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 theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2010 SAE International All rights reserved. No part of this publication ma
3、y 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: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2344_201003SURFACEVEHICLEINFORMATIONREPORTJ2344 MAR2010 Issued 1998-06Revised 2010-03 Superseding
5、 J2344 JUN1998 (R) Guidelines for Electric Vehicle Safety RATIONALEThis document was generated to provide vehicle safety criteria for Electric Vehicles. It was the intent to include Hybrid vehicles for their High Voltage (HV) systems but we now have additional variations of Hybrid Electric (HEV), Pl
6、ug-In Hybrid Electric (PHEV), Fuel Cell (FCV) and Plug-In Fuel Cell (PFCV) designs to mention a few. The architecture and the size and chemistry of EVs HV source, has also significantly changed since this document was issued due to newer technologies and packaging, and alternative High Voltage sourc
7、es such as UltraCaps, etc have been included in designs. This document is being updated to include these variations and additions. FOREWORDVehicle safety is an important design element for all types of vehicles designed for use on public streets, roadways, and highways. Vehicles produced with liquid
8、 fuels have a long history of creating appropriate safety countermeasures. With the onset of new electric propulsion and charging systems, proposed for large scale production, new safety design parameters will need to be provided to vehicle developers. This SAE Information Report is an attempt to fo
9、rmalize a list of important safety items for vehicle developers. Automotive manufacturers, insurance companies, the repair industry, and first responders groups will need to work together to update this document as more data becomes available.TABLE OF CONTENTS 1. SCOPE 31.1 Purpose . 31.2 Field of A
10、pplication 32. REFERENCES 32.1 Applicable Documents 32.1.1 SAE Publications . 32.1.2 ANSI/IEEE Publications 42.1.3 FMVSS Publication . 42.1.4 IEC Publications 42.1.5 ISO Publication . 42.1.6 UL Publications . 52.1.7 Other Publications . 52.2 Related Publications . 52.2.1 SAE Publications . 52.2.2 CI
11、SPR Publications . 72.2.3 ISO Publications 72.2.4 Federal and Military Publications 8Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2344 Revised MAR2010 Page 2 of 173. DEFINITIONS . 83.1 FEDERA
12、L MOTOR VEHICLE SAFETY STANDARD . 83.2 HIGH VOLTAGE SOURCE . 83.3 MOTOR VEHICLE 83.4 MOTORING 83.5 POTENTIALLY HAZARDOUS VOLTAGE 83.6 POTENTIALLY HAZARDOUS ENERGY 83.7 HAZARDOUS VOLTAGE INTERLOCK LOOP (HVIL) . 93.8 ELECTRICAL ISOLATION 93.9 RECHARGEABLE ENERGY STORAGE SYSTEM (RESS) 93.10 DISCONNECT
13、94. TECHNICAL SAFETY GUIDELINES 94.1 EV Crashworthiness . 94.2 Single-Point Failure . 94.3 Electrical Safety 94.3.1 Electrical Isolation . 94.3.2 High Voltage Withstand Capability 104.3.3 Automatic Hazardous Voltage Disconnects 104.3.4 Manual Disconnects 114.3.5 Interlocks. 114.3.6 Special Tools . 1
14、24.3.7 Grounding . 124.3.8 High-Voltage Wiring Assemblies 124.3.9 High Voltage Connectors 124.3.10 Fusing . 134.4 Fault Monitoring 134.5 Hazardous Liquid Leakage . 134.6 Hazardous Gas Leakage 134.7 Vehicle Immersion. 134.8 Electromagnetic Compatibility (EMC) and Electrical Transient 134.9 Safety Lab
15、eling . 144.10 Charging Communications 144.11 Mechanical Safety . 144.11.1 Shift Mechanisms with “P“ Position 144.11.2 Other Types of Shift Mechanisms . 154.11.3 Towability Design Criteria . 154.12 Rechargeable Energy Storage System State-of-Charge 154.13 High Voltage Batteries 154.14 Fuel Cell Vehi
16、cles . 155. OPERATION . 166. EMERGENCY RESPONSE 167. MAINTENANCE 178. NOTES 178.1 Marginal Indicia . 17FIGURE 1 HAZARDOUS VOLTAGE SYMBOL . 14Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2344
17、Revised MAR2010 Page 3 of 171. SCOPE This SAE Information Report identifies and defines the preferred technical guidelines relating to safety for vehicles that contain High Voltage (HV), such as Electric Vehicles (EV), Hybrid Electric Vehicles (HEV), Plug-In Hybrid Electric Vehicle (PHEV), Fuel Cell
18、 Vehicles (FCV) and Plug-In Fuel Cell Vehicles (PFCV) during normal operation and charging, as applicable. Guidelines in this document do not necessarily address maintenance, repair, or assembly safety issues. 1.1 Purpose The purpose of this SAE Information Report is to provide introductory safety g
19、uideline information that should be considered when designing electric vehicles for use on public roadways. 1.2 Field of Application This document covers electric vehicles having a gross vehicle weight rating of 4536 kg (10 000 lb) or less that are designed for use on public roads. 2. REFERENCES 2.1
20、 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. Applicable FMVSS standards and regulations shall supersede any SAE recommended practices as described in th
21、is document.2.1.1 SAE Publications 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.SAE J1142 Towability Design Criteria and Equipment Use - Passenger Cars, Vans, and Light-Duty T
22、rucks SAE J1654 High Voltage Primary Cable SAE J1673 High Voltage Automotive Wiring Assembly Design SAE J1718 Measurement of Hydrogen Gas Emission from Battery-Powered Passenger Cars and Light Trucks During Battery Charging SAE J1742 Connections for High Voltage On-Board Road Vehicle Electrical Wiri
23、ng 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 SAE Electric Vehicle
24、 inductively Coupled Charging SAE J1797 Recommended Practice for Packaging of Electric Vehicle Battery Modules SAE J1798 Recommended Practice for Performance Rating of Electric Vehicle Battery Modules SAE J2288 Life Cycle Testing of Electric Vehicle Battery Modules Copyright SAE International Provid
25、ed by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2344 Revised MAR2010 Page 4 of 17SAE J2289 Electric-Drive Battery Pack System: Functional Guidelines SAE J2380 Vibration Testing of Electric Vehicle Batteries SAE J2464 Electric an
26、d Hybrid Electric Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse TestingSAE J2578 Recommended Practice for General Fuel Cell Vehicle Safety SAE J2758 Determination of the Maximum Available Power from a Rechargeable Energy Storage System on a Hybrid Electric Vehicle 2.1.2 ANSI/IEE
27、E Publications Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ANSI/IEEE C62.41 Surge Voltages in Low-Voltage AC Power Circuits ANSI/IEEE C62.45 Recommended Practice on Surge Testing for Equipment connected to Low-Voltage (1000 V and less) AC Power
28、Circuits 2.1.3 FMVSS Publication Available from the Superintendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320.FMVSS 305 Electric powered vehicles: electrolyte spillage and electrical shock protection 2.1.4 IEC Publications Available from International E
29、lectrotechnical Commission, 3, rue de Varembe, P.O. Box 131, 1211 Geneva 20, Switzerland, Tel: +41-22-919-02-11, www.iec.ch.IEC 60417 Graphical Symbols for use on Equipment IEC 60479-1 Effects of current on human beings and livestock - Part 1: General aspects IEC 60479-2 Effects of current passing t
30、hrough the human body - Part 2: Special aspects 2.1.5 ISO Publication Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ISO 2575 Road vehicles - Symbols for controls, indicators and tell-tales ISO 11451 Road vehicles - Electrical disturbances by narro
31、wband radiated electromagnetic energy - Vehicle Test MethodsCopyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2344 Revised MAR2010 Page 5 of 172.1.6 UL Publications Available from Underwriters Lab
32、oratories Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096, Tel: 847-272-8800, .UL 991 Standard for Tests for Safety-Related Controls Employing Solid-State Devices UL 1998 Standard for Safety-Related Software UL 2202 Electric Vehicle Charging Equipment October 1996 UL 2231 Personnel Protection Sy
33、stems for Electric Vehicle (EV) Supply Circuits: Part 1: General Requirements, July 1, 1996 UL 2251 Plugs, Receptacles, and Couplers for Electric Vehicles UL 2279 Standard for Electrical Equipment for Use in Class I, Zone 0, 1, and 2 Hazardous (Classified) Locations 2.1.7 Other Publications The foll
34、owing documents should be consulted for additional information regarding EV safety: Applicable State and Local laws and regulations FCC Rules and Regulations Parts 15 and 18 Canadas ICEs 002 European Union 72/245/EEC as amended by 95/54/EC 2.2 Related Publications The following publications are prov
35、ided for information purposes only and are not a required part of this SAE Technical Report.2.2.1 SAE Publications 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.SAE TSB 002 Pre
36、paration of SAE Technical Reports SAE TSB 003 Rules for SAE Use of SI (Metric) Units 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
37、Disturbance Characteristics of Vehicles, Motorboats, and Spark-Ignited Engine-Driven Devices SAE J551-4 Test Limits and Methods of Measurement of Radio Disturbance Characteristics of Vehicles and Devices, Broadband and Narrowband, 150 kHz to 1000 MHz SAE J551-5 Performance Levels and Methods of Meas
38、urement of Magnetic and Electric Field Strength from Electric Vehicles, Broadband, 9 kHz to 30 MHz Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2344 Revised MAR2010 Page 6 of 17SAE J551-11 Ve
39、hicle Electromagnetic Immunity - Off-Vehicle Source SAE J551-12 Vehicle Electromagnetic Immunity - On-Board Transmitter Simulation SAE J551-13 Vehicle Electromagnetic Immunity - Bulk Current Injection SAE J1113-2 Electromagnetic Compatibility Measurement Procedures and Limits for Vehicle Components
40、(Except Aircraft) - Conducted Immunity, 30 Hz to 250 kHz - All Leads SAE J1113-3 Conducted Immunity, 250 kHz to 400 MHz, Direct Injection of Radio Frequency (RF) Power SAE J1113-4 Immunity to Radiated Electromagnetic Fields - Bulk Current Injection (BCI) Method SAE J1113-11 Immunity to Conducted Tra
41、nsients on Power Leads SAE J1113-12 Electrical Interference by Conduction and Coupling - Capacitive and Inductive Coupling via Lines Other than Supply Lines SAE J1113-13 Electromagnetic Compatibility Measurement Procedure for Vehicle Components - Part 13: Immunity to Electrostatic Discharge SAE J111
42、3-21 Electromagnetic Compatibility Measurement Procedure for Vehicle Components - Part 21: Immunity to Electromagnetic Fields, 30 MHz to 18 GHz, Absorber-Lined Chamber SAE J1113-24 Immunity to Radiated Electromagnetic Fields; 10 kHz to 200 MHz - Crawford TEM Cell and 10 kHz to 5 GHz - Wideband TEM C
43、ell SAE J1113-25 Electromagnetic Compatibility Measurement Procedure for Vehicle Components - Immunity to Radiated Electromagnetic Fields, 10 KHz to 1000 MHz - Tri-Plate Line Method SAE J1113-26 Electromagnetic Compatibility Measurement Procedure for Vehicle Components - Immunity to AC Power Line El
44、ectric Fields SAE J1113-41 Limits and Methods of Measurement of Radio Disturbance Characteristics of Components and Modules for the Protection of Receivers Used on Board Vehicles SAE J1113-42 Electromagnetic Compatibility - Component Test Procedure - Part 42 - Conducted Transient Emissions SAE J1115
45、 Guidelines for Developing and Revising SAE Nomenclature and Definitions SAE J1142 Towability Design Criteria and Equipment Use - Passenger Cars, Vans, and Light-Duty Trucks SAE J1715 Hybrid Electric Vehicle (HEV) General Requirements, UL 2231 July 1996 in Section 5 and in UL 2202 Electric Vehicle C
46、harging Equipment October 1996 in Section 6. Systems which are 30 VAC or 60 VDC and above should be designed to protect against direct contact. 3.6 POTENTIALLY HAZARDOUS ENERGY Means the capability for damage to property or injury to persons, other than by electric shock. Potentially hazardous energ
47、y is considered to exist, if between a live part and an adjacent dead metal part or between live parts of different polarity. Refer to SAE J1766 and UL 2202 for further definition on hazardous energy levels. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduct
48、ion or networking permitted without license from IHS-,-,-SAE J2344 Revised MAR2010 Page 9 of 173.7 HAZARDOUS VOLTAGE INTERLOCK LOOP (HVIL) Means a continuous electrical circuit which begins and ends in an automatic disconnect device and sends a small (non-hazardous) electric current through a loop, where hazardous
