 Inspection rules
7.1 Inspection classification
Inspection is divided into exit-factory inspection and type inspection.
See Table 4 for motor inspection items.
7.2 Exit-factory inspection
The motors and controllers shall be inspected by the mass inspection department of the
manufacturer one by one.
7.3 Type inspection
7.3.1 Type inspection requirements
Type inspection shall be carried out, under one of the following conditions.
7.3.2 Sampling rules
For type inspection, samples shall be selected from the products, that have passed the
exit-factory inspection. A total of 4 units are selected, 2 of which were used for type
inspection and 2 were reserved for re-inspection.
7.3.3 Judgment rules
In the type inspection, if one product fails one item, it is allowed to re-inspect the item
by double number of reserved samples.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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