SAE J 2578-2014 Recommended Practice for General Fuel Cell Vehicle Safety《通用燃料电池车辆安全性用推荐实施规程》.pdf

1、SURFACE VEHICLERECOMMENDED PRACTICEJ2578 AUG2014Issued 2002-12Revised 2014-08Superseding J2578 JAN2009Recommended Practice for General Fuel Cell Vehicle SafetyRATIONALEThis revision to SAE J2578 represents an evolution to requirements for the integration of hydrogen and electrical systems for hydrog

2、en and fuel cell vehicles (FCVs). Rationale for specific changes are summarized below:x Sections 4.2.4.1 and 5.2 and Appendices C and D were updated to clarify and streamline verification test requirements for hydrogen discharges from the vehicle. See Appendices C and D for detailed discussion of is

3、sues and recommended verification procedures.x Sections 4.2.4.2 and 4.2.5 and Appendix E were changed to clarify guidance with regard to locating hydrogen storage systems within passenger, luggage, and cargo compartments to ensure that discharges from vents and Pressure Relief Devices (PRDs) are pro

4、perly managed and directed. x Section 4.2.6 was modified and the new Appendix F was added to ensure that either the vehicle cannot be moved while the fueling nozzle is connected or the fueling receptacle is properly installed, protected, and secured. x Sections 4.2.6, 4.7, and 5.1 were updated to cl

5、arify fuel system labeling requirements and harmonize with vehicle badging requirements in SAE J2990 for emergency responders.x Sections 4.2.7, 4.4.3, 4.4.3.1, 6, and 7.2 were re-worded to clarify previously-defined issues and guidance. x Section 4.4.3 and subordinate subsections were revised to acc

6、ount for Y-capacitors in high voltage circuits and their effect on body current if the high DC and AC voltage circuits are touched. x Section 5.2.2 and Appendix C was changed to extend allowable discharge scaling to smaller (micro) vehicles and not just larger vehicles such as buses. Clarifications

7、to the analytical bases of requirements were also made.x Appendix A was modified to correct post-crash formulas, improve the explanations, and provide an alternative approach for calculating the mass leakage rate.x Appendix E was also modified to clarify guidance with regard to using Pressure Relief

8、 Devices (PRDs) in series._SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent i

9、nfringement arising therefrom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2014 SAE InternationalAll rights reser

10、ved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada

11、)Tel: +1 724-776-4970 (outside USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/J2578_201408SAE INTERNATIONAL J2578 Revised AUG2014 Page 2 of 71FOR

12、EWORDVehicles manufactured with liquid hydrocarbon as fuels have a long history of creating appropriate safety countermeasures. With the onset of new hydrogen fuel cell systems, new mechanical and electrical system safety design parameters will need to be provided to vehicle developers. This SAE rep

13、ort establishes safety criteria and methodologies for fuel cell vehicle and subsystem developers.The purpose of this document is to identify the unique requirements and criteria for the integration of hydrogen fuel systems(as defined in SAE J2579) and fuel cell systems into vehicles.TABLE OF CONTENT

14、S1. SCOPE 4 1.1 Purpose. 4 1.2 Field of Application 4 2. REFERENCES 4 2.1 Applicable Documents 4 2.2 Related Publications . 7 3. DEFINITIONS . 11 4. TECHNICAL SYSTEMS SAFETY GUIDELINES . 16 4.1 General Vehicle Safety . 16 4.2 Fuel System Safety. 18 4.3 Fuel Cell System Safety 22 4.4 Electrical Syste

15、m Safety . 23 4.5 Mechanical Safety. 28 4.6 Fail-Safe Procedures 29 4.7 Safety Labels and Badging . 30 5. OPERATION . 32 5.1 Owners Guide or Manual . 32 5.2 Normal Vehicle Discharges. 32 5.3 Inadvertent or Inappropriate Operation of the Vehicle 34 5.4 Byproducts 34 6. EMERGENCY RESPONSE 34 7. MAINTE

16、NANCE 35 7.1 Service Manual . 35 7.2 Defueling Procedures 35 7.3 Facility Safety 35 8. NOTES 35 8.1 Marginal Indicia. 35 SAE INTERNATIONAL J2578 Revised AUG2014 Page 3 of 71APPENDIX A POST-CRASH CRITERIA FOR COMPRESSED HYDROGEN SYSTEMS . 36 APPENDIX B GUIDANCE FOR CONDUCTING HIGH VOLTAGE TESTS 50 AP

17、PENDIX C GUIDANCE FOR CONDUCTING DISCHARGE EVALUATIONS INTO SPACES SURROUNDING VEHICLES 54APPENDIX D GUIDANCE FOR CONDUCTING LOCAL EXHAUST FLAMMABILITY AND TOXICITY EVALUATIONS OF VEHICLE DISCHARGES 61APPENDIX E GUIDANCE FOR THE PACKAGING OF HYDROGEN SYSTEMS INCLUDING PRDS, SHIELDS, AND FLOW BARRIER

18、S 68APPENDIX F TEST METHOD FOR DRIVE-AWAY PROTECTION .71 FIGURE 1 POTENTIAL FLAMMABILITY OF HYDROGEN DISCHARGES IN AIR 14 FIGURE 2 HIGH VOLTAGE SYMBOL . 27 FIGURE 3 EXAMPLES OF BLUE DIAMOND HYDROGEN VEHICLE BADGING 32 FIGURE A1 PRESSURE LOSS WITH 606 G HYDROGEN LEAKAGE. 37 FIGURE A2 PRESSURE LOSS WI

19、TH 606 G HYDROGEN LEAKAGE. 38 FIGURE A3 TIME PERIODS FOR 5% PRESSURE LOSS 39 FIGURE A4 TEST PROCEDURE. 40 FIGURE A5 HYDROGEN PRESSURE DENSITY CORRELATION. 41 FIGURE A6 LEAKAGE MASS CHARACTERISTICS OVER TIME 42 FIGURE A7 HYDROGEN LEAKAGE FOR VARIOUS INITIAL TEST PRESSURE . 42 FIGURE A8 LEAKAGE MASS I

20、N 60-MINUTE AT DIFFERENT GAS TEMPERATURE . 43 FIGURE A9 HELIUM LEAKAGE OVER 60 MINUTES . 44 FIGURE A10 HELIUM PRESSURE LOSS OVER 60 MINUTES . 44 FIGURE A11 HELIUM PRESSURE LOSS OVER 60 MINUTES . 44 FIGURE A12 TIME PERIODS FOR 5% PRESSURE LOSS 45 FIGURE A13 PRESSURE CHARACTERISTICS AND TIME PERIODS F

21、OR 5% PRESSURE LOSS . 46 FIGURE A14 TIME PERIODS FOR 5% PRESSURE LOSS 47 FIGURE A15 TIME PERIODS FOR 5% PRESSURE LOSS WITH A SAME PRESSURE SENSOR RANGE RATIO. 47 FIGURE B1 ILLUSTRATION OF ELECTRIC SHOCK DUE TO CONTACT WITH A HIGH VOLTAGE SYSTEM HAVING A LOW ISOLATION RESISTANCE . 50 FIGURE B2 TYPICA

22、L APPROACH FOR CONDUCTING THE HIGH VOLTAGE ISOLATION TEST FOR THE VEHICLE IN NORMAL OPERATION . 50 FIGURE C1 CALCULATED STEADY-STATE HYDROGEN CONCENTRATIONS VS HYDROGEN EMISSION RATE FOR VARIOUS AIR EXCHANGE RATES WITH STANDARD ENCLOSURE . 56 FIGURE C2 ALLOWABLE LEAKAGE AND PERMEATION FROM THE HYDRO

23、GEN STORAGE SYSTEM FOR STANDARD VEHICLES AND FOR LARGER VEHICLES FOR 0.03 ACH 57 FIGURE D1 TEST SETUP FOR DETERMINATION OF SUSTAINABLE IGNITION THRESHOLD 63 FIGURE D2 TEST SETUP FOR DETERMINING EFFECTS OF START-UP EMISSIONS (INJECTED VOLUME METHOD SHOWN). 66 FIGURE D3 TEST SETUP FOR DETERMINING EFFE

24、CTS OF SHUTDOWN EMISSIONS (INJECTED VOLUME METHOD SHOWN). 66 TABLE 1 SUMMARY OF ISOLATION REQUIREMENTS FOR IN-USE OF VARIOUS TYPES OFHIGH VOLTAGE SYSTEMS. 24 SAE INTERNATIONAL J2578 Revised AUG2014 Page 4 of 711. SCOPEThis SAE Recommended Practice identifies and defines requirements relating to the

25、safe integration of the fuel cell system, the hydrogen fuel storage and handling systems (as defined and specified in SAE J2579) and high voltage electrical systems into the overall Fuel Cell Vehicle. The document may also be applied to hydrogen vehicles with internal combustion engines.This documen

26、t relates to the overall design, construction, operation and maintenance of fuel cell vehicles.1.1 PurposeThe purpose of this document is to provide mechanical and electrical system safety guidelines, safety criteria and methodologies that should be considered when designing fuel cell vehicles for u

27、se on public roads.1.2 Field of ApplicationThis document is applicable to fuel cell vehicles designed for use on public roads.2. REFERENCES2.1 Applicable DocumentsThe following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue

28、 of SAE publications shall apply.2.1.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.Applicable FMVSS standards and regulations should supersede any SAE recomme

29、nded practices as described in this document.SAE J1142 Towability Design Criteria and Equipment Use - Passenger Cars, Vans, and Light-Duty TrucksSAE J1645 Fuel Systems and Components - Electrostatic Charge MitigationSAE J1718 Measurement of Hydrogen Gas Emission from Battery-Powered Passenger Cars a

30、nd Light Trucks During Battery ChargingSAE J1739 Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)SAE J1742 Connections for High Voltage On-Board Road Vehicle Electrical Wiring Harne

31、sses - Test Methods and General Performance RequirementsSAE J1766 Recommended Practice for Electric, Fuel Cell and Hybrid Electric Vehicle Crash Integrity TestingSAE J1772 SAE Electric Vehicle and Plug in Hybrid Electric Vehicle Conductive Charge CouplerSAE J1773 SAE Electric Vehicle Inductively Cou

32、pling ChargingSAE J2344 Guidelines for Electric Vehicle SafetySAE INTERNATIONAL J2578 Revised AUG2014 Page 5 of 71SAE J2574 Fuel Cell Vehicle TerminologySAE J2579 Standard for Fuel Systems in Fuel Cell and Other Hydrogen Vehicles2.1.2 ANSI PublicationAvailable from American National Standards Instit

33、ute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ANSI Z535.4 Product Safety Sign and Label2.1.3 Motor Vehicle Safety StandardsMotor vehicle standards for the U.S. and Canada are listed below. In other countries, other regulations may apply.2.1.3.1 Federal Motor Vehi

34、cle Safety Standards (FMVSS)Available from DLA Document Services, Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6396, http:/quicksearch.dla.mil/.The following Federal Motor Vehicle Safety Standards are specifically applicable to this document for use in the U.S. See the

35、 Code of Federal Regulations (49 CFR 571) for other applicable FMVSS. FMVSS 301 Fuel System IntegrityFMVSS 303 Fuel System Integrity of Compressed Natural Gas VehiclesFMVSS 305 Electric Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection2.1.3.2 Canadian Motor Vehicle Safety Standa

36、rds (CMVSS)Available from Transport Canada, Road Safety and Motor Vehicle Regulation Directorate, P.O. Box 8880, Ottawa Post Terminal, Ottawa, Ontario, K1G.3J2, www.tc.gc.ca.The following Canadian Motor Vehicle Safety Standards are specifically applicable to this document for use in Canada. See the

37、Canada Motor Vehicle Act for other applicable CMVSS.CMVSS 301.2 Fuel System IntegrityCMVSS 305 Electric Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection2.1.4 IEC PublicationsAvailable from IEC Central Office, 3, rue de Varembe, P.O. Box 131, CH-1211 Geneva 20, Switzerland, Tel:

38、 +41 22 919 02 11, www.iec.ch.IEC 60079 (Parts 0 through 20) Electrical Apparatus for Explosive Gas AtmospheresIEC 60417 (Parts 1 and 2) Graphical Symbols for Use on EquipmentIEC 60950 Safety TestingSAE INTERNATIONAL J2578 Revised AUG2014 Page 6 of 712.1.5 ISO PublicationsAvailable from American Nat

39、ional Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, Tel: 212-642-4900, www.ansi.org.ISO 6469-1 Electrically propelled road vehiclesSafety specificationsPart 1: On-board rechargeable energy storage system RESSISO 6469-2 Electrically propelled road vehicles - Safety specific

40、ations - Part 2: Functional safety means and protection against failuresISO 6469-3 Electrically propelled road vehicles - Safety specifications - Part 3: Protection of persons against electric shockISO 26262 Road Vehicle Functional Safety (Parts 1 through 10)ISO 20653 Road vehicles - Degrees of prot

41、ection (IP code) - Protection of electrical equipment against foreign objects, water and access2.1.6 UL PublicationsAvailable from UL, 333 Pfingsten Road, Northbrook, IL 60062-2096, Tel: 847-272-8800, .UL 991 Standard for Tests for Safety-Related Controls Employing Solid-State DevicesUL 1998 Standar

42、d for Safety-Related SoftwareUL 2202 Standard for Electric Vehicle (EV) Charging System EquipmentUL 2231 Personnel Protection Systems for Electric Vehicle (EV) Supply CircuitsUL 2251 Plugs, Receptacles, and Couplers for Electric VehiclesUL 2279 Standard for Electrical Equipment for Use in Class I, Z

43、one 0, 1, and 2 Hazardous (Classified) Locations2.1.7 Other PublicationsThe following publications are provided for information purposes only and are not a required part of this SAE Technical Report.DGMK Research Report 508, 1996 Avoiding the Ignition of Otto-type Fuel/Air Mixtures when Refueling Au

44、tomobiles at Gas StationsEPRI TR-105939 Final Report Prepared Underwriters Laboratories, December 1995, “Personnel Protection Systems for Electric Vehicle Charging Circuits”NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment 1998 EditionSAE INTERNATIONAL J2578 Revised AU

45、G2014 Page 7 of 712.2 Related PublicationsThe following publications are provided for information purposes only and are not a required part of this SAE Technical Report.2.2.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (insid

46、e USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J551-1 Performance Levels and Methods of Measurement of Electromagnetic Compatibility of Vehicles, Boats (up to 15 m), and Machines (16.6 Hz to 18 GHz)SAE J551-2 Test Limits and Methods of Measurement of Radio Disturbance Characteristi

47、cs of Vehicles, Motorboats, and Spark-Ignited Engine-Driven DevicesSAE J551-4 Test Limits and Methods of Measurement of Radio Disturbance Characteristics of Vehicles and Devices, Broadband and Narrowband, 150 kHz to 1000 MHzSAE J551-5 Test Performance Levels and Methods of Measurement of Magnetic an

48、d Electric Field Strength from Electric Vehicles, Broadband, 9 kHz to 30 MHzSAE J551-11 Vehicle Electromagnetic Immunity - Off-Vehicle SourceSAE J551-12 Vehicle Electromagnetic Immunity- On-Board Transmitter SimulationSAE J551-13 Vehicle Electromagnetic Immunity- Bulk Current InjectionSAE J1113-2 El

49、ectromagnetic Compatibility Measurement Procedures and Limits for Vehicle Components (Except Aircraft) - Conducted Immunity, 15 Hz to 250 kHz- All LeadsSAE J1113-3 Conducted Immunity, 250 kHz to 400 MHz, Direct Injection of Radio Frequency (RF) PowerSAE J1113-4 Immunity to Radiated Electromagnetic Fields- Bulk Current Injection (BCI) MethodSAE J1113-11 Immunity to Conducted Transients on Power LeadsSAE J1113-12 Electrical