GB/T 18488.2-2015 PDF English
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[Replaced by GB/T 18488-2024] Drive motor system for electric vehicles -- Part 2: Test methods
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The electrical machines and controllers for electric vehicles -- Part 2: Test methods
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Test procedures of the electrical machines and controllers for electric vehicles
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GB/T 18488.2-2015: [Replaced by GB/T 18488-2024] Drive motor system for electric vehicles -- Part 2: Test methods
---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/GBT18488.2-2015
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.040
T 35
Replacing GB/T 18488.2-2006
Drive Motor System for Electric Vehicles -
Part 2.Test Methods
Issued on: FEBRUARY 4, 2015
Implemented on: SEPTEMBER 1, 2015
Jointly Issued by. General Administration of Quality Supervision,
Inspection and Quarantine of the People's Republic of
China;
Standardization Administration of the People's
Republic of China.
Table of Contents
Foreword... 3
1 Scope... 6
2 Normative References... 6
3 Terms and Definitions... 7
4 Test Preparation... 7
5 General Test Items... 9
6 Temperature Rise Test... 17
7 Input/Output Characteristic Test... 19
8 Safety Test... 30
9 Environmental Adaptation Test... 30
10 Reliability Test... 33
Appendix A (Informative) Correction Methods for Working Torque
Measurement Result of Drive Motor System... 34
1 Scope
This Part of GB/T 18488 specifies the instruments and meters, test preparation and
each test method used for the test of drive motor system for electric vehicles.
This Part is applicable to the drive motor system for electric vehicles, drive motor and
drive motor controller. The vehicle motor only having power generation function and its
controller may implement this Part by reference.
2 Normative References
The following documents are essential for the application of this document. For dated
reference, only the dated edition applies to this document. For undated references, the
latest edition (including any amendments) applies to this document.
GB 755-2008 Rotating Electrical Machines - Rating and Performance
GB/T 2423.1-2008 Environmental Testing - Part 2.Test Methods - Tests A.
Cold
GB/T 2423.2-2008 Environmental Testing - Part 2.Test Methods - Tests B. Dry
Heat
GB/T 2423.10-2008 Environmental Testing for Electric and Electronic Products
- Part 2.Tests Methods - Test Fc. Vibration (Sinusoidal)
GB/T 2423.17-2008 Environmental Testing for Electric and Electronic Products
- Part 2.Test Method - Test Ka. Salt Mist
GB/T 2900.25 Electrotechnical Terminology - Rotating Electrical
Machines
GB/T 2900.33 Electrotoechnical Terminology - Power Electronics
GB/T 3859.1-2013 Semiconductor Converters - General Requirements and
Line Commutated Converters - Part 1-1.Specification of
Basic Requirements
3 Terms and Definitions
The terms and definitions defined in GB/T 2900.25, GB/T 2900.33, GB/T 19596 and
GB/T 18488.1 are applicable to this document.
4 Test Preparation
4.1 Test environment conditions
Unless otherwise specified, all the tests shall be carried out under the following
conditions.
a) Temperature. 18°C~28°C;
b) Relative humidity. 45%~75%;
c) Atmospheric pressure. 86 kPa~106 kPa;
d) Altitude. not exceeding 1,000 m; if it exceeds 1,000 m, it shall be in accordance
with the relevant requirements of GB 755-2008.
4.2 Selection of test instrument
4.2.1 Accuracy of instrument
The accuracy or error of instrument shall not be inferior to the requirements specified
in Table 1, and shall meet the accuracy requirement of actually measured parameter;
especially, the instrument and meter for measurement of electrical parameter shall be
able to meet the accuracy and waveform requirements for the measurement of
corresponding DC parameter and AC parameter.
4.2.2 Measurement requirements
a) If measuring current with shunt, the resistance of measuring line shall be
selected according to the adopted measuring instrument.
b) During the measurement, the reading of each instrument shall be read at the
same time.
4.3 Test power supply
4.3.1 In the test process, the test power supply shall be provided by DC power supply,
or be jointly provided by DC power supply and other energy storage (energy
consumption) equipment; when the DC working voltage of test power supply is not
greater than 250 V, the voltage stabilization error shall not be greater than ±2.5 V; when
the DC working voltage of test power supply is greater than 250 V, the voltage
stabilization error shall not exceed ±1% of the DC working voltage of the tested drive
motor system.
4.3.2 The test power supply shall be able to meet the power requirement of the tested
drive motor system, and be able to work under the corresponding working voltage state.
5 General Test Items
5.1 Appearance
It shall mainly be inspected visually; for the technical parameters having explicit
strength requirement, such as the joint strength of fastener, the necessary tools like
torque wrench shall be adopted.
5.2 Overall and installation dimensions
According to the requirements for overall and installation dimensions of tested motor
system, and the size range - the vernier caliper, spiral micrometer, mater ruler and
other measuring instruments meeting the measurement accuracy requirements shall
be selected for measurement.
5.3 Mass
The mass of drive motor and drive motor controller shall be measured with weighing
apparatus meeting the measurement accuracy requirements; the measuring error of
weighing apparatus shall not exceed ±2% of the nominal mass of the tested sample.
5.4 Mechanical strength of drive motor controller housing
During the test, the weights of corresponding pressure shall be applied slowly in 3
directions of drive motor controller housing respectively according to the requirements
of 5.2.4 in GB/T 18488.1-2015, in which, the contact area of weights and drive motor
controller housing shall not be less than 5 cm×5 cm at least, to inspect whether the
housing has obvious plastic deformation.
5.5 Cooling circuit sealing property of liquid cooling system
5.5.1 For this test, the cooling circuit of drive motor and drive motor controller should
be measured independently after being separated.
5.5.2 Before the test, it is not allowed to apply the coating which may prevent
seepage on the surface of drive motor or drive motor controller, however, it is allowed
to conduct the chemical preservation treatment without sealing function.
5.5.3 The medium used for test may be fluid or gas; the liquid medium may be the
water containing antirust agent, kerosene or the non-corrosive liquid with viscosity not
higher than water; and the gas medium may be air, nitrogen or inert gas.
5.5.4 The accuracy of the measuring instrument used for measuring the test medium
pressure shall not be lower than Grade 1.5; and the measuring range shall be 1.5~3
times of the test pressure.
5.5.5 During the test, the temperature of test medium shall be consistent with that of
test environment and shall remain stable; one end of the cooling circuit of the tested
sample shall be blocked; however, the deformation affecting the sealing property
cannot be generated; the test medium shall be filled into circuit; and the applied
medium pressure shall be measured with pressure instrument. When the liquid
medium is used for test, the air in cooling circuit cavity shall be emptied. Then, the test
pressure specified in 5.2.5 of GB/T 18488.1-2015 shall be added gradually, and this
pressure shall be maintained at least 15 min.
5.5.6 In the process of pressure maintenance, the indicated value of pressure
instrument shall not decrease; in this period, visible seepage shall not pass through
the shell wall of tested sample and any fixed joint. If the test medium is fluid, visible
liquid drop or wet surface shall be avoided.
5.6 Cold state DC resistance of drive motor stator winding
The cold state DC resistance of drive motor stator winding should be measured under
the actual cold state; the environment temperature value during the measurement shall
be recorded.
5.6.1 Measurement of environment temperature
The drive motor shall be placed in the space with uniform temperature for a period of
time, to make the temperature inside and outside the drive motor to be consistent with
the environment temperature; and the temperature value shall be recorded. The
criteria to judge whether the temperature is consistent shall meet one of the following
conditions.
a) The temperature of motor winding, iron core and environment is measured with
thermometer (or embedded temperature detector); the difference between the
measured temperature and the environment temperature shall not exceed 2K.
If necessary, heat insulation measures shall be taken for thermometer and
outside; the time for thermometer placement is not less than 15min. During the
measurement of winding temperature, the temperature of winding head and
winding slot part is measured at different positions according to the size of
motor (in case of any difficulty, the surface temperature of iron core tooth and
iron core yoke may be measured); and the average value is adopted as the
temperature of winding under actual cold state.
b) The drive motor is at the non-operating state and its storage period in the space
with stable environment temperature exceeds 12h.
5.6.2 Measurement of winding DC resistance
5.6.2.1 The winding DC resistance shall be measured with micro-Ohmmeter. During
the measurement, the test current passing through winding shall not exceed 10% of
its rated current, and the power on time shall not exceed 1 min.
5.6.2.2 During measurement, the rotor of drive motor shall stay still. When both the
start- and tail-ends of each phase and each branch circuit of the winding are led out,
the DC resistance of each phase and each branch circuit shall be measured
respectively.
5.6.2.3 If the windings of different phases are connected in the motor, the resistance
shall be measured between each outlet terminal. For three-phase motor, the resistance
value of each phase shall be calculated according to the following formula [see
Formula (1) ~Formula (6)].
5.7 Insulation resistance
5.7.1 State of the tested sample during measuring
5.7.1.1 The insulation resistance test shall be respectively carried out at the actual
cold state or thermal state (e.g., after the temperature rise test or high and low
temperature test or damp heat test) of the tested sample.
5.7.1.2 During routine testing, unless otherwise specified, the insulation resistance
shall be measured only at the actual cold state; and the temperature of ambient
medium of the tested sample shall be recorded.
5.7.1.3 If the insulation resistance is required to be measured at thermal state or in
the case that any cooling fluid passes through cooling circuit, the environmental
temperature refers to the temperature of the space where the test sample is located or
the temperature of cooling fluid during the test.
5.7.2 Selection of megameter
5.7.2.1 Megameter shall be selected according to the maximum working voltage of
the tested winding (or measuring point).
5.7.2.2 When the maximum working voltage does not exceed 250 V, then 500 V
megameter shall be selected; when the maximum working voltage exceeds 250 V but
does not exceed 1,000 V, then 1,000 V megameter shall be selected.
5.7.2.3 During measuring, the value shall be read after the megameter pointer or
display value is stable.
5.7.3 Insulation resistance of drive motor stator winding against housing
5.7.3.1 If the start- and tail-ends of each winding are led out separately, the insulation
resistance of each winding against housing shall be measured respectively; other
windings and embedded temperature detecting elements, etc. which are not involved
in the test shall have electrical connection with iron core or housing; and the housing
shall be grounded.
5.7.3.2 If the neutral points are connected together and not easy to separate, then
the insulation resistance of all the connected windings against housing shall be
measured.
5.7.3.3 After the measurement, each circuit shall have electrical connection with the
grounded housing so as to discharge.
5.7.4 Insulation resistance of drive motor stator winding against temperature
sensor
6 Temperature Rise Test
6.1 Measurement of drive motor winding resistance
6.1.1 The temperature rise of motor winding should be measured with resistance
method. In this method, the temperature rise of winding is determined according to the
corresponding change increment of the DC resistance of drive motor winding along
with temperature change during the test.
6.1.2 Before test, measure the actual cold state DC resistance (or the winding DC
resistance at the beginning of the test) of a certain winding of drive motor according to
the method of 5.6.If each phase windings is connected in motor, then the DC
resistance between two outlet ends may be measured, and the winding temperature
may be recorded.
6.1.3 During test, make the drive motor system operate at certain working state; shut
down the motor after energy disconnection; and minimize the influence of shutdown
process on the temperature change of drive motor winding. Record the time at the
energy disconnection moment; record the temperature of cooling medium. Measure
the drive motor winding resistance changing with time as soon as possible; the
measuring point of winding resistance is the same as that before test. The first record
time shall not exceed the energy disconnection moment by 30 s; starting from the first
record point, record data once at the maximum interval of 30 s until the winding
resistance changes gently; the total record time length should not be less than 5min.
6.2 Calculation of temperature rise of drive motor winding
6.2.1 If the drive motor winding is copper winding, the temperature rise at the energy
disconnection moment of motor shall be obtained through calculation according to
Formula (8).
7 Input/Output Characteristic Test
7.1 Working voltage range
7.1.1 In bench test, set the DC bus voltage of drive motor system at maximum
working voltage and minimum working voltage respectively; test it at different working
voltages; test the maximum working torque at different working speeds; and record the
stable speed and torque.
7.1.2 The number of measuring points within the speed range of drive motor system
shall not be less than 10; draw speed-torque characteristic curve; inspect whether the
torque output meets the requirements of product technical documents.
7.2 Torque-speed characteristic and efficiency
7.2.1 Selection of test point
7.2.1.1 Selection of speed test point
During test, generally no less than 10 speed points are selected within the working
speed range of drive motor system; the minimum speed point should not be larger than
10% of maximum working speed; the interval between adjacent speed points shall not
be larger than 10% of the maximum working speed. In the selection of test points,
necessary characteristic points shall be included, for example.
- Rated working speed point;
- Maximum working speed point;
- Corresponding minimum working speed point of continuous power;
- Other specially specified working points, etc.
7.2.1.2 Selection of torque test point
Under motor-driven or feed state of drive motor system, generally no less than 10
torque points are selected from each speed point; for high-speed working state, the
number of torque points selected from each speed point may be reduced properly, but
should not be less than 5.In the selection of test points, necessary characteristic points
shall be included, for example.
a) The point at continuous torque value;
b) The point at peak torque (or maximum torque) value;
c) The point on continuous power curve;
d) The point on peak power (or maximum power) curve;
e) Other specially specified working points, etc.
7.2.2 Selection of measurement parameter
During test, some or all of the following data at relevant test points may be selected for
measuring according to test purpose.
a) The DC bus voltage and current of drive motor controller;
b) The voltage, current, frequency and electric power of drive motor;
c) The torque, speed and mechanical power of drive motor;
d) The efficiency of drive motor, drive motor controller or drive motor system;
e) The resistance and temperature of drive motor armature winding;
f) The flow and temperature of cooling medium;
g) Other specially specified measurement parameters, etc.
8 Safety Test
8.1 Safe grounding inspection
The grounding inspection method and requirements of measuring tools in accordance
with 5.1.3 in GB/T 13422-2013 shall be used for measuring the corresponding
grounding resistance of the tested drive motor system. Milliohm meter is recommended
as the measuring tool.
8.2 Protection function of controller
It shall be in accordance with the requirements of 7.5.3 in GB/T 3859.1-2013.
8.3 Discharge time of drive motor controller support capacitance
8.3.1 Passive discharge time
During test, the DC bus voltage shall be set as the maximum working voltage. After
voltage stabilization, cut off the DC power supply immediately; meanwhile, use electric
measuring instrument to measure the open-circuit electric claw on the both ends of the
drive motor controller support capacitance. During the test, the drive motor controller
is not involved in any work. Record the time from the cut off moment of support
capacitance open-circuit voltage to the moment that it drops to 60 V; this value is the
passive discharge time of drive motor controller support capacitance.
8.3.2 Active discharge time
For the drive motor controller with active discharge function, during test, the DC bus
voltage shall be set as the maximum working voltage. After voltage stabilization, cut
off DC power supply immediately; drive motor controller is involved in discharge
process; use electric measuring instrument to measure the open-circuit voltage on the
both ends of drive motor controller support capacitance; record the time from the cut
off moment of support capacitance open-circuit voltage to the moment that it drops to
60 V; this value is the active discharge time of drive motor controller support
capacitance.
9 Environmental Adaptation Test
9.1 Low temperature test
9.1.1 During cold storage test, connect drive motor and drive motor controller
correctly; put them into cryogenic box according to the requirements of GB/T 2423.1-
2008; make the temperature in the cryogenic box drop to -40°C; keep it for 2h. In the
test process, the drive motor system is not at power-up state. For liquid-cooled drive
motor and drive motor controller, cooling fluid is not added. After 2h low temperature
storage, re-measure the insulation resistance in cryogenic box according to the method
of 5.7; during re-measurement of insulation resistance, the temperature in cryogenic
box shall be maintained at -40°C.
9.1.2 After 2h low temperature storage, the temperature in cryogenic box shall be
kept as -40°C; energize drive motor system in cryogenic box to inspect whether it can
be started normally at idle load. For liquid-cooled drive motor and drive motor controller,
if it is required to add cooling fluid during starting, the composition, temperature and
flow of cooling fluid shall meet the requirements of product technical documents.
9.1.3 At the end of the test, after restoring to normal state according to the
requirements of GB/T 2423.1-2008, set the working voltage of drive motor controller
DC bus as the rated voltage; the drive motor works under continuous torque and
continuous power conditions; inspect whether the system can work normally.
9.2 High temperature test
9.2.1 During high temperature storage test, put drive motor and drive motor controller
into high temperature cabinet according to the requirements of GB/T 2423.2-2008;
make the temperature in the cabinet rise to 85°C; keep it for 2h. In the test process,
the drive motor system is not at power-up state. For liquid-cooled drive motor and drive
motor controller, cooling fluid is not added. After 2h high temperature storage, inspect
whether the grease in drive motor bearing overflows; re-measure the insulation
resistance in high temperature cabinet according to the method of 5.7.During the re-
measurement of insulation resistance, the temperature in high temperature cabinet
shall be maintained at 85°C.
10 Reliability Test
The test shall be carried out according to the requirements of GB/T 29307-2012.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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