1、Test ProcedureRoadGME14105Power Generation and Storage - Jumpstart Test1 IntroductionNote: Nothing in the specification supersedes appli-cable laws and regulations.Note: In the event of a conflict between the Eng-lish and the domestic language, the English languageshall take precedence.1.1 Purpose.
2、To define the test conditions for theelectrical and physical functionality at jumpstart andpossible customer errors (Misuse).To investigate if the jumpstart requirement is fulfilled,during certain State Of Charge (SOC) for the battery.The measurements to be recorded are: Charging current Consuming c
3、urrent Jump start current Battery voltage Charging voltage Ambient temperature Engine RPM1.2 Foreword. Not applicable.1.3 Applicability. This document is only applicableto the Power Generation and Storage subsystems(PGAS). The engine speed, system voltage, batterystatus and vehicle loads shall be co
4、nsidered as aninterrelated system.1.4 Definitions.1.4.1 State of Charge (SOC). The state-of-chargeof the battery is the percentage of available capacity(ampere-hour, but generally thought of as availablepower).1.4.2 Charge Acceptance. Charge acceptance isthe ability of the battery to use supplied ge
5、nerator cur-rent to recharge the battery by reversing the chemicalreactions that occur during discharge.1.4.3 Fully Charge Battery. A fully charged (100 %state-of-charge) battery is one thata hasbeenchargedatavoltageof16Vfor24hwiththe current limited to 5 x I20orb after a CCA test, the charging time
6、 may be limitedto 16 h1.4.4 Soak Time. Soak time is the time a battery ismaintained at a specified temperature without electri-cal stresses or charging to allow the electrolyte andbattery materials to reach the specified soak temper-ature.1.4.5 100 % SOC (Twenty Hour Capacity). TheTwenty Hour Capaci
7、ty is a measure of the total dis-charge ampere-hour capacity of a battery dischargedfrom 100 % capacity until the terminal voltage is10.5 V, at +25 C at a constant current I20for 20 h.The current I20canbecalculatedfromthefollowingequation:1.4.6 Less than 100 % SOC. Start with a fullycharged battery
8、according to paragraph 1.4.3. Calculate the time to discharge the battery at aver-age I20from the following equation:t = 1 - (% capacity desired) x 20 hExample: Capacity desired is 80 %,t = 1 - 0.8 x 20 h = 4 h Calculate the I20from the following equation C20(Ah) = I20(A) 20 (h)Example: Capacity is
9、70 Ah, I20=70/20=3.5ADischarge the battery with the calculated current (I20)with the calculated time (t), at the ambient tempera-ture +25 C.1.4.7 0 % SOC (Twenty Hour Capacity). TheTwenty Hour Capacity is a measure of the total dis-charge ampere-hour capacity of a battery dischargedfrom a fully char
10、ged battery (100 % capacity) untilthe terminal voltage is 10.5 V, at +25 C at constantcurrent I20for 20 h. The current I20canbecalculatedfrom the following equation: Copyright 2005 General Motors Corporation All Rights ReservedPublication Department: GME Specification CenterJune 2005 - Issue No. 1 P
11、age1of 6PRD045 - VPRE ST 1 10/03GME14105 GM EUROPE ENGINEERING STANDARDS1.4.8 Total Discharged Battery. A total dischargedbattery is a battery discharged from a fully chargedbattery (100 % capacity) until the terminal voltage is10.5 V, at +25 C at constant current I20for 20 h. Thecurrent I20canbecal
12、culatedfromthefollowingequa-tion: C20Axh=I20A x 20 h. Afterwards the bat-tery is completely discharged with a lamp (25 W max.and then should the battery stand still for 168 h with a2.5 mm2cable between plus+ and minus- pole during1week.2 ReferencesNote: Only the latest approved standards are appli-c
13、able unless otherwise specified.None.3 Resources3.1 Facilities. Verification tests shall preferable beperformed in field during summer and winter condi-tions.3.2 Equipment.3.2.1 Measurement. Voltage sensors (vehicle battery, jumpstart battery) 3 Current clump, (charging current, Jumpstart cur-rent,
14、consuming current) 1 IPE TRONIC Master module 1IPETRONICvoltagemodule(VIN) 1 Laptop with DIAdem software installed 1 PCMCIA kvaser card + connection cable (typeHS251) Connection box + wiring harness Or other available equipment (put the results in theenclosed list)3.2.2 Other. 1 auxiliary battery to
15、 supply measurement equip-ment Jumpstartcables16mm2,length2.5mforgasolineengines Jumpstart cables 25 mm2, length 2.5 m for Dieselengines 1 battery (highest capacity released for the respec-tive engine) prepared to 0 % SOC (10.5 V) 1 fully discharged battery (see paragraph 1.4.8)(highest capacity rel
16、eased for the respectiveengine) 1 battery for car giving start aid 2 fully charged 12 V 85 Ah batteries (for misusetest)3.3 Test Vehicle / Test Piece.3.3.1 Vehicle, battery and alternator according tothe latest released status, with a run-in engine(1500.5000) km).3.3.2 The test shall be performed wi
17、th all availablevariants on the specific car model, i.e. engine, gear-box, battery (highestcapacity released forthe respec-tive engine) and vehicle electrical loads alternative.3.4 Test Time. Not applicable.3.5 Test Required Information. Not applicable.3.6 Personnel / Skills. Not applicable.4 Proced
18、ure4.1 Preparation.4.1.1 Preparation of Battery.0%SOC: Dischargeafully chargedbattery(100%SOC, see paragraph 1.4.3) until the terminal voltageis 10.5 V, at +25 C with constant current I20for 20 h.The current I20can be calculated from the equation:C20Axh=I20Ax20hLet the battery “soak” in the specific
19、 testing tempera-ture 24 h, without electrical stress.Total Discharged Battery Discharge a fullycharged battery (100 % SOC see paragraph 1.4.3)until the terminal voltage is 10.5 V, at +25 Cwithconstant current I20for 20 h. The current I20can becalculated from the equation:C20Axh=I20Ax20hDischarge th
20、e battery afterwards by using a lamp(25 W max.). The battery shall then stand still for168hwitha2.5mm2cable between plus(+) andminus(-) pole during 1 week.4.1.2 An engine inspection shall be performed.4.1.3 The ”old” battery shall be replaced with the 0% SOC battery for the first test and with the T
21、otaldischarged battery for the second test.4.1.4 Thecurrentclampsshallbeplacedonthecharging battery cable, on the jumpstart cable and onthe consuming cable, the clamps shall be connectedto the IPE TRONIC test equipment.4.1.5 The voltage sensors shall be connected at thebatteries (see Figure 1). Copy
22、right 2005 General Motors Corporation All Rights ReservedPage2of 6 Issue No. 1 - June 2005PRD045 - VPRE ST G 10/03GM EUROPE ENGINEERING STANDARDS GME14105Figure 1: Connection of Voltage Sensors1 Consuming current2 Generator3 Starter4 Current clamp5 Jumpstart cable6 Battery7 Jumpstart Battery8 Batter
23、y voltage4.1.6 The IPE TRONIC test equipment shall be con-nected to the high-speed bus.4.1.7 DIAdem shall be prepared to record the follow-ing data frames from the CAN bus and the voltagesensors. The sample speed shall be set to 100 Hzand the sample time to 1 000 000 cycles.Table 1: Data Frames CAN
24、BusCAN signals1 Outside Temperature, ambient CAN2 Engine Speed CAN Copyright 2005 General Motors Corporation All Rights ReservedJune 2005 - Issue No. 1 Page3of 6PRD045 - VPRE ST U 10/03GME14105 GM EUROPE ENGINEERING STANDARDSTable 2: Data Frames Voltage sensorsVoltage sensors(8channels)1 Jumpstart V
25、oltage IPE Tronic VIN2 Charging Voltage IPE Tronic VIN3 Jumpstart Current IPE Tronic VIN4 Charging Current IPE Tronic VIN5 Consuming current IPE Tronic VIN6 Spare7 Spare8 Spare4.1.8 The measurement program in the laptop shallbe started and connected to the IPTRONIC module,the measurement set shall b
26、e tested.Paragraph4.1.4to4.1.8orotheravailableequipment.4.2 Conditions.4.2.1 Environmental Conditions. Unless oth-erwise specified in the relevant tests, tests shallbe performed at (+23 5) C without any specialpre-conditioning.Forverification thistestshallbeperformedinSummerenvironment (+40 C) and W
27、inter environment (0 C).In this test the battery shall be tested with a 0 % SOCand total discharge.4.2.2 Test Conditions. Deviations from the require-ments of the test procedures shall have been agreedupon. Such requirements shall be specified on com-ponent drawings, test certificates, reports etc.4
28、.3 Instructions.4.3.1 The test shall be performed as following:The capacity of the donator battery shall not be morethan one category above or below that of the recipientbattery (The charge status of the donator battery shallbe between (70.80) %).4.3.1.1 Check that all measuring points are installed
29、and the jumpstart plus (+) cable have a good con-tact to the positive poles. Wait to connect the jump-start minus (-) connector to avoid pre-load of the dis-charged battery.4.3.1.2 Check that a 0 %SOC battery is installed.4.3.1.3 Start the measurement program in the laptop.Control that all measuring
30、 values are correct exceptthe charging current value.4.3.1.4 Connect the jumpstart minus (-) connectorand re-check all measuring values.4.3.1.5 Start the charging vehicle and run it at idlespeed.4.3.1.6 Try to start the discharged battery vehiclewithin the first 30 s. If it does not start, repeat th
31、estart attempts every minute for 15 s until it starts orstop the test after 15 min if it doesnt start at all.4.3.1.7 If the vehicle starts, disconnect the jumpstartcables and run the engine at idle for 5 min. Try torestart the engine without the jump cables.4.3.1.8 Stop the measurement program in th
32、e laptop.Control that all measuring values are OK. Edit the filewith data i.e. vehicle no., battery data, test engineer,comments etc.4.3.1.9 Store the data according to paragraph4.3.1.8.4.3.1.10 Disconnect the battery and re-place it withthe total discharged battery.4.3.1.11 Re-start the measuring p
33、rogram repeat thetest according to paragraph 4.3.1.3 to 4.3.1.8.4.3.1.12 Disconnect all measuring equipment installa fully charged battery.4.3.1.13 The engine shall start.4.3.2 Misuse Test. Two conditions shall be testedadditionally (misuse test):The battery charge shall be such that the starter doe
34、snot turn and/or the engine does not start.The car shall be jump started per owners manual,unnecessary consumers shall be switched off. Copyright 2005 General Motors Corporation All Rights ReservedPage4of 6 Issue No. 1 - June 2005PRD045 - VPRE ST G 10/03GM EUROPE ENGINEERING STANDARDS GME14105 (12.7
35、 /+0.1) V (use a 100 % SOC battery with thesame capacity of the discharged battery) polarityreversedfor2smax.shallnotresultinanydamageof electrical components. Exception: Fuses blownduring reversed polarity to avoid extensive defectson components are allowed and shall be replaced. (25.4 /+0.2) V (st
36、art aid from truck battery, usetwo85Ahbatteries with 100 % SOC in serial) for60 s max.Note: Protective eyewear and gloves are mandatoryduring the tests. The cross section of the jumpercables shall be sufficiently dimensioned. A fire extin-guisher shall be readily available.4.3.3 Checks. A complete f
37、unctional check shall beperformed. Error codes shall be read out.5Data5.1 Calculations. Not applicable.5.2 Interpretation of Results. With reference tothis Test Procedure, the identification of all versions,equipment, instruments device and results shall bestatedinatest report.5.3 Test Documentation
38、. The measured valuesshall be presented in graphs according to Table 3:Table 3:Plot No. Signals (voltage and current)Plot 1 Charging current/Jumpstart currentPlot 2 Consuming currentPlot 3 Battery voltage/Charge voltagePlot 4 Engine speedThe measured values shall be presented in a testreport.6 Safet
39、yThis method may involve hazardous materials, oper-ations and equipment. This method does not proposeto adress all the safety problems associated with itsuse. It is the responsibility of user of this methodto establish appropriate safety and health practicesand determine the applicability of regulat
40、ory limita-tions prior to use.7 Coding SystemThis test procedure shall be called up in other docu-ments, drawings, VTS, CTS etc. as follows:Example: “Test to GME14105”8 Release and Revisions8.1 Release. This standard was first approved andreleased on 13/JUN/2005.Content Owner: ITDC PE Electric/Elect
41、ronic; SaabThis document was first approved by Saab on13/JUN/2005.8.2 Revisions.Rev. Date Description (Org.)1 JUN 2005 First Release (ITDC) Copyright 2005 General Motors Corporation All Rights ReservedJune 2005 - Issue No. 1 Page5of 6PRD045 - VPRE ST U 10/03GME14105 GM EUROPE ENGINEERING STANDARDSAp
42、pendixACrosssectionofjumpercablesforgasolineengines=16mm2Crosssectionofjumpercablesfordieselengines=25mm2Donatorbattery=Carbatterynotmorethan1capacitycategorybeloworabovethatofthedischargedbatteryNoLoadVoltageofDischargedBatteryinVVehicleno.Ambient/OilTemperatureinCEngine/trans- missionDate/ TestEng.beforestartafterstartTimeinsuntilEnginestartsBatteryCategoryofDischargedBatteryinAhBatteryCategoryofDonatorBatteryinAhNotes Copyright 2005 General Motors Corporation All Rights ReservedPage6of 6 Issue No. 1 - June 2005PRD045 - VPRE ST G 10/03
