1、_ 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 infringement arising there
2、from, 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 International All rights reserved. No part of this p
3、ublication 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) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2910_201404 SURFACE VEHICLE RECOMMENDED PRACTICE J2910 APR2014 Issued 2014-04 Re
5、commended Practice for the Design and Test of Hybrid Electric and Electric Trucks and Buses for Electrical Safety RATIONALE Hybrid Electric powertrain technology has been newly introduced to the commercial Class 4 through 8 truck and bus market. With this introduction, hybrid trucks and buses now co
6、ntain components with higher voltages and stored potential energy. The presence of high voltage batteries, motors, and electronics therefore creates new potential electrical hazards that were not before present on non-hybrid trucks and buses. The safer operation of trucks and buses is a shared prior
7、ity of all truck and bus operators, fleet owners, OEMs, and suppliers and is not a basis for competition. Therefore, the SAE Truck and Bus Council formed the Truck and Bus Hybrid Safety committee. The committee members have volunteered to develop common, consistent design and test practices that can
8、 be applied to hybrid technology for Class 4 through 8 vehicles, in order to benefit the drivers, maintainers, and emergency personnel who come in contact with these vehicles. Although specifications for hybrid electric technology have been developed and published for passenger cars, specifications
9、have yet to be adopted for Class 4 through 8 vehicles. This recommended practice is intended to leverage the existing body of SAE hybrid standards, and to also leverage procedures already developed individually by truck and bus industry manufacturers for the safer operation and service of their vehi
10、cles. The focus of this document will be the documentation of practices for those aspects of hybrid technology that relate uniquely to Class 4 through 8 trucks and buses. SAE INTERNATIONAL J2910 Issued APR2014 Page 2 of 23 TABLE OF CONTENTS 1. SCOPE 2 1.1 Purpose . 2 2. REFERENCES 2 2.1 Applicable D
11、ocuments 2 3. DEFINITIONS . 4 3.1 Terms 4 3.2 Symbols 7 3.3 Acronyms and Abbreviations 8 4. RECOMMENDATIONS . 8 4.1 Design Recommendations 8 4.2 Vehicle Validation Test Recommendations 18 4.3 Design Verification Checklist 22 5. NOTES 23 5.1 Marginal Indicia . 23 FIGURE 1 BLOCK DIAGRAM OF TYPICAL HYB
12、RID ELECTRIC DRIVE SYSTEM 5 FIGURE 2 EXAMPLES OF HIGH VOLTAGE WARNING SYMBOLS AND LABELS 7 1. SCOPE This document will cover the aspects of the design and test of Class 4 through 8 electric and hybrid-electric trucks and buses for electrical safety. The document is intended to address the safety con
13、cerns of electrical systems in commercial vehicles that employ voltages greater than 60 VDC or 30 VAC RMS. 1.1 Purpose The document is intended to provide direction to manufacturers of hybrid electric trucks and buses and their suppliers on design requirements and test procedures that are intended t
14、o make these vehicles safer to operate, service, or recover from an accident. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Pu
15、blications Available 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. The following SAE requirements for high voltage components, wiring, and energy storage are incorporated: SAE J1113 Ele
16、ctromagnetic Susceptibility Measurement Procedures for Vehicle Components (Except Aircraft) SAE J1654 Unshielded High Voltage Primary Cable SAE J1673 High Voltage Automotive Wiring Assembly Design SAE INTERNATIONAL J2910 Issued APR2014 Page 3 of 23 SAE J1742 Connections for High Voltage On-Board Veh
17、icle Electrical Wiring Harnesses - Test Methods and General Performance Requirements SAE J1766 Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Integrity Testing SAE J1772 SAE Electric Vehicle and Plug In Hybrid Electric Vehicle Conductive Charge Coupler SAE J1773
18、SAE Electric Vehicle Inductively Coupled Charging SAE J2074 The Air Bag Systems in Your Car “What the Public Needs to Know“ SAE J2344 Guidelines for Electric Vehicle Safety SAE J2464 Electric and Hybrid Electric Vehicle Rechargeable Energy Storage Sysytem (RESS) Safety and Abuse Testing SAE J2929 Sa
19、fety Standard for Electric and Hybrid Vehicle Propulsion Battery Systems Utilizing Lithium-based Rechargeable Cells SAE J2950 Recommended Practices (RP) for Shipping Transport and Handling of Automotive-Type Battery System - Lithium Ion 2.1.2 ISO Publications Available from American National Standar
20、ds Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. The following ISO requirements for high voltage components, wiring, and energy storage were used for reference in developing this standard: ISO 6469-1 Electric Road Vehicles - Safety Specifications - Part 1:
21、 On-Board Electrical Energy Storage ISO 6469-2 Electric Road Vehicles - Safety Specifications - Part 2: Functional Safety Means And Protection Against Failures ISO 6469-3 Electric Road Vehicles - Safety Specifications - Part 3: Protection of Persons Against Electric Hazards ISO 14572 Road Vehicles -
22、 Round, Sheathed, 60 V And 600 V Screened and Unscreened Single- or Multi-Core Cables - Test Methods and Requirements for Basic- and High-Performance Cables ISO 16750 Environmental Conditions and Testing for Electrical and Electronic Equipment ANSI/IEC 60529 Degrees of Protection Provided by Enclosu
23、res 2.1.3 Federal Motor Vehicle Safety Standards (FMVSS) The following U. S. Federal Motor Vehicle Safety Standard, that applies to electrical safety of hybrid automobiles less than 10 000 pounds, is referenced. FMVSS-124 Accelerator Control Systems FMVSS-305 Electric Powered Vehicles Electrolyte Sp
24、illage and Electrical Shock Protection SAE INTERNATIONAL J2910 Issued APR2014 Page 4 of 23 2.1.4 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. Code of Federal Regulations, 49 CFR Parts 100-185 Code
25、 of Federal Regulations, 49 CFR Part 390.21 Code of Federal Regulations, 29 CFR Part 1910.147 UN38.3 Recommendations on the Transportation of Dangerous Goods Manual of Tests and Criteria Provisions for the classification of lithium batteries (sub-section 38.3) ECE R100 Protection from Electrical Sho
26、ck, Battery Electric Vehicles National Fire Protection Agency Part 70 (National Electric Code) - Article 480 Storage Batteries - Article 490 Equipment, Over 600 V, Nominal Article 625 Electric Vehicle Charging System Underwriters Laboratories UL2202 (October 1996) Electric Vehicle (EV) Charging Syst
27、em Equipment Underwriters Laboratories UL2231 (July 1996) Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits IEEE 1584-2002 IEEE Guide for Performing Arc Flash Hazard Calculations 3. DEFINITIONS 3.1 Terms 3.1.1 Hybrid Electric Vehicle A motor vehicle whose motive power is derived
28、 from a combination of torque generated by an internal combustion engine and an electric machine. 3.1.2 Hybrid Electric System An electric drive system coupled to the powertrain or drive train of a hybrid electric vehicle. The purpose of the hybrid electric system is to add functionality to the vehi
29、cle that improves the efficiency of the vehicle. The hybrid electric system will consist of an electric machine, an energy storage system, and an electronic converter that controls the flow of electricity between the electric machine and energy storage system. SAE INTERNATIONAL J2910 Issued APR2014
30、Page 5 of 23 FIGURE 1 - BLOCK DIAGRAM OF TYPICAL HYBRID ELECTRIC DRIVE SYSTEM 3.1.3 Withstand Voltage, AC An AC test voltage defined as two times the peak working AC voltage plus 1,000 VAC. Withstand Voltage is greater than or equal to (2 x Peak Voltage + 1000) VAC RMS 3.1.4 Chassis Ground Those met
31、al or conducting parts that are electrically connected to the frame of the vehicle and at the same potential as the frame and body structure of the vehicle. 3.1.5 Co-routed wires Any wire that is routed in the same wire harness bundle as a high voltage wire. 3.1.6 De-energized The state of the hybri
32、d electric system in which the energy storage system has been disconnected and the external high voltage circuits have been discharged to a low voltage state. 3.1.7 Dielectric Strength A measure of the ability of an insulation system to maintain separation between high voltage conductors and adjacen
33、t conducting components. 3.1.8 Direct Contact The physical contact and electrical connection between a human and a wire or enclosure designed to conduct a potentially hazardous voltage. 3.1.9 Electrical Insulation The materials that physically separate high voltage conductors to prevent transfer of
34、electrical current or energy to other conductors and to prevent direct contact with humans. Energy StoragePower ConverterElectric MachineHigh VoltageAC CableHigh Voltage Distribution(protection General Requirements, UL 2231 in Section 5 and in UL 2202 Electric Vehicle Charging Equipment in Section 6
35、. 3.1.24 Withstand Voltage, DC The withstand voltage based on UL and ISO standards is twice the peak voltage DC plus 1000VDC. 3.1.25 Working Voltage The maximum RMS voltage developed during system operation. 3.2 Symbols Labels should be posted on high voltage devices such as battery packs and power
36、inverters to identify them as components conducting high voltage potential. The following labels are examples: Warning High Voltage High Voltage Warning High Voltage Danger FIGURE 2 - EXAMPLES OF HIGH VOLTAGE WARNING SYMBOLS AND LABELS SAE INTERNATIONAL J2910 Issued APR2014 Page 8 of 23 Labels shoul
37、d conform to the following standards: ISO3864-1 and ISO3864-2 “Graphical symbols - Safety colors and safety signs - Design principles for safety signs and safety markings ISO7000 Symbol 1641 “Graphical symbols for use on equipment” ANSI Z535.3-2007 “Criteria for Safety Symbols” Labels shall be print
38、ed in the languages pertinent for the country into which the vehicle is sold. For example, hybrid vehicles sold in Canada shall have labels printed in both English and French. 3.3 Acronyms and Abbreviations AIAG Automotive Industry Action Group AC Alternating Current CAN Controller Area Network DC D
39、irect Current ESS Energy Storage System EV Electric Vehicle EVSE Electric Vehicle Supply Equipment FMEA Failure Mode and Effects Analysis HEV Hybrid Electric Vehicle HV High Voltage HVIL High Voltage Inter-Lock IP-64 (water) Ingress Protection (rating) - 64 LV Low Voltage NIOSH - National Institute
40、of Occupational Safety and Health. OEM Original Equipment Manufacturer. PHEV Plug-In Hybrid Electric Vehicle PM Permanent Magnet PMSM Permanent Magnet Synchronous Machine PTO Power Take-Off RESS Remote Energy Storage System RF Radio Frequency Riso Isolation Resistance RMS Root Mean Squared VDC Volts
41、 Direct Current. referring to a continuous voltage VAC Volts Alternating Current, referring to a sinusoidal oscillating voltage. TBD To be determined. TEM Truck Equipment Manufacturer 4. RECOMMENDATIONS 4.1 Design Recommendations 4.1.1 Isolation of High Voltage The design should incorporate electric
42、al isolation sufficient to isolate high voltage from contact with the vehicle chassis and low voltage (12V or 24V) conductors. 4.1.1.1 Insulation Strengths The insulation of high voltage wire harnesses, buss bars, and other high voltage conductors should have sufficient dielectric strength to withst
43、and a voltage potential of two times peak working voltage + 1,000 = withstand voltage i.e., 750 VDC system would be (2 x 750) + 1000 = 2500 VDC) between high voltage conductors and the vehicle chassis or low voltage conductors. SAE INTERNATIONAL J2910 Issued APR2014 Page 9 of 23 DC Circuits: Test vo
44、ltage = 2x working voltage DC + 1000 VDC AC Circuits: Test voltage = 2x peak working voltage AC + 1000 VAC RMS AC circuits are to be tested with a frequency of either 50 Hz or 60 Hz and the switching frequency of the high voltage components. The duration of the test is recommended for 60 s. The leak
45、age current should be less than 1 ma during the test. 4.1.1.2 Insulation Resistance The insulation of high voltage wire harnesses, buss bars, and other high voltage conductors must provide sufficient resistance to limit current flow to safer levels. The resistance must be greater than 500 /V for con
46、ductors carrying high voltage AC electricity, and 100 /V for conductors carrying DC electricity, measured between the high voltage conductors and the vehicle chassis. The complete system needs to meet the 500 /V level. Consequently, individual components should be specified to levels higher than 500
47、 /V. The recommended practice is that component insulation specifications for individual components should be specified to (N x 500) /V or more in order to meet the system requirement where “N” represents the number of components that are interconnected. 4.1.1.3 Insulation during environmental expos
48、ure The HEV system should be demonstrated to maintain its electrical isolation in environmental conditions to which the system will be exposed, for example: water, temperature extremes, temperature changes, vibration, ultraviolet light, or chemical exposure. 4.1.1.4 Co-Routed wires High voltage and
49、low voltage circuits should not be co-routed without ground or shield separation, due to capacitive and inductive coupling of HV transients onto LV circuits If High voltage circuits are routed in parallel with HV wires, the high voltage and low voltage circuits should be separated by grounding or shielding. Any wires routed in bundles without ground or shield separation fro
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