1、_ 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7KLVUHSRUWLVSXEOLVKHGE6$(WRDGYDQFHWKHVWDWHRIWHFKQLFDO 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 tKHUHIURPLVWKHVROHUHVSRQVL
2、ELOLWRIWKHXVHU 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 2013 SAE International All rights reserved. No part of this publication may be reproduced, st
3、ored 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: +1 724-776-4970 (outside USA) Fax: 724-776-079
4、0 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/J2380_201312 SURFACE VEHICLE RECOMMENDED PRACTICE J2380 DEC2013 Issued 1998-01 Revised 2013-12 Superseding J2380
5、MAR2009 Vibration Testing of Electric Vehicle Batteries RATIONALE 5 Year review. FOREWORD This document provides a test procedure for characterizing the effect of long-term, road-induced vibration and shock on the performance and service life of electric vehicle batteries. For mature, production-rea
6、dy batteries, the intent of the procedure is to qualify the vibration durability of the battery. Either swept sine wave vibration or random vibration is typically used for the performance of such testing. Random vibration is the focus of this document. The vibration tests defined in this procedure a
7、re based on rough-road measurements at locations likely to be appropriate for mounting of traction batteries in EVs. The data were analyzed to determine an appropriate cumulative number of occurrences of shock pulses at various given G-levels over the life of the vehicle. The vibration envelopes sho
8、wn in Figure 1 of this procedure correspond to approximately 100 000 miles of usage at the 90th percentile. The vibration spectra contained in this procedure have been designed to approximate this cumulative exposure envelope. For testing efficiency, a time-compressed vibration regime is specified t
9、o allow completion of the test procedure in a minimum of 13.6 h and a maximum of 92.6 h of testing, depending on the type of shaker table available and the choice of acceleration levels. SAE INTERNATIONAL J2380 Revised DEC2013 Page 2 of 7 FIGURE 1 - CUMULATIVE VIBRATION ENVELOPES TABLE OF CONTENTS 1
10、. SCOPE 2 2. REFERENCES 3 2.1 Applicable Documents 3 2.2 Related Publication . 3 3. DEFINITIONS . 3 4. TECHNICAL REQUIREMENTS 3 4.1 Prerequisites . 3 4.2 Test Equipment . 4 4.3 Determination of Test Conditions and Test Termination Criteria 4 4.4 Test Procedure 4 4.5 Testing Precautions 6 4.6 Data Ac
11、quisition and Reporting 6 5. NOTES 7 5.1 Marginal Indicia . 7 TABLE 1 VIBRATION SCHEDULE FOR RANDOM VIBRATION TEST 5 FIGURE 1 CUMULATIVE VIBRATION ENVELOPES 2 FIGURE 2 VIBRATION SPECTRA FOR RANDOM VIBRATION TEST 5 1. SCOPE This SAE Recommended Practice describes the vibration durability testing of a
12、 single battery (test unit) consisting of either an electric vehicle battery module or an electric vehicle battery pack. For statistical purposes, multiple samples would normally be subjected to such testing. Additionally, some test units may be subjected to life cycle testing (either after or durin
13、g vibration testing) to determine the effects of vibration on battery life. Such life testing is not described in this procedure; SAE J2288 may be used for this purpose as applicable. Finally, impact testing, such as crash and pothole, is not included in this procedure. SAE INTERNATIONAL J2380 Revis
14、ed DEC2013 Page 3 of 7 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 Publications Available from SAE International, 400 Common
15、wealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J1715 Hybrid Electric Vehicle (HEV) & Electric Vehicle (EV) Terminology SAE J1766 Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Int
16、egrity Testing SAE J1798 Recommended Practice for Performance Rating of Electric Vehicle Battery Modules SAE J2288 Life Cycle Testing of Electric Vehicle Battery Modules SAE J2464 Electric and Hybrid Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing SAE J2929 Safety Standard
17、 for Electric and Hybrid Vehicle Propulsion Battery Systems Utilizing Lithium-based Rechargeable Cells 2.2 Related Publication The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. 2.2.1 USABC Publication Available from Nation
18、al Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161, Tel: 703-605-6000, www.ntis.gov. USABC Electric Vehicle Battery Test Procedures Manual, Revision 2, January 1996. Obtainable by mail order as Report No. DOE/ID-10479, Rev. 2. http:/avt.inl.gov/energy_storage_lib.shtml 3.
19、DEFINITIONS Except as specifically noted in this section, the definitions of SAE J1715 shall apply to this document. DOD - Depth of Discharge where: 0% DOD is a fully charged battery according to the battery manufacture suggested charging recommendations. 80% DOD is 80% of the rated capacity removed
20、 via a C/3 discharge rate from a 0% DOD start. 4. TECHNICAL REQUIREMENTS 4.1 Prerequisites A battery test plan or other test requirements document is normally required for testing using this procedure. The test plan specifies the appropriate test conditions for the Reference Performance Tests (see 4
21、.4.1) and certain vibration frequencies to be used, along with testing precautions and any special handling/testing instructions specified for the battery by the manufacturer and/or the test sponsor. Note that SAE J2464 also describes shock tests (25 g acceleration, half sine wave form with duration
22、 of 15 msec). SAE INTERNATIONAL J2380 Revised DEC2013 Page 4 of 7 Performance of certain Reference Performance Tests specified in SAE J1798 is normally required before and after the conduct of vibration testing. For completeness, these are itemized within the procedure steps in 4.4. Unless otherwise
23、 specified in a test plan document, the test unit shall be tested early in its life (i.e., prior to the performance of any life cycle testing.) 4.2 Test Equipment 4.2.1 Equipment Performance of this procedure requires a one- to three-axis table capable of producing accelerations up to 1.9 G over the
24、 vibration spectra detailed in Figure 2, extending from 10 to approximately 200 Hz. If the unit to be tested can only be vibrated while in a particular physical orientation, a multi-axis table will be required. Additionally, the time required to perform the test can be significantly reduced if the l
25、ongitudinal and lateral axis vibration (or all three axes) can be performed concurrently. Additional equipment should include shielding, spill tank, and/or explosion proof chambers where applicable. 4.2.2 Fixtures Test fixtures are required to properly secure the test unit to the shaker table. The e
26、xact nature of these fixtures depends on the type of table used, the test unit itself, and any restrictions on physical orientation of the test unit. 4.2.3 Instrumentation Special instrumentation hookups capable of withstanding the vibration are required so that important battery conditions can be m
27、onitored during testing. (See 4.5.) 4.3 Determination of Test Conditions and Test Termination Criteria 4.3.1 Electrical Test Conditions Electrical test conditions are determined according to the procedures in SAE J1798 which are specified in 4.4.1. 4.3.2 Vibration Frequencies Vibration test conditio
28、ns are as specified in the procedure steps in 4.4. 4.3.3 Test Termination Vibration testing shall be suspended or terminated if any observed component degradation produces conditions which are abnormal or outside the operating ranges of the battery as specified by the manufacturer. Conditions to be
29、monitored are defined in 4.5. 4.4 Test Procedure 4.4.1 Perform a sequence of Reference Performance Tests consisting of a C/3 Constant Current discharge, a Dynamic Capacity Test discharge to 100% of rated capacity, and a Peak Power discharge, as defined in SAE J1798. 4.4.2 Charge the battery fully us
30、ing the manufacturers recommended charge method. 4.4.3 For each of the vertical, longitudinal, and lateral axes of the battery, select either the normal or alternative G-levels from Table 1 and program the shaker table appropriately. This choice will determine the vibration time required for each ax
31、is, also in accordance with Table 1. (The vibration spectra, shown in Figure 2, are expressed in G2/Hz, so they can be scaled for either set of G-levels.) SAE INTERNATIONAL J2380 Revised DEC2013 Page 5 of 7 TABLE 1 - VIBRATION SCHEDULE FOR RANDOM VIBRATION TEST TEST CONDITIONS VIBRATION SPECTRUM TES
32、T CONDITIONS SOC (%) NORMAL TEST Acceleration (g rms) NORMAL TEST Time (h) NORMAL TEST Cumulative Time, h ALTERNATIVE TEST Acceleration (g rms) ALTERNATIVE TEST Time (h) ALTERNATIVE TEST Cumulative Time, h Vertical Axis Vibration: Vertical 1 spectrum 100 1.9 0.15 0.15 1.9 0.15 0.15 Vertical 1 spectr
33、um 100 0.75 5.25 5.4 0.95 3.5 3.65 Vertical 2 spectrum 100 1.9 0.15 5.55 1.9 0.15 3.8 Vertical 2 spectrum 100 0.75 5.25 10.8 0.95 3.5 7.3 Vertical 3 spectrum 20 1.9 0.15 10.95 1.9 0.15 7.45 Vertical 3 spectrum 20 0.75 5.25 16.2 0.95 3.5 10.95 Longitudinal Axis Vibration: Longitudinal spectrum 60 1.5
34、 0.09 16.29 1.5 0.09 11.04 Longitudinal spectrum 60 0.4 19.0 35.29 0.75 6.7 17.74 Longitudinal spectrum 60 1.5 0.09 35.38 1.5 0.09 17.83 Longitudinal spectrum 60 0.4 19.0 54.38 0.75 6.7 24.53 Lateral Axis Vibration: Longitudinal spectrum 60 1.5 0.09 54.47(1)1.5 0.09 24.62(1)Longitudinal spectrum 60
35、0.4 19.0 73.47(1)0.75 6.7 31.32(1)Longitudinal spectrum 60 1.5 0.09 73.56(1)1.5 0.09 31.41(1)Longitudinal spectrum 60 0.4 19.0 92.56(1)0.75 6.7 38.11(1)1. These cumulative times apply only if all three axes are done separately. FIGURE 2 - VIBRATION SPECTRA FOR RANDOM VIBRATION TEST 4.4.4 Mount the t
36、est unit so that it will be subjected to vibration along the appropriate axes, based on the manufacturers recommended physical orientation. This procedure permits the required vibration to be performed in one, two, or all three axial directions simultaneously depending on the capabilities of the sha
37、ker table used (but see 4.4.5 for other considerations.) SAE INTERNATIONAL J2380 Revised DEC2013 Page 6 of 7 4.4.5 Perform the programmed vibration for the required times, while battery depth-of-discharge is varied from 0% (full charge) to 80% (minimal charge) over the course of the vibration testin
38、g of a given battery. Two approaches are permitted to accomplish this: a. If a one- or two-axis vibration table is used, approximately two-thirds of the vertical axis testing should be done at full charge, followed by the longitudinal and lateral vibration at 40% DOD, and then the remaining vertical
39、 axis vibration at 80% DOD. b. If a three-axis table is used to perform all vibration regimes simultaneously, the total testing period can be divided into three intervals of roughly equal length. The first interval should be performed with the battery fully charged, the second interval with the batt
40、ery at 40% DOD, and the third interval at 80% DOD. 4.4.6 Between each pair of the three intervals of vibration specified in 4.4.5, the battery should be discharged at a C/3 constant current rate for 40% of the rated capacity of the battery. Following the third vibration interval, the battery should
41、be fully recharged. 4.4.7 Repeat the Reference Performance Tests using SAE J1798. This sequence includes a C/3 Constant Current discharge, a Dynamic Capacity Test discharge to 100% of rated capacity, and a Peak Power discharge. 4.5 Testing Precautions At all times during the application of the vibra
42、tion regimes, the test unit shall be instrumented to determine the presence of any of the following conditions: a. Loss of electrical isolation between the battery positive connection and the battery case and/or test equipment ground. The degree of isolation shall be verified regularly, e.g., daily,
43、 during any period of vibration testing to be 0.5 M: or greater (1.0 mA or less leakage at 500V DC). b. Abnormal battery voltages indicating the presence of open- or short-circuit conditions. c. Unexpected resonance conditions within the battery, indicating failure of mechanical tie-down components.
44、 d. Abnormal temperature conditions indicating possible damage to battery cells or thermal management system components. e. Manufacturers recommended measurements not listed above. This should include normal limits and failure limits. Detection of any of the conditions listed in (a) through (e) shal
45、l cause testing to be suspended until the condition has been evaluated and a determination has been made that either it is safe to proceed or the testing should be terminated. 4.6 Data Acquisition and Reporting 4.6.1 Data to be acquired during the Reference Performance Tests of 4.4.1 or 4.4.7 shall
46、be as required for the normal conduct of those tests. Data from these measurements (other than summary results) need not be retained if no anomalous behavior is observed during testing. 4.6.2 A report shall be prepared detailing the actual vibration regimes applied, a compilation and interpretation
47、of all data acquired, and any results of detailed component failure analyses. Also, the pre- and post-vibration electrical performance data that confirms the adequacy of the battery design to withstand the vibration environments shall be summarized. SAE INTERNATIONAL J2380 Revised DEC2013 Page 7 of
48、7 5. NOTES 5.1 Marginal Indicia A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE SAE BATTERY STANDARDS TESTING COMMITTEE
