GB/T 24347-2021 PDF English
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DC/DC converter for electric vehicles
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| GB/T 24347-2009 | English | 70 |
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GB/T 24347-2021: DC/DC converter for electric vehicles---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/GBT24347-2021
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.080.01
CCS T 47
Replacing GB/T 24347-2009
DC/DC Converter for Electric Vehicles
Issued on: AUGUST 20, 2021
Implemented on: MARCH 1, 2022
Issued by. State Administration for Market Regulation;
Standardization Administration of the People’s Republic of
China.
Table of Contents
Foreword... 3
1 Scope... 5
2 Normative References... 5
3 Terms and Definitions... 6
4 Technical Requirements... 7
4.1 Appearance Requirements... 7
4.2 Input and Output Performance... 8
4.3 Protective Functions... 9
4.4 Environmental Adaptability... 10
4.5 Electromagnetic Compatibility... 11
4.6 Electrical Safety... 14
5 Test Methods... 15
5.1 Test Requirements... 15
5.2 Appearance Test... 16
5.3 Input and Output Performance Test... 16
5.4 Protective Functions Test... 21
5.5 Environmental Adaptability Test... 24
5.6 Electromagnetic Compatibility Test... 25
5.7 Electrical Safety Test... 26
Bibliography... 28
1 Scope
This Standard specifies the technical requirements and test methods of DC/DC
converter for electric vehicles.
This Standard is applicable to DC/DC converter for electric vehicles. Other circuits with
DC/DC conversion function may take this document as a reference.
2 Normative References
The contents of the following documents constitute indispensable clauses of this
document through normative references in the text. In terms of references with a
specified date, only versions with a specified date are applicable to this document. In
terms of references without a specified date, the latest version (including all the
modifications) is applicable to this document.
GB/T 18655-2018 Vehicles, Boats and Internal Combustion Engines - Radio
Disturbance Characteristics - Limits and Methods of Measurement for the Protection
of On-board Receivers
GB/T 19596 Terminology of Electric Vehicles
GB/T 19951 Road Vehicles - Disturbances Test Methods for Electrical / Electronic
Component from Electrostatic Discharge
GB/T 28046.3-2011 Road Vehicles - Environmental Conditions and Testing for
Electrical and Electronic Equipment - Part 3.Mechanical Loads
GB/T 28046.4-2011 Road Vehicles - Environmental Conditions and Testing for
Electrical and Electronic Equipment - Part 4.Climatic Loads
GB/T 29259 Road Vehicle - Electromagnetic Compatibility Terminology
ISO 7637-2.2011 Road Vehicles - Electrical Disturbances from Conduction and
Coupling - Part 2.Electrical Transient Conduction along Supply Lines Only
3 Terms and Definitions
What is defined in GB/T 19596 and GB/T 29259, and the following terms and
definitions are applicable to this document.
3.1 DC/DC Converter
DC/DC converter is a device that can convert the electric energy of one DC voltage
value into the electric energy of another DC voltage value.
[source. GB/T 19596-2017, 3.2.4.1, modified]
3.2 Overshoot and Response Time
When the input or output undergoes a jump, during the process from the moment of
change to the recovery to the range of control error of the controlled variable of the
DC/DC converter, the percentage of the maximum deviation of the transient value from
the steady-state value to the steady-state value is the overshoot. From the moment
that the input or output changes, the time that the controlled variable reaches and
remains within the allowable deviation range is the response time.
3.3 Quiescent Current
Quiescent current refers to the current of the low-voltage battery consumed by the
DC/DC converter in the dormant state.
3.4 Weighted Efficiency
Weighted efficiency refers to the weighted average value of each efficiency of the load
spectrum corresponding to the DC/DC converter.
3.5 DC/DC for High Voltage Output
DC/DC for high voltage output refers to DC/DC converter with rated output voltage
level greater than 60 V and not greater than 1,500 V.
3.6 DC/DC for Low Voltage Output
DC/DC for low voltage output refers to DC/DC converter with rated output voltage level
not greater than 60 V.
3.7 Ripple Factor
Ripple factor refers to the ratio of the half of the difference between the peak value and
the valley value of the pulsating DC power to the absolute value of its DC component.
[source. GB/T 19826-2014, 3.8]
4 Technical Requirements
4.1 Appearance Requirements
4.1.1 The outer surface of the DC/DC converter for electric vehicles (hereinafter
referred to as “DC/DC”) shall manifest no obvious defects, for example, damage or
deformation.
4.1.2 The terminals or lead wires of the DC/DC shall be intact and undamaged; the
fastener connections shall not be loose.
4.1.3 The accessible surface of the DC/DC shall be free of rust, burrs, trimmings and
similar sharp edges.
4.1.4 The installation of the marks containing product information shall be upright and
firm, and the handwriting shall be clear.
4.2 Input and Output Performance
4.2.1 Efficiency
The weighted efficiency of DC/DC for low voltage output is classified into three grades.
E1, E2 and E3.The weighted efficiency of DC/DC for high voltage output is not
classified. The weighted efficiency value shall comply with the stipulations of Table 1.
Table 1 -- Weighted Efficiency
4.2.2 Rated power
Under the specified environmental conditions, rated input voltage and rated output
voltage, the maximum continuous operating power of the DC/DC shall not be less than
the nominal rated power value.
4.2.3 Control errors
4.2.3.1 Voltage control error
The DC/DC operates under a constant-voltage state, its voltage control error shall not
exceed ± 2%.
4.2.3.2 Current control error
The DC/DC operates under a constant-current state. When the controlled current is
greater than or equal to 20% of the rated current, the current control error shall not
exceed ± 2%; when the controlled current is less than 20% of the rated current, the
current control error shall comply with the stipulations of the product technical
documents.
4.2.4 Overshoot and response time
When the DC/DC load undergoes a jump, the overshoot of the output voltage shall not
be greater than 10%; the response time shall not be greater than 5 ms.
When the output load of the DC/DC used for fuel cell power system undergoes a jump,
the overshoot of the input current shall not be greater than 10%; the response time
shall not be greater than 20 ms.
4.2.5 Quiescent current
When the DC/DC does not have output, for the port that has a fixed electrical
connection with the low-voltage battery (cannot be controlled to disconnect), the
quiescent current shall not be greater than 3 mA.
4.2.6 Ripple factor of output voltage
The ripple factor of the DC/DC output voltage shall not be greater than 5%.
4.3 Protective Functions
4.3.1 Input overvoltage and undervoltage protection
When the DC/DC input voltage is greater than or equal to the overvoltage protection
value, or less than or equal to the undervoltage protection value, the output shall be
turned off or limited. After troubleshooting, the output can be automatically restored, or
after necessary human intervention.
The input overvoltage protection value and input undervoltage protection value shall
comply with the stipulations of the product technical documents.
4.3.2 Output overvoltage and undervoltage protection
When the DC/DC output voltage is greater than or equal to the overvoltage protection
value, or less than or equal to the undervoltage protection value, the output shall be
turned off or limited. After troubleshooting, the output can be automatically restored, or
after necessary human intervention.
The output overvoltage protection value and output undervoltage protection value shall
comply with the stipulations of the product technical documents.
4.3.3 Output short-circuit protection
For the DC/DC with short-circuit protection function, when a short-circuit occurs at the
DC/DC output terminal, the power output shall be turned off or limited. After
troubleshooting, the output can be automatically restored, or after necessary human
intervention.
4.3.4 Over-temperature protection
The DC/DC shall have over-temperature protection function. When the temperature of
the DC/DC temperature sampling point reaches the set value of the over-temperature
protection, the output shall be turned off or limited. After troubleshooting, the output
can be automatically restored, or after necessary human intervention.
The over-temperature protection value shall comply with the product technical
documents.
4.4 Environmental Adaptability
4.4.1 Environmental conditions
4.4.1.1 Ambient temperature
If there are no special requirements, the temperature limits specified in Table 2 shall
be abided by; the requirements for the coolant parameters shall comply with the
stipulations of the product technical documents.
Table 2 -- Ambient Temperature
4.4.1.2 Relative humidity
Relative humidity 5% ~ 95%.
4.4.1.3 Altitude
The altitude shall not be higher than 2,000 m or shall comply with the stipulations of
the product technical documents.
4.4.2 Low-temperature
4.4.2.1 Low-temperature storage
The low-temperature storage resistance of the DC/DC shall comply with the
requirements of 5.1.1.1 in GB/T 28046.4-2011.
4.4.2.2 Low-temperature operation
The low-temperature operation resistance of the DC/DC shall comply with the
requirements of 5.1.1.2 in GB/T 28046.4-2011.
4.4.3 High temperature
4.4.3.1 High-temperature storage
The high-temperature storage resistance of the DC/DC shall comply with the
requirements of 5.1.2.1 in GB/T 28046.4-2011.
4.4.3.2 High-temperature operation
4.4.4 Damp heat
4.4.4.1 Damp heat cycle
The damp heat cycle resistance of the DC/DC shall comply with the requirements of
5.6 in GB/T 28046.4-2011.
4.4.4.2 Steady-state damp heat
The steady-state damp heat resistance of the DC/DC shall comply with the
requirements of 5.7 in GB/T 28046.4-2011.
4.4.5 Salt spray
The salt spray resistance of the DC/DC shall comply with the requirements of 5.5 in
GB/T 28046.4-2011.
4.4.6 Vibration resistance
The vibration resistance of the DC/DC shall comply with the requirements of 4.1 in
GB/T 28046.3-2011.
4.4.7 Mechanical shock
The mechanical shock resistance of the DC/DC shall comply with the requirements of
4.2 in GB/T 28046.3-2011.
4.5 Electromagnetic Compatibility
4.5.1 Functional feature status
Functional feature status, which defines the expected target of functional features of
the device under test (DUT) in the test environment, is applicable to each independent
function of the DUT. It describes the working status of the expected function during and
after the test. Four functional feature statuses are provided below.
---Status I. the design function can be completed during and after the test;
---Status II. the design function cannot be completed during the test, but it can
automatically return to the normal status after the test;
---Status III. the design function cannot be completed during the test, but after the
test, through the simple operation of the testing personnel, it can return to the
normal status, for example, by turning on / off the DUT, or restarting;
---Status IV. the design function cannot be completed during the test, and more
complicated operations are required after the test to return to the normal status.
It shall not cause any permanent damage to the functions of the DUT. For
example, disconnecting the battery or power supply, then, re-connecting.
Each test shall determine the minimum functional status. The supplier and the vehicle
manufacturer may have additional requirements through negotiations.
4.5.2 Electromagnetic immunity
4.5.2.1 Electrostatic discharge (ESD) immunity
The DC/DC shall be able to satisfy the test items in Table 3 and the requirements of
the corresponding functional feature status.
4.5.2.2 Low-voltage electrical transient conduction immunity along the power
line
The test level and functional feature status requirements of the low-voltage electrical
transient conduction immunity along the power line shall comply with the stipulations
of Table 4 and Table 5.
4.5.2.3 Low-voltage conduction immunity along the non-power line
For the DC/DC containing low-voltage non-power line, the low-voltage conduction
immunity along the non-power line shall comply with the requirements of test level III
in Appendix B of ISO 7637-3.2016.
The functional feature status requirements shall be Status I.
4.5.2.4 Anechoic chamber immunity
In the 80 MHz ~ 2,000 MHz frequency band, the test severity level of the anechoic
chamber immunity test is 75 V/m.
The functional feature status requirements shall be Status I.
4.5.2.5 Bulk current injection (BCI) method immunity
In the frequency band from 1 MHz to 400 MHz, the severity level of the BCI method
immunity test is 100 mA.
The functional feature status requirements shall be Status I.
4.5.2.6 Magnetic field immunity
The magnetic field immunity test shall satisfy the requirements of Level III in Table A.1
of ISO 11452-8.2015.
The functional feature status requirements shall be Status I.
5 Test Methods
5.1 Test Requirements
5.1.1 Requirements for standard test environment
When there are no special stipulations on the environment, the test shall be carried out
in accordance with the following environmental conditions.
a) Ambient temperature. 23 °C ± 5 °C;
b) Relative humidity. 25% ~ 75%;
c) Ambient air pressure. 86 kPa ~ 106 kPa;
Test Voltage Maximum Operating Voltage Udmax
Maximum Operating Voltage Udmax Test Voltage
NOTE 1.the test voltage in this Table is the effective value of AC voltage (50 ± 5) Hz.
NOTE 2.the test voltage may adopt the equivalent DC voltage of the corresponding voltage value in this Table
(1.4 times the effective value of the AC voltage).
d) The coolant parameters of the liquid-cooled DC/DC shall comply with the
stipulations of the product technical documents.
5.1.2 Requirements for instruments and equipment
The test equipment shall be at least one level higher than the technical indicators of
the equipment under test, and shall have sufficient resolution, accuracy and stability. If
there are no special regulations, the following requirements shall be satisfied.
a) The accuracy of the generally used instruments shall be selected in
accordance with Table 7 and the measured error level;
b) The error of the instrument for temperature measurement shall be ± 1 °C;
c) The relative error of the instrument used for time measurement shall be 1%;
d) The constant-temperature and constant-humidity test chamber requires a
temperature control error of ± 2 °C and a relative humidity control error of ±
3%, and a volume not less than 5 times the volume of the tested sample;
e) The accuracy of other test instruments shall comply with the requirements of
relevant standards and be within the validity period of the metrological
certification.
5.2 Appearance Test
Conduct visual inspection and surface touch inspection.
5.3 Input and Output Performance Test
5.3.1 Schematic diagram of input and output performance test circuit
The schematic diagram of the input and output performance test circuit is shown in
Figure 2.
5.3.2 Efficiency test
The test methods and steps are as follows.
a) In accordance with Figure 2, properly connect the test circuit. Set the
electronic load to constant-current (or constant-resistance) load mode;
b) Under the conditions of rated input and rated output, turn on the DC/DC. After
30 min of operation, start the efficiency measurement;
c) Maintain the input voltage at the rated voltage. In accordance with the load
spectrum shown in Table 8 (high voltage DC/DC shall comply with Table 9),
adjust the output current. Respectively record the input power and output
power under each load condition; calculate the efficiency i under various
working conditions;
d) In accordance with the weight coefficient in Formula (1) and Table 8 (high
voltage DC/DC shall comply with Table 9), calculate the weighted efficiency.
NOTE 1.the input power of the DC/DC is calculated by multiplying the measured
value of the voltage and current at the input terminal.
5.7 Electrical Safety Test
5.7.1 Insulation resistance test
When the DC/DC is not working, use an insulation resistance tester to measure the
insulation resistance of the DC/DC; apply a DC test voltage of 500 V and maintain a
steady-state value for 60 s, then, determine the insulation resistance.
5.7.2 Voltage resistance test
During the test, the terminals of the same independent circuit loop in the DC/DC shall
be short-circuited. In accordance with the voltage resistance value in Table 6, apply
the test voltage.
a) Between the terminal and the ground (enclosure);
b) Between circuits without electrical connection.
During the loading process, the applied voltage shall be gradually increased to the
specified value by 5 s or within 5 s, so that the voltage does not manifest obvious jump.
The full test voltage shall last for 1 min.
Record the size of the leakage current during the test.
NOTE. for some components (such as. pulse transformers and transformers, etc.) that
cause high voltage to enter the low-voltage circuit due to electromagnetic field
induction, they may be isolated or removed before the test.
5.7.3 Safety grounding check test
Use a multimeter with an accuracy of 1/1,000 (or other instruments with the same
functions and accuracy level) to measure the electrical resistance between the
accessible metal parts in the DC/DC and the grounding point of the enclosure.
Bibliography
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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