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Drive motor system for electric vehicles

Part 1: Specification

 

1 Scope

This part of GB / T 18488 specifies the operating system, voltage rating, type designation, requirements, inspection rules and marking and marking of the drive motor system for electric vehicles.

This part applies to electric vehicle drive motor system, drive motor, drive motor controller. For a motor vehicle with a power generation function and its controller, refer to this section.

 

2 normative reference documents

The following documents are indispensable for the application of this document. For dated references, the only dated edition applies to this document. For undated references, the latest edition (including all modifications) applies to this document.

Rotating motor quota and performance

GB 755-2008

GB 1971 Rotating electrical machine terminal mark and rotation direction

GB / T 2423.17 Environmental testing for electric and electronic products – Part 2: Test methods Test Ka: Salt mist

GB 2894 Safety signs and guidelines for their use

GB / T 2900.25 Electrotechnical terms Rotating electrical machines

GB / T 2900.33 Electrical terminology Power electronics technology

GB 4208 enclosure protection class (IP code)

GB / T 4942.1 Degree of protection of the overall structure of a rotating electrical machine (IP code) Classification

GB / T 19596 Electric vehicle terminology

GB / T 28046.3-2011 Road vehicles – Environmental conditions and tests for electrical and electronic equipment – Part 3: Mechanical load

GB / T 29307-2012 Reliability test method for drive motor systems for electric vehicles.

 

3 terms and definitions

GB / T 2900.25, GB / T 2900.33 and GB / T 19596, as well as the following terms and definitions apply to this document.

3.1  Drive motor system

A drive motor, a drive motor controller, and a combination of auxiliary means for their operation.

3.2  Drive motor drive motor

An electrical device that converts electrical energy into mechanical power to provide a driving force for vehicle travel, and which can also have the function of converting mechanical energy into electrical energy.

3.3  Drive motor controller

The device for controlling the energy transfer between the power supply and the driving motor is composed of a control signal interface circuit, a driving motor control circuit and a driving circuit.

3.4 DC bus voltage

The DC input voltage of the drive motor system.

3.5  Rated voltage rated voltage

Nominal voltage of the DC bus.

3.6  Maximum operating voltage

The maximum value of the DC bus voltage.

3.7  Input and output characteristics input & output characteristic

Representation of the drive motor, drive motor controller or drive motor system speed, torque, power, efficiency, voltage, current and other parameters of the relationship between.

3.8  Continuous torque

Specifies the maximum, long-term working torque.

3.9  Continuous power continuous power

Specifies the maximum, long-term power of work.

3.10  Speed control accuracy

The deviation between the actual value of the speed and the expected value of the speed, or the deviation between the actual value of the speed and the expected value of the rotational speed is the percentage of the desired value of the speed.

3.11  Torque control accuracy

The deviation of the torque actual value from the torque expected value, or the deviation between the torque actual value and the torque expectation value as a percentage of the torque desired value.

3.12  Speed response time respond time of speed

The time elapsed since the drive motor controller has received the instruction information from the beginning to the desired value of the specified tolerance range.

3.13  Torque response time respond time of torque

The time elapsed since the drive motor controller has received the instruction information from the beginning to the desired value of the specified tolerance range.

3.14  Active discharge

When the drive motor controller is cut off the power, cut into the special discharge circuit, the controller supports the process of rapid discharge capacitor.

3.15  Passive discharge

When the drive motor controller is cut off the power, do not cut into a special discharge circuit, the controller supports the natural discharge process of the capacitor.

3.16  Drive motor controller support capacitor discharge time

When the drive motor controller is powered off, the motor controller supports the time it takes for the capacitor to discharge to 60 V.

3.17  Drive motor controller operating current drive motor controller current

When the drive motor controller is in normal operation, the current on the power lines connected to the drive motor is connected.

3.17.1  Drive motor controller continuous current

Can drive the motor controller for a long time to work the maximum working current.

3.17.2  Drive motor controller short time working current drive motor controller short-time current

The maximum operating current of the drive motor controller capable of operating normally within a specified period of time.

3.17.3  Drive motor controller maximum operating current

Can reach and can withstand the drive motor controller operating current maximum.

3.18  Drive motor system efficiency drive motor system efficiency

The percentage of the output power of the drive motor system and the input power.

 

4 working system, voltage class and model name

4.1 working system

Developed by manufacturer and user with reference to GB 755.

4.2 Voltage rating

Drive Motor System DC Bus Rated Voltage Take the following ratings: 36 V, 48 V, 60 V, 72 V, 80 V, 120 V, 144 V’168 V, 192 V, 216 V, 240 V, 264 V, 312 V’336 V’360 V, 384 V’408 V, 540 V, 600 V’650 V, 700 V, 750 V.

Note: marked for the preferred level.

4.3 drive motor and drive motor controller model name

Drive motor and drive motor controller designation Refer to Appendix A.

 

5 requirements

5.1 General requirements

(Such as periodic abnormal sound, abnormal sound after bearing damage, small foreign matter stuck in the rotation caused by abnormal sound, etc.); drive motor controller should have a To meet the vehicle requirements of the communication function, fault diagnosis function.

5.2 General items

5.2.1 appearance

Drive motor and drive motor controller surface should not be rust, bumps, scratches, coating should not be peeling, fasteners should be firmly connected, lead wire or terminal should be intact, color and logo should be correct, nameplate The writing and content should be clear and correct, and should not fall off.

5.2.2 Outline and mounting dimensions

The dimensions and mounting dimensions of the drive motor and drive motor controller shall comply with the dimensions and mounting dimensions specified between the manufacturer and the user.

5.2.3 quality

Shall not exceed the value negotiated between the manufacturer and the user.

5.2.4 Drive motor controller housing mechanical strength

The drive motor controller housing shall be capable of withstanding a pressure of not less than 10 kPa without significant plastic deformation.

5.2.5 Liquid cooling system cooling circuit sealing performance

For liquid-cooled drive motor and drive motor controller, should be able to withstand no less than 200 kPa pressure, no leakage.

5.2.6 Drive motor stator winding cold DC resistance

The DC resistance of the drive motor stator winding should be in accordance with the technical documentation.

Note: The product technical documentation may be a technical agreement or other specification negotiated between the product specification, the manufacturer and the user.

5.2.7 Insulation resistance

5.2.7.1 Insulation resistance of the drive motor stator windings to the housing

5.2.7.1.1 Drive motor stator winding The cold insulation resistance of the enclosure shall be greater than 20 Mn.

5.2.7.1.2 Drive motor stator winding The thermal insulation resistance of the enclosure shall not be less than the value calculated in accordance with equation (1):

Where:

R – drive motor stator winding on the chassis of the thermal insulation resistance, in megger (Mn);

Udmax – the maximum operating voltage, the unit is volts (V);

P – The continuous power of the drive motor, in kilowatts (kw).

When the insulation resistance calculated by the formula (1) is less than 0.38 Mn, it is determined by the 0.38 Mn evaluation.

5.2.7.2 Insulation resistance of the stator winding of the drive motor to the temperature sensor

If the temperature sensor of the drive motor is fixed in the stator winding, the thermal insulation resistance value of the drive motor winding to the temperature sensor should be greater than 20. The thermal insulation resistance value of the stator winding of the drive motor to the temperature sensor should not be lower than that of the equation (1) Value, if according to formula (1) dollars

If the insulation resistance is less than 0.38 Mn, it is determined by 0.38 Mn.

5.2.7.3 Drive motor controller insulation resistance

The thermal and thermal insulation resistance between the power terminals and the housing, the signal terminals and the enclosure, the power terminals and the signal terminals shall be not less than 1 Mn.

5.2.8 Withstanding voltage

5.2.8.1 Inter-turn impulse withstand voltage for drive motor windings

5.2.8.1.1 Driving motor winding Turn-to-turn withstand voltage test The peak value of the impact test voltage shall meet:

  1. A) Drive motor armature winding Turn-to-turn insulation test voltage peak (except armature of brushless DC motor)

The peak voltage of the armature winding of the drive motor shall not be less than that calculated by the formula (2) (except for the armature of the brushless DC motor), and the value of the number of bits (100 volts) shall be corrected by the rounding principle.

UT = 1.7XUG (2)

Where:

UT – Motor winding winding insulation impact test voltage peak, the unit is volts (V);

UG – motor winding to ground insulation voltage withstand voltage test value (RMS), the unit is volts (V), according to the provisions of 5.2.8.2.1 take.

  1. B) drive motor excitation winding inter-turn insulation impact test voltage peak

For the excitation winding of the drive motor, the peak voltage of the turn-to-turn insulation test voltage is generally not lower than that of the formula (2). When the total number of turns is 6 turns or less, the peak value of the impact test voltage is 250X The number of turns, in volts (V), shall be at least 1 000 V.

  1. C) Brush DC drive motor armature winding interdigital insulation impact test voltage peak

For brushless DC drive motors with a maximum operating voltage of 660 V or less, the peak value of the impulse voltage between the commutator segments of the armature shall not be less than 350 V; brushless DC drive motors with a maximum operating voltage of 660 V or more Of the inter-chip impulse voltage peak should not be less than 500 V.

5.2.8.1.2 Drive motor winding turn-to-turn withstand voltage test The wavefront time of the impact test voltage can be 0.2 ys (tolerance) and 1.2 … (tolerance person ^ priority recommendation 0.2 ….

5.2.8.1.3 The reference winding and the test winding discharge waveforms measured by the inter-turn impact voltage test of the motor windings shall be two normal attenuation oscillations with no significant difference.

5.2.8.2 Power frequency withstand voltage

5.2.8.2.1 drive motor winding on the chassis of the power frequency withstand voltage

Driving motor windings should be able to withstand Table 1 specified voltage limits of the power frequency sine withstand voltage test, no breakdown phenomenon, leakage current limit should be consistent with the product technical documents.

 

Table 1 drive motor winding on the chassis power frequency withstand voltage limit

 

序号 Drive the motor or parts Test voltage (rms)
1 Armature windings of drive motors with continuous power less than 1 kW and maximum operating voltage less than 100 V 500 V + 2 times the maximum operating voltage
2 Armature windings of drive motors with continuous power not less than 1 kW or maximum operating voltage not less than 100 V 1000 V + 2 times the maximum operating voltage, the minimum is 1500 V
3 The excitation field of the drive motor 1 000 V + 2 times the maximum excitation voltage, the minimum is 1 500 V

 

 

5.2.8.2.2 Drive motor winding to the temperature sensor voltage withstand voltage

If the temperature sensor of the drive motor is fixed in the stator windings, the motor windings shall be capable of withstanding a withstand voltage test of 1 500 V, no breakdown, and no more than 5 mA.

5.2.8.2.3 drive motor controller frequency withstand voltage

Drive motor controller between the power terminals and the shell, power terminals and signal terminals should be able to withstand the test voltage specified in Table 2, drive motor controller signal between the terminal and the shell should be able to withstand 500 V power frequency resistance Voltage test. Drive motor controller power terminal and shell, power terminal and signal terminals, the signal terminal and the shell between the frequency withstand voltage test duration of 1 min, no breakdown phenomenon, leakage current limit should be consistent with the product technical documents. For the controller that drives the motor controller signal to the housing, it is only necessary to test the power frequency withstand voltage between the power supply terminal and the housing of the drive motor controller.

 

Table 2 drive motor controller between the power terminal and the shell, between the power terminal and the signal terminal voltage withstand voltage limit for the unit

 

Maximum operating voltageUdmax Test voltage (rms)
C^dmax^60 500
6〇<l/dmax<125 1 000
125<l/dmax<250 1 500
250<l/dmax<500 2 000
l/dmax>500 1 000 + 2 X Udmax

 

 

 

5.2.9 overspeed

Driving motor in the hot state should be able to withstand 1.2 times the maximum working speed test, the duration of 2 min, the mechanical should not be harmful

Deformation.

5.3 temperature rise

Under the specified working system, the temperature rise of the drive motor shall comply with the temperature limit specified in 8.10 of GB 755-2008.

5.4 Input and output characteristics 5.4.1 Operating voltage range

The operating voltage range of the drive motor system shall be in accordance with the product technical documentation.

5.4.2 Torque-speed characteristics

The torque – speed characteristics of the drive motor shall be in accordance with the product technical documentation.

5.4.3 Continuous Torque

The continuous torque of the drive motor shall comply with the product technical documentation.

5.4.4 Continuous power

The continuous power of the drive motor shall be in accordance with the product technical documentation.

5.4.5 Peak Torque

The peak torque of the drive motor shall comply with the product technical documentation.

5.4.6 Peak power

The peak power of the drive motor should be in accordance with the product technical documentation. The drive motor in the specified peak power conditions, the provisions of the operating time should be no abnormal phenomenon.

5.4.7 Stall torque

The torque of the drive motor should be in accordance with the technical documentation.

5.4.8 Maximum working speed

At the rated voltage, the maximum speed that can be reached by the drive motor drive operation shall comply with the product technical documentation.

5.4.9 Drive motor system efficiency

5.4.9.1 Maximum efficiency of the drive motor system

At maximum rated voltage, the maximum efficiency of the drive motor system shall not be less than the value negotiated between the manufacturer and the user.

5.4.9.2 Drive motor system efficient working area

At rated voltage, the effective working area of the drive motor system (not less than 80% efficiency) shall not be less than the percentage determined by the manufacturer and the user.

5.4.10 Control accuracy

5.4.10.1 Speed control accuracy

With the speed control function of the drive motor system, speed control accuracy should be consistent with the product technical documents.

5.4.10.2 Torque control accuracy

With the torque control function of the drive motor system, torque control accuracy should be consistent with the product technical documents.

5.4.11 Response time

5.4.11.1 Speed response time

With the speed control function of the motor system, speed response time should be consistent with the product technical documents.

5.4.11.2 Torque response time

With the torque control function of the motor system, the torque response time should be consistent with the product technical documents.

5.4.12 drive motor controller operating current

5.4.12.1 Drive motor controller continuous operating current

The continuous operating current of the drive motor controller should be in accordance with the product technical documentation.

5.4.12.2 Drive motor controller short-term operating current

Under cold working conditions, the short-time operating current of the drive motor controller should be in accordance with the technical documentation of the product, and the duration thereof shall be in accordance with the technical documentation. In the case of electric conditions, the duration of the short-time operating current of the controller should not be less than 30 s.

5.4.12.3 Maximum operating current of the drive motor controller

The maximum operating current of the drive motor controller should be in accordance with the product technical documentation.

5.4.13 Feeding characteristics

When the drive motor is rotated or dragged by inertia, the drive motor is running in the power generation state. The drive motor should be powered by the drive motor, the feed voltage range, the feed current size and the feed efficiency should be in accordance with the product technical documentation.

5.5 security

5.5.1 Safety ground check

The resistance of the conductive part and the housing ground point that can be touched in the drive motor and drive motor controller shall not be greater than o.i n. The grounding point should have a clear grounding mark. If there is no specific ground, a ground mark should be set in a representative location.

5.5.2 Protection function of the drive motor controller

The drive motor controller should have short circuit, overcurrent, overvoltage, undervoltage and overheat protection.

5.5.3 Drive motor controller supports capacitor discharge time

When the drive motor controller has a passive discharge requirements, the drive motor controller support capacitor discharge time should not be greater than 5 min; when the drive motor controller has active discharge requirements, drive motor controller support capacitor discharge time should not exceed 3 S

5.6 Environmental adaptability

5.6.1 Low temperature

5.6.1.1 Low temperature storage

Unless otherwise specified, the drive motor and drive motor controller shall be capable of withstanding a low temperature storage test of 40 ° C for a duration of 2 h. During the low temperature storage for 2 h, the drive motor and the drive motor controller are in the non-energized state. After 2 h of low temperature storage, the insulation resistance in the box should meet the requirements of 5.2.7. After returning to normal, the drive motor and drive motor controller should be able to operate at rated voltage, continuous torque, and continuous power.

5.6.1.2 Low temperature operation

Unless otherwise specified, the drive motor and the drive motor controller should start normally after a 2 h at a low temperature of 40 ° C. After the test, the insulation resistance inside the box should meet the requirements of 5.2.7.

5.6.2 Bureau temperature 5.6.2.1 high temperature storage

Unless otherwise specified, the drive motor and drive motor controller shall be capable of withstanding a high temperature storage test at 85 ° C for 2 h. During the high temperature storage for 2 h, the drive motor and the drive motor controller are in the non-energized state. The oil in the drive motor bearing is not allowed to spill. After 2 h of high temperature storage, the insulation resistance in the box should meet the requirements of 5.2.7. After returning to normal, the drive motor and drive motor controller should be able to operate at rated voltage, continuous torque, and continuous power.

5.6.2.2 high temperature work

The drive motor and drive motor controller shall be capable of working for 2 h at rated voltage, continuous torque, continuous power, and operating at 55 ° C. After the test, the insulation resistance in the box shall meet the requirements of 5.2.7.

If there are special requirements, should be in accordance with the temperature limits specified in Table 3, according to the user and the manufacturer in consultation with the test requirements additional test.

If special requirements, should be in accordance with the temperature limits specified in Table 3, according to the user and the manufacturer in consultation with the test requirements additional test。

Table 3 high temperature operating   temperature limit in degrees Celsius

Product installation site Upper working temperature
A product mounted on an engine 120;105;90
A product placed under a hood or exposed to sunlight 85;70
Installed in other parts of the product 65;55

 

 

5.6.3 hot and humid

Unless otherwise specified, the drive motor and drive motor controller shall be capable of withstanding (40 ± 2) ° C, 90% to 95% relative humidity, 48 h constant hot and humid test, drive motor and drive motor controller should be no obvious Appearance quality deterioration and affect the normal work of the corrosion phenomenon. After the test, the insulation resistance of the rehearsal drive motor in the box shall comply with the requirements of 5.2.7.1 and 5.2.7.2. The insulation resistance between the power lines and the ground (shell) 5.2.7.3. After returning to normal, the drive motor and drive motor controller should be able to operate at rated voltage, continuous torque, and continuous power.

5.6.4 Vibration resistance

5.6.4.1 Sweep vibration

5.6.4.1.1 The drive motor and the drive motor controller shall be capable of withstanding the swept vibration test in three directions of X, Y and Z. If there is no special requirement, the frequency and vibration of the drive motor and drive motor controller shall be tested according to the installation part The severity level shall meet the requirements of Table 4.

 

表4扫频振动试验严酷度等级

Product installation site 频率 振幅 加速度

m/s2

扫频速率

oct/min

每一方向试验时间 h
Hz mm
10 〜50 2.5
On the engine 50 〜200 0.16 1 8
200〜500 250
other 10 〜25 1.2 1 8
25 〜500 30

Note 1: The amplitude and acceleration in the table are applied to the “Z” direction, and for “X” and direction, the amplitude and acceleration can be divided by two.

Note 2: The “Z” direction at the time of vibration inspection is defined as the product mounted on the engine in a direction parallel to the axis of the engine cylinder bore; Other parts of the product is parallel to the vertical direction of the car.

 

5.6.4.1.2 Drive motors and drive motor controllers are normally tested in non-energized state. The test point of the vibration test is generally defined as the junction of the test fixture and the test bed. Driving motor and drive motor controller after vibration test, the parts should be no damage, fasteners should be no loose phenomenon; should be able to rated voltage, continuous torque, continuous power under normal work.

5.6.4.2 Random vibration

5.6.4.2.1 The drive motor and the drive motor controller shall be subjected to random vibration test in three directions of X, Y and Z. If there is no special requirement, the severe limits and test of the random vibration of the installation parts, motor and controller shall continue Time should refer to the provisions of GB / T 28046.3-2011. 5.6.4.2.2 Drive motors and drive motor controllers are normally tested in non-energized state. The test point of the vibration test is generally defined as the junction of the test fixture and the test bed. Driving motor and drive motor controller after vibration test, the parts should be no damage, fasteners should be no loose phenomenon; should be able to rated voltage, continuous torque, continuous power under normal work.

5.6.5 waterproof, dustproof

Shall meet the IP44 or higher protection requirements specified in GB / T 4942.1 and GB 4208.

5.6.6 salt spray

Drive motor and drive motor controller resistance to salt spray capacity, should be able to meet the relevant provisions of GB / T 2423.17. The test period is not less than 48 h. After the test, drive the motor and drive the motor controller to resume 1 h ~ 2 h, should be able to work properly.

5.6.7 Electromagnetic compatibility

5.6.7.1 Electromagnetic radiation harassment

The electromagnetic radiation generated by the drive motor system during operation should be in accordance with the technical documentation.

5.6.7.2 Immunity to electromagnetic radiation

The electromagnetic radiation immunity of the drive motor system should be in accordance with the technical documentation of the product.

5.7 reliability

Meet the provisions of GB / T 29307-2012.

 

6 Inspection rules

6.1 Factory inspection

Drive motor and drive motor controller should be manufactured by the quality inspection department by Taiwan inspection qualified, together with the certificate. The inspection items are in accordance with Appendix B.

6.2 Type inspection

6.2.1 Type test shall be carried out in one of the following conditions:

  1. A) new products or old products to the factory production;
  2. B) after the formal production, such as structure, materials, processes have a greater change, may affect the product performance;
  3. C) normal production for 2 years should be a periodic test;
  4. D) After the product has been discontinued for a long period of time,
  5. E) the factory inspection results and the last type of inspection are quite different;
  6. F) the requirements of the State Quality Supervision Agency to carry out the type inspection.

6.2.2 Sampling

Type inspection should be taken from the factory inspection of qualified products. The number of samples sent for the 3 sets, of which 2 sets for type test, another set of reserve reserve.

6.2.3 Inspection procedures

The inspection items and prototype numbers are specified in Appendix B.

6.2.4 Evaluation of test results

6.2.4.1 Qualified

Type test with the prototype of all items to meet the requirements, the type of inspection qualified.

6.2.4.2 Unqualified

As long as there is a prototype of any project does not meet the requirements, then type test failed.

6.2.4.3 Occasional failure

When the prototype failure is an accidental failure of an isolated nature, it is permissible to replace the failed prototype with a spare prototype, make up all tests before failure (including failure), and then continue the test. If any of the items do not meet the requirements, Unqualified.

6.2.4.4 Performance degradation

The prototype is subjected to environmental testing, allowing the performance to be reduced without affecting its use. The permissible values for performance degradation are specified in the product documentation.

 

7 Marking and marking

7.1 Leads and terminals

Drive motor and drive motor controller The power lines or terminals should have obvious signs. The signals of the power lines or terminals of the drive motors shall comply with the provisions of GB 1971; the positive and negative poles of the power input interface of the motor controller are driven by the “+ a” mark to drive the motor controller and the driving motor Line or power terminals should be marked with the power lines or terminals of the drive motor

Consistent.

7.2 Motor nameplate

The motor nameplate should include the following information:

  1. A) manufacturer name;
  2. B) model, number, name;
  3. C) The main parameters: rated voltage, continuous torque, continuous power, phase, work, peak torque, peak power, the maximum working speed, insulation level, protection level.

7.3 Controller nameplate

The controller nameplate should include the following information:

  1. A) manufacturer name;
  2. B) model, number, name;
  3. C) The main parameters: working system, the number of phases, continuous working current, short-term operating current, protection class.

7.4 Hazard warning

Drive motor and drive motor controller should be in the eye-catching position according to the provisions of GB 2894 set “attention to electric shock” warning signs, and in the “warning” warning signs next to indicate the necessary safe operation tips.