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Delivery: <= 3 days. True-PDF full-copy in English will be manually translated and delivered via email. TCSAE143-2020: Test and assessment specifications for integrated electric drive system of battery electric passenger cars
Basic dataStandard ID: T/CSAE 143-2020 (T/CSAE143-2020)Description (Translated English): Test and assessment specifications for integrated electric drive system of battery electric passenger cars Sector / Industry: Chinese Industry Standard Classification of Chinese Standard: T40 Word Count Estimation: 21,267 Date of Issue: 2020-08-07 Issuing agency(ies): China Society of Automotive Engineers TCSAE143-2020: Test and assessment specifications for integrated electric drive system of battery electric passenger cars---This is a DRAFT version for illustration, not a final translation. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.) will be manually/carefully translated upon your order. T/CSAE 143-2020 Testandassessment specifications for integrated electric drive system of batteryelectric passenger cars ICS 43.040 T 35 Group standard Specification for evaluation of integrated electric drive assembly of pure electric passenger car Testandassessment specifications for integrated electric drive system of batteryelectric passenger cars Drafting guidelines for commercial grades standard of Chinese medicinal materials 2020-08-07 released 2020-08-07 Implementation Issued by Chinese Society of Automotive Engineers Table of contentsForeword...III 1 Scope...1 2 Normative references...1 3 Terms and definitions...1 4 Test conditions and requirements...2 4.1 Test environmental conditions...2 4.2 Instrumentation...2 4.3 Test equipment requirements...2 4.4 Test requirements...2 5 Test methods and technical requirements...3 5.1 General test...3 5.1.1 Appearance and quality...3 5.1.2 Tightness...3 5.1.3 Insulation resistance...4 5.1.4 Withstand voltage...4 5.1.5 Grounding resistance...4 5.2 Performance test...4 5.2.1 Dynamic sealing...4 5.2.2 Input and output characteristics...4 5.2.3 Differential reliability...7 5.2.4 Drag moment...8 5.3 Safety test...8 5.3.1 Temperature rise...8 5.3.2 Overspeed test...9 5.3.3 High voltage control module support capacitor discharge time...9 5.4 Environmental adaptability test...9 5.4.1 Temperature and humidity test...9 5.4.2 Mechanical load test...10 5.4.3 Chemical load test...10 5.4.4 Flowing mixed gas corrosion test...11 5.4.5 Salt spray test...11 5.4.6 IP protection level test...11 5.5 EMC test...11 5.5.1 Conducted emissions...11 5.5.2 Radiated emissions...12 5.5.3 Radiation immunity (anechoic chamber method, large current injection method)...12 5.5.4 Magnetic field immunity...12 5.5.5 Handheld transmitter immunity...12 5.5.6 Transient conduction immunity along the power line...12 5.5.7 Electrostatic discharge...13 5.5.8 Coupling electrical transient emission immunity...13 5.6 NVH test...13 5.7 Reliability test...13 5.7.1 Assembly endurance test...13 5.7.2 Pulsation reliability of cooling circuit...14 Specification for evaluation of integrated electric drive assembly of pure electric passenger car1 ScopeThis standard specifies the test conditions, test requirements, test methods, and judgment standards for the integrated electric drive assembly of pure electric passenger vehicles. This standard applies to the integrated electric drive assembly (hereinafter referred to as the assembly) of pure electric drive passenger car, namely the high-voltage control module, the drive motor module Combination of block, single-stage reducer module and/or differential module. Other integrated electric drive assemblies can be implemented as reference.2 Normative referencesThe following documents are indispensable for the application of this document. For dated reference documents, only the dated version applies to this article Pieces. For undated reference documents, the latest version (including all amendments) is applicable to this document. GB/T 2423.18-2012 Environmental test Part 2.Test method Test Kb. Salt spray, alternating (sodium chloride solution) GB/T 10592-2008 Technical conditions of high and low temperature test chamber GB/T 18386-2017 Electric vehicle energy consumption rate and driving range test method GB/T 18488.1 Drive motor system for electric vehicles Part 1.Technical conditions GB T 18488.2 Drive Motor System for Electric Vehicle Part 2.Test Method GB/T 18655-2018 Limits and measurement methods of radio disturbance characteristics of vehicles, ships and internal combustion engines used to protect on-board receivers GB/T 28046.4-2011 Environmental Conditions and Tests of Electrical and Electronic Equipment of Road Vehicles Part 4 Climatic Load GB/T 28046.3-2011 Environmental conditions and tests for electrical and electronic equipment of road vehicles-Part 3 Mechanical load GB/T 28046.5-2013 Environmental conditions and experiments of electrical and electronic equipment for road vehicles-Part 5 Chemical load GB/T 30038-2013 Road vehicle electrical and electronic equipment protection level (IP code) GB/T 36282-2018 Electromagnetic compatibility requirements and test methods for drive motor systems for electric vehicles QC/T 1022-2015 Technical requirements for reducer assembly for pure electric passenger car QC/T 1132-2020 Noise measurement method for electric power system of electric vehicles3 Terms and definitionsThe following terms and definitions defined in GB/T 19596 apply to this document. 3.1 Integrated electric drive system The power drive assembly unit of a pure electric drive passenger car. The coupled components include but are not limited to the following parts. drive motor module, reducer Module, high voltage control module. 3.2 High-voltage control module Motor controller or all-in-one controller. c) When the assembly performs input and output characteristics, drag torque, temperature rise, overspeed, NVH, and reliability tests, complete the grinding according to the following conditions Combined test. 1) The output speed maintains 50% of the maximum design speed, and the maximum allowable deviation is ±10 r/min; 2) The output torque is 10% of the peak torque, and the maximum allowable deviation is ±5 N·m; 3) Running-in time. forward rotation for 2 hours, reverse rotation for 1 hour; 4) The lubricating oil of the reducer should be replaced after running-in. If there is no special requirement, during the test, the speed difference between the two shaft ends of the assembly should not exceed 1%. The difference between the output torque and the total output torque should not exceed 1%. When the total output torque is greater than 1000 N·m, the percentage shall not exceed 1% or specified by the design, and it shall not exceed 10 N·m in other cases.5 Test methods and technical requirements5.1 General test 5.1.1 Appearance and quality The appearance is mainly based on visual inspection. The sample has no abnormal appearance and no stains, that is, no visible oil leakage, scratches, deformation, corrosion, cracking, etc. Measure and record the mass of the assembly with a weighing instrument that meets the requirements of measurement accuracy. The assembly should be marked with the polarity of the DC power supply, the direction of water inlet and outlet, high voltage danger, and grounding. 5.1.2 Tightness 5.1.2.1 Cooling circuit tightness 5.1.2.1.1 Test requirements The test requirements are as follows. a) For this test, all cooling circuits of the assembly should be jointly measured; b) If there is no corresponding coating requirement in the manufacturing, it is not allowed to coat the surface of the drive motor or the drive motor controller before the test. Coating to prevent leakage, but allows chemical anti-corrosion treatment without sealing effect; c) The test medium can be liquid or gas, and the liquid medium can be water, kerosene or non-corrosive with a viscosity not higher than water. Liquid, gas medium can be air, nitrogen or inert gas; d) The range of the gas or liquid pressure measuring instrument is 1.5 to 3 times the test pressure. 5.1.2.1.2 Test methods and criteria During the test, the temperature of the test medium should be consistent and stable with the temperature of the test environment; block one end of the cooling circuit of the sample under test, But it can't produce the deformation that affects the sealing performance; Fill the circuit with the test medium, and use the pressure meter to measure the applied medium pressure. a) When using a gaseous medium to test, keep the cooling circuit dry, and gradually increase the pressure until the test pressure is not less than.200 kPa. After 60 s, the pressure drop should not be greater than 1 kPa, or during the pressure maintaining process, the leakage rate meter display value should not drop more than 4 mL/min; b) When using a liquid medium to test, the air in the cooling circuit cavity should be evacuated and gradually pressurized until the test pressure is not less than.200 kPa. And keep the pressure for at least 15 minutes without leakage. 5.1.2.2 Cavity tightness The cavity tightness requirements are as follows. a) If the assembly is composed of independent cavities, it should be measured separately; b) Reserve a vent valve to send filtered water compressed gas with a pressure of 20 kPa ± 2 kPa into the cavity, close the vent valve and keep it for 30 s, The pressure drop should be no more than 25 Pa, or during the pressure maintaining process, the drop of the leak rate meter display value should be no more than 5 mL/min. 5.1.3 Insulation resistance The insulation resistance of the DC input terminal of the assembly to the enclosure should be measured in cold and hot states respectively. The relevant test methods and requirements specified in GB/T 18488.2 apply to this document. 5.1.4 Withstand voltage The DC withstand voltage of the DC terminal of the assembly to the chassis should be measured. The DC voltage is the pair specified in 5.2.8.2.1 of GB/T 18488.1-2015. It should be 1.414 times the effective value of the AC withstand voltage, and the leakage current should not be greater than 5 mA. The relevant test methods and requirements specified in GB/T 18488.2 apply to this document. 5.1.5 Grounding resistance The maximum resistance between all accessible conductive parts in the assembly and the grounding point of the enclosure should not be greater than 0.1 Ω, and the grounding point should have an obvious connection. 地marks. The relevant test methods and requirements specified in GB/T 18488.2 apply to this document. 5.2 Performance test 5.2.1 Dynamic seal The test methods and requirements specified in 6.2.4.1 of QC/T 1022-2015 are applicable to this document. The test oil temperature can be specified by the user according to the conditions of use. 5.2.2 Input and output characteristics If there is no special requirement, the inlet temperature of the assembly cooling system is set to 50 ℃ ± 2 ℃; the flow rate is set according to the technical requirements of the product; air cooling The temperature of the blowing point and the heat sink of the machine shall be implemented according to the regulations of the manufacturer; the temperature of the lubricating oil of the reducer shall be regulated according to the technical requirements of the product or controlled at 80 ℃ ±5 ℃, if necessary, increase the temperature tolerance; the motor winding temperature is between 60 ℃ and the maximum allowable temperature. 5.2.2.1 Operating voltage range During the test, if there is no special requirement, the DC bus voltage of the assembly should be set to the rated working voltage and the minimum according to the product technical documents. High working voltage and minimum working voltage; under different working voltages, test the maximum output torque at different output speeds, and record stable Speed and torque values. The number of measurement points within the assembly speed range is not less than 10, draw the speed-torque characteristic curve, and check whether the torque output is in line with the product Provisions of technical documents. 5.2.2.2 Speed-torque characteristics 5.2.2.2.1 Selection of speed test points During the test, generally no less than 10 speed points are selected within the working speed range of the assembly, and the lowest speed point should not be greater than the highest working speed. 10%, the interval between adjacent speed points is not more than 10% of the maximum working speed. The selection of test points should include necessary feature points, such as. --Rated working speed point; --Maximum working speed point; --Other specially defined working points. 5.2.2.2.2 Selection of measurement parameters During the test, the following data should be measured or calculated at the relevant test points. a) Assembly DC bus voltage and current; b) The voltage, current and electric power of the assembly drive motor; c) The torque, speed and mechanical power output by the assembly; d) Oil temperature of the assembly reducer; e) The temperature of the windings of the assembly drive motor; f) The flow rate and temperature of the cooling medium; g) Other specially defined measurement parameters. 5.2.2.2.3 Test method The test method is as follows. a) During the test, the DC terminal power of the assembly should be directly measured with a power measuring device; during measurement, the voltage measurement point should be in the assembly Near the DC terminal; b) During the test, in order to ensure the measurement accuracy, the working torque and speed of the assembly should be directly measured at the end of the output shaft. Assembly output shaft end There should be a rigid connection with the torque and speed measuring equipment, if the transmission efficiency of the coupling device and the wind friction loss in the middle can be ignored It is also possible to place a coupling link between the shaft end of the assembly and the torque and speed measuring device. The reading of the speed and torque measuring device is The output value of the shaft end of the assembly; c) If considering the transmission efficiency of the coupling device and the wind friction loss during the test, follow the GB/T 18488.2-2015 appendix Method A is to modify the test results. 5.2.2.3 Continuous torque During the test, make the assembly work at the lowest speed corresponding to the continuous torque and continuous power, and use the method of 5.2.2.2.3 to conduct the test and In measurement, the assembly should be able to work normally for a long time and the temperature rise within 10 minutes should not be higher than 2K. The working time requirement can be determined by the user through negotiation. 5.2.2.4 Continuous power According to the continuous torque obtained in 5.2.2.3 and the corresponding working speed, use the following formula to calculate the continuous torque of the assembly at the corresponding working point power. ...(1) Where. --The power at the output end of the assembly, in kW, --Test torque of left half-axis dynamometer, unit N·m, --Test torque of the right half-axis dynamometer, in N·m, --Output speed of left half shaft, unit r/min, --The output speed of the right half shaft, in r/min. 5.2.2.5 Peak torque The peak torque test result should be marked with the test environment temperature. During the test, make the assembly work under the peak torque, speed and duration specified in the technical documents, using the method of 5.2.2.2.3 Test, the duration of the peak torque test is 30 s or in accordance with the requirements of the user or manufacturer, and record the duration. During the test Cheng should be able to work normally. If multiple peak torque tests are required, it is advisable to restore the assembly to a cold state. 5.2.2.6 Peak power According to the peak torque obtained by the test in 5.2.2.5 and the corresponding working speed, use formula (1) to calculate the peak value of the assembly at the corresponding working point Value power and peak power should be marked with test duration. 5.2.2.7 Maximum working speed During the test, the assembly should be in a hot state. During the test, adjust the test bench at a constant speed to increase the speed of the assembly to the maximum working speed. The torque shall not be lower than the torque specified in the product technical documents, and the steady-state work duration shall be no less than 3 min. Test according to the method of 5.2.2.5 Test, record the output speed and torque of the assembly every 30 s. 5.2.2.8 Efficiency 5.2.2.8.1 Selection of test points The selection requirements for test points are as follows. a) Selection of speed test points According to 5.2.2.2.1, the speed points of 2%, 4%, and 6% should be included below 10% of the maximum input speed. b) Selection of torque test points In the state of assembly electric or power feeding, generally no less than 10 torque points are taken at each speed point. The selection of test points should include the necessary Feature points. 1) Continuous torque; 2) Peak torque (or maximum torque); 3) Other specially defined working points. Note. The test point under 10% of peak torque should include at least 2 points. c) The selection of measurement parameters shall be implemented in accordance with 5.2.2.2.2; d) The test method is carried out in accordance with 5.2.2.2.3. 5.2.2.8.2 Measurement of efficiency The efficiency measurement requirements are as follows. a) Work point efficiency When the assembly is in an electric working state, the input power is the electrical power PE input by the DC bus of the assembly, and the output power is the mechanical end of the assembly shaft. Power PM, efficiency is calculated according to formula (2). ...(2) When the assembly is in the feeding state, the input power is the mechanical power PM at the shaft end of the assembly, and the output power is the electricity output by the assembly's DC bus. Power PE, efficiency is calculated according to formula (3). ...(3) Where. η1, η2--The efficiency (%) of the assembly under the electric and feed state. b) High-efficiency zone classification At each speed point, record the test results from low torque to high torque, and from high torque to low torque, and use the same torque After the test is completed, the reducer module in the assembly should be disassembled and analyzed, and the following requirements should be met. a) There are no signs of pitting or sintering on the bearing surface; b) There is no abnormality in the gear status; c) All oil seals are in normal condition; d) The gear and differential are in normal condition. Note. The assembly without differential is not subject to this test. 5.2.4 Drag moment 5.2.4.1 Working mode The test should be carried out in one of the following working modes. --Working mode I. All high and low voltage wiring harnesses and connectors of the assembly are not connected. No coolant is injected into the cooling circuit, and the joints are sealed. --Working mode II. The assembly only provides low-voltage power supply. The cooling system is set up in accordance with the technical documentation. 5.2.4.2 Test method During the test, the assembly can be equipped with an oil temperature sensor, and the connection inclination of the half shaft should meet the requirements of the technical documents. Select the working mode according to the characteristics of the assembly. The speed switching point of the two modes is when the assembly does not exceed the speed, due to the rotation of the rotor Back-EMF will not cause damage to the assembly. The towing test should be carried out in the cold state and the hot state respectively. The cold state means that the temperature of the lubricating oil does not differ from room temperature by more than ±3 ℃; the hot state The lubricating oil temperature is 60±5 ℃. The assembly runs from zero speed to the maximum working speed or the user's maximum allowable speed, with a step length of 100 r/min. Wait for the speed and torque to stabilize After setting, record the torque value of the left and right half shaft ends at each speed, the algebraic sum of the torque value is the drag torque of the assembly at th......Tips & Frequently Asked Questions:Question 1: How long will the true-PDF of TCSAE143-2020_English be delivered?Answer: Upon your order, we will start to translate TCSAE143-2020_English as soon as possible, and keep you informed of the progress. The lead time is typically 1 ~ 3 working days. The lengthier the document the longer the lead time.Question 2: Can I share the purchased PDF of TCSAE143-2020_English with my colleagues?Answer: Yes. 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