Technical column
CASES
New energy vehicle power battery pack EMC test introduction
Release time:
2022-08-06 00:00
Source:
1 reference standard
standard name
ISO 7637- 2: 2004Road vehicles -- Electrical disturbance by conduction and coupling
ISO 7637- 3: 2007Road vehicles -- Electrical disturbance by conduction and coupling
CISPR25:2008Radio disturbance characteristics for the protection of receivers used on board vehicles, boats, and on devices-Limits and methods of measurement
ISO11452-2:2004Road vehicles – Component test methods for electrical disturbances from narrowband radiated electromagnetic energy—Part 2: Absorber-lined shielded enclosure
ISO11452-4:2005Road vehicles – Component test methods for electrical disturbances from narrowband radiated electromagnetic energy—Part 4:Bulk current injection (BCI)
ISO10605:2008Road vehicles- Test methods for electrical disturbances from electrostatic discharge
ISO 16750 -2：2006Road Vehicles – Environmental Conditions and testing of E/E equipment
2 functional status levels
In order to be able to represent the effect of the battery pack system after testing, the test results are defined as several functional states.
Functional status:
State A: The sample can meet all the specified functional specification requirements during and after the test;
State B: All functions of the sample can meet all the specified functional specification requirements during the test, but one or more parameters are allowed to exceed the limit requirements, and all functions can automatically return to the normal limit range after the test; storage memory function The requirements of functional status A shall be met;
State C: One or more functions of the sample do not meet the requirements of the functional specification during the test, but all functions automatically return to normal state after the test;
State D: One or more functions of the sample do not meet the requirements of the functional specification during the test, but after the test, the function returns to the normal state after reset or simple technical treatment (such as replacing the fuse);
State E: During and after the test, one or more functions of the sample do not meet the requirements of the functional specification and must be replaced or repaired.
3 working modes
The battery pack system will work in the following modes:
|
|
no power |
fast charging |
discharge |
slow charging |
cool down |
|
A |
√ |
|
|
|
|
|
B |
|
|
√ |
|
|
|
C |
|
|
√ |
|
√ |
|
D |
|
|
|
√ |
|
|
AND |
|
√ |
|
|
|
|
F |
|
|
|
√ |
√ |
4Example of mechanical structure
Please see the following for the mechanical appearance and structure as a reference
4.1 Example of Mechanical Outline of Battery Pack System
4.2 Example of Battery Pack System Interface
5 test requirements
5.1 General test requirements
The low-voltage power supply voltage of the battery pack in the test bench needs to meet: 13V≤U≤14.5V, and a lead-acid battery with a nominal voltage of 12V is connected in parallel at the same time (starting or power battery is acceptable);
The battery system needs function monitoring during the test process, and after the test is completed, a function check must be carried out. (See Appendix A: Examples of Functional Monitoring and Inspection Items)
Unless otherwise specified, the test conditions are as follows:
Test temperature: 23 °C ± 5 °C ambient temperature
Supply voltage: 14V ± 0.2V
Measuring equipment: have sufficient accuracy and stability, and its accuracy should be an order of magnitude higher than the accuracy of the measured index or the error should be less than 1/3 of the allowable error of the measured parameter
Working voltage range:
|
Rated voltage U(V) |
Operating Voltage |
|
|
Umin |
Max |
|
|
12 |
9V |
16V |
special requirements:
The frequent spontaneous combustion of new energy vehicles is largely due to the possibility of fire, combustion or even explosion in lithium battery packs due to immature technology, which threatens people's lives and property, as shown in the figure below Show.
Therefore, the security of the test environment is particularly important. For the wedge used in the anechoic chamber, it must meet the fire class A2 (non-combustible) according to the DIN EN 13501-1 standard. At present, the sharpening materials of the ten-meter method, three-meter method and one-meter method of the three Franconia darkrooms configured in our company's laboratory all meet this fire protection requirement, as shown in the figure below.
10-meter darkroom 3-meter darkroom
1-meter dark chamber A2 fire rating test
5.2 General Electrical Test Items
5.2.1 Reverse polarity protection
--Test purposes
Simulate the anti-reverse polarity protection ability of the test piece when the external power supply is started and the polarity is reversed
--experiment method:
|
Test Conditions |
|
|
temperature |
Room temperature (+23 ° C ± 5 ° C ) |
|
duration |
（60 ± 6）s |
|
Test voltage |
-14V ± 0.2V |
The test piece is connected normally, and according to the test conditions, apply test voltage to all low-voltage power supply input ports of the test piece, and observe the phenomenon.
After the normal working voltage is restored, perform a functional test on the controller and observe the phenomenon.
--skills requirement:
Functional class: C
5.2.2 Long-term overvoltage resistance test
--Test purposes
Simulate the situation when the output voltage of DC/DC is at the maximum output voltage of 16V.
--experiment method:
|
Test Conditions |
|
|
temperature |
35°C |
|
test duration |
60 min |
|
Test voltage |
15.8~16V |
|
Operating mode |
C (fan duty cycle setting 50%) |
The test piece is connected normally, and according to the test conditions, apply test voltage to all low-voltage power supply input ports of the test piece, and observe the phenomenon;
After the normal working voltage is restored, perform a functional test on the controller and observe the phenomenon.
--skills requirement:
Functional class: A
5.2.3 Short-term overvoltage withstand test
--Test purposes:
Simulate the situation when the DC/DC output overvoltage protection fails and the output voltage of the DC/DC is higher than the normal voltage.
--experiment method:
|
Test Conditions |
|
|
temperature |
room temperature |
|
test duration |
60s |
|
Test voltage |
24V ± 0.2V |
|
Operating mode |
C (fan duty cycle setting 50%) |
The test piece is connected normally, according to the test conditions, apply test voltage to all low-voltage power input ports of the test piece, and observe the phenomenon
After the normal working voltage is restored, perform a functional test on the battery pack system and observe the phenomenon.
--skills requirement:
Functional level: C (allows the fan to enter overvoltage protection, and the function is normal after the voltage is restored. The battery pack system functions normally)
5.2.4 Quiescent current
--Test purposes:
Measure the system quiescent current of the battery pack system.
--experiment method:
System status of the battery pack system: turn off all electrical appliances that can be directly shut down in the battery pack system, and only connect the low-voltage test power supply terminal and the fan power line, so that the battery pack system is in a closed-loop state, and measure the current flowing through the low-voltage test power supply terminal port.
Measuring time: The measuring time is not less than 20min. Observe the change of quiescent current. There should be at least one current drop. If the quiescent current does not drop within 30 minutes and is greater than 200mA, check whether the battery pack system is completely shut down.
Measurement method: When the system is working, disconnect all signals, and test the current of the low-voltage side power supply terminal 3 minutes after the controller is not working.
--skills requirement:
<1mA。
5.2.5 Reset performance during voltage drop
--Test purposes:
The reset performance of the sample when the voltage drop is simulated. This test is applicable to samples with reset function.
--experiment method:
Working mode: C (fan duty cycle is set to 50%);
Test implementation: see Figure 3.
Apply voltage Uomin ≥ 10 s.
Voltage drop amplitude: 0.5 V/time.
Voltage change time: < 100ms.
Buck dwell time: 5s.
Functional test time (at Uomin): ≥10 s.
When the voltage reaches ≤0.5 V, the test ends.
--skills requirement:
In the operating voltage range: Functional state A
Operating voltage outside the range: Functional state C
5.2.6 Short circuit protection
--Test purposes:
Analog input and output are shorted.
--experiment method:
Working mode: the battery pack system is powered on, the external input and output lines of the battery pack system and the low-voltage connector of the fan are short-circuited to the power supply terminal and the ground terminal in turn, and the duration is 60S, and other input and output lines are open.
step:
Connect to the power supply, activate the output, last for 60S, turn off the output, disconnect the power supply, function test;
Connect to ground, activate the output, last for 60S, turn off the output, disconnect the power supply, function test;
--skills requirement
Functional status C.
5.2.7 Slow rise and fall of supply voltage
--Test purposes:
Simulate the slow discharge and charge of a 12V battery
--experiment method:
Working mode: C (fan duty cycle is set to 50%);
Apply the test voltage to all low-voltage power input terminals;
The supply voltage drops from Umax to 0V;
The supply voltage rises from 0V to Umax;
Voltage change (0.5±0.1)V/min.
--skills requirement
Within the working voltage range: functional level A;
Outside the working voltage range: functional class C;
5.2.8 Functions during undervoltage and overvoltage
--Test purposes:
Verify the function of the test piece under overvoltage and undervoltage.
--experiment method:
Working mode: C (fan duty cycle is set to 50%);
Apply the test voltage to all power input terminals of the test piece.
--skills requirement
The test voltage <6V allows the test piece to have no function;
6V≤test voltage<9V (select 6V voltage point), the output and input functions of the test piece are closed, the communication function is normal, and the voltage undervoltage event can be recorded;
9V≤test voltage≤16V, (choose 9V and 16V voltage points) all functions of the test piece are normal;
16V<test voltage≤18V (choose 18V voltage point), the output and input functions of the test piece are closed, the communication function is normal, and the voltage overvoltage event can be recorded. After the normal working voltage is restored, the function returns to normal;
18V<test voltage≤26.5V (26.5V voltage point is selected), the output and input functions of the test piece are closed, the communication function can be maintained normally for 1min, and the sample cannot be damaged. After the normal working voltage is restored, the function returns to normal.
5.3 EMC test
5.3.1 Radiated Emissions (RE)
--Test purposes:
To examine the RF radiation emission of components, the test method and test equipment meet the requirements of CISPR 25:2008.
--Test arrangement: (Refer to CISPER 25 6.4.3 Figure 11, Figure 12, Figure 13.)
--Test requirements:
Application frequency range: 150kHz ~ 2500MHz.
Specimen working mode: C (fan duty cycle 0, 90% test respectively, discharge circuit connected to resistive load, 3A current discharge);
Antenna system requirements: 150kHz ~ 30MHz frequency range measurement using monopole vertical antenna;
30MHz ~ 200MHz frequency range measurement using biconical antenna, including vertical polarization
and horizontal polarization direction;
200MHz～1000MHz frequency range measurement using logarithmic periodic antenna, including vertical
Straight polarization and horizontal polarization direction;
1000MHz ~ 2500MHz frequency range measurement using a horn antenna, including vertical polarization and horizontal polarization direction;
List of limit values:
Note: quasi-peak test method --- use the peak value to pre-scan first, select the maximum exceeding point for the frequency band whose peak value does not meet the quasi-peak limit, read the quasi-peak value and record it, do not directly use the quasi-peak value to scan.
5.3.2 Conduct Emissions (CE)
--Test purposes:
Investigate the size of the RF conducted emission of the power cord of the component, and the test method and test equipment meet the requirements of CISPR 25:2008;
--Test layout: (refer to CISPER25 6.2.2.2 Figure 5)
--Test requirements:
Measured on low voltage power lines only
Application frequency range: 150kHz ~ 108MHz.
Specimen working mode: C (fan duty cycle 0, 90% test respectively, discharge circuit connected to resistive load, 3A current discharge);
List of limit values:
|
Average and quasi-peak limit requirements for conducted emissions |
||||
|
Test frequency band |
RF business |
Frequency Range |
Average limit dB( μ V) |
Quasi-peak limit dB( μ V) |
|
1 |
Broadcast LW |
0.15MHz～0.30MHz |
70 |
77 |
|
2 |
/ |
0.30MHz～0.53MHz |
70 |
77 |
|
3 |
Broadcast MW |
0.53MHz～1.8MHz |
50 |
57 |
|
4 |
/ |
1.8MHz～5.9MHz |
50 |
57 |
|
5 |
Broadcast SW |
5.9MHz～6.2MHz |
45 |
52 |
|
6 |
/ |
6.2MHz～26MHz |
45 |
52 |
|
7 |
Mobile Business CB |
26MHz～28MHz |
36 |
43 |
|
8 |
/ |
28MHz～30MHz |
36 |
43 |
|
9 |
Mobile service VHF |
30MHz～68MHz |
36 |
43 |
|
10 |
TV band I |
68MHz～76MHz |
30 |
37 |
|
11 |
Radio FM |
76MHz～108MHz |
30 |
37 |
|
Note: quasi-peak test method --- use the peak value to pre-scan first, select the maximum exceeding point for the frequency band whose peak value does not meet the quasi-peak limit, read the quasi-peak value and record it, do not directly use the quasi-peak value to scan. |
||||
5.3.3 RF conducted emission-current method
--Test purposes:
Investigate the size of all wiring harnesses of components to space conduction emission to avoid interference with other circuits;
--Test methods and equipment:
Meet the requirements of CISPR 25-2008. The experimental harness is all put into the test ring;
--Test distance:
The distance between the current clamp and the EUT terminal is 50mm and 750mm;
--Test requirements:
Application frequency range: 150kHz ~ 108MHz.
Specimen working mode: C (fan duty cycle 0, 90% test respectively, discharge circuit connected to resistive load, 3A current discharge);
List of limit values (in quasi-peak and average values):
Note: quasi-peak test method --- use the peak value to pre-scan first, select the maximum exceeding point for the frequency band whose peak value does not meet the quasi-peak limit, read the quasi-peak value and record it, do not directly use the quasi-peak value to scan.
5.3.4 Radiated Immunity (free field)
--Test purposes:
To examine the ability of parts to resist narrow-band electromagnetic energy radiation, the test methods and test equipment meet the requirements of ISO 11452-2;
--Test layout: (refer to ISO11452-2 7.6 Figure 2, Figure 3)
--Test requirements:
Test frequency: 200M~2000MHz
Working mode: C (fan duty cycle 50%, discharge circuit connected to resistive load, 3A current discharge);
List of limit values:
Test level: 3
Functional status: A
5.3.5 Bulk Current Injection (BCI)
--Test purposes:
To examine the ability of components to resist narrow-band electromagnetic energy radiation, the test methods and test equipment meet the requirements of ISO 11452-4.
--Test arrangement: (refer to ISO11452-4)
Keywords: 1 EUT 2 wiring harness 3 load simulator 4 simulation and detection system 5 power supply 6 artificial network 7 optical fiber 8 measurement equipment 9 radio frequency measurement probe 10 radio frequency injection probe 11 ground plane 12 insulating mat 13 shielded room
--Test requirements:
Test frequency: 1M~400MHz;
Working mode: C (fan duty cycle, 50%, the discharge circuit is connected to a resistive load, 3A current discharge);
List of test levels:
Test level: Ⅲ
Functional status: A
5.3.6 ESD
--Test purposes:
To examine the anti-static discharge ability of components, the test method and test equipment meet the requirements of ISO10605-2008;
The test is divided into passive mode discharge test and active working mode discharge test.
—Test arrangement
Passive test mode layout:
Active test mode layout:
--Test requirements:
Passive test mode:
During the test, the device under test is not connected to the power supply and load;
Test points: each pin of the connector, the grounding point of the shell of the battery pack system, and the mounting bracket of the battery pack system.
The test levels are shown in the table below:
|
discharge type |
severity level |
Number of discharges per polarity |
functional status |
|
contact discharge C=150pF,R=330Ω |
±8kV |
3 times |
C |
|
air discharge C=150pF,R=330Ω |
±15kV |
3 times |
C |
Active test mode:
Working mode C (fan duty cycle 50%, discharge circuit connected to resistive load, 3A current discharge);
Test points: the grounding point of the battery pack system casing, and the battery pack system mounting bracket.
The test levels are shown in the table below:
Direct discharge:
|
discharge type |
severity level |
Number of discharges per polarity |
functional status |
|
contact discharge C=150pF,R=330Ω |
±8kV |
3 times |
A |
|
air discharge C=150pF,R=330Ω |
±15kV |
3 times |
A |
indirect discharge
|
discharge type |
severity level |
Number of discharges per polarity |
functional status |
|
contact discharge C=150pF,R=330Ω |
±8kV |
50 times |
A |
5.3.7 Power line transient anti-interference experiment
--Test purposes:
To examine the ability of components to withstand transient voltage pulses of power lines, the test methods and test equipment meet the requirements of ISO 7637-2:2004, and there are a total of pulse 1, 2a, 2b, 3a, 3b tests.
--Test requirements:
See the following table for the severity level requirements of the power line transient conduction anti-interference test pulse test:
|
Severity level requirements for power line transient conduction anti-interference test |
|||
|
test pulse |
test level |
Minimum pulse number or test time |
Functional failure level |
|
Pulse 1 |
－100V |
500 pulses |
C |
|
Pulse 2a |
+50V |
500 pulses |
A |
|
Pulse 2b |
+10V |
10 pulses |
C |
|
Pulse 3a |
－150V |
1h |
A |
|
Pulse 3b |
+100V |
1h |
A |
工作模式：C(风扇占空比50%)。
--试验脉冲波形：
试验脉冲1：模拟电源与感性负载断开连接时所产生的瞬态现象。
|
试验脉冲1参数 |
|
|
UA |
+13.5V |
|
Us |
－100 V |
|
Ri |
10 Ω |
|
Tr |
1μs |
|
Td |
2 ms |
|
T1 |
0.5~5s，保证EUT可以正确初始化 |
|
T2 |
200 ms |
|
T3 |
<100μs，切断电源到应用脉冲所需要最小时间 |
试验脉冲2a：模拟由于线束电感原因，使与试样并联的装置内电流突然中断引起的瞬态现象。
|
试验脉冲2a参数 |
|
|
UA |
+13.5V |
|
Us |
+50 V |
|
Ri |
2Ω |
|
tr |
1μs |
|
td |
50μs |
|
t1 |
0.5s |
试验脉冲2b：模拟点火开关断开时的瞬态现象。
|
试验脉冲2b参数 |
|
|
UA |
+13.5V |
|
Us |
+10 V |
|
Ri |
0.05 Ω |
|
td |
0.5 s |
|
tr |
1 ms±0.5 ms |
|
t12 |
1 ms±0.5ms |
|
t6 |
1 ms±0.5 ms |
试验脉冲3a和3b：模拟由开关过程引起的瞬态现象，这些瞬态现象的特性受线束的分布电容和分布电感的影响。
|
试验脉冲3a参数 |
|
|
UA |
+13.5V |
|
Us |
－150 V |
|
Ri |
50 Ω |
|
td |
0.1μs |
|
tr |
5 ns |
|
t1 |
100 μs |
|
t 4 |
10 ms |
|
t 5 |
90 ms |
|
Test pulse 3b parameters |
|
|
U A |
+13.5V |
|
Us |
+100 V |
|
Ri |
50 Ω |
|
td |
0.1 μs |
|
tr |
5 ns |
|
t 1 |
100 μs |
|
t 4 |
10 ms |
|
t 5 |
90 ms |
5.3.8 I/O Line Transient Conduction Anti-interference
--Test purposes:
To examine the ability of components to withstand transient voltage pulses of I/O lines, the test methods and test equipment meet the requirements of ISO 7637-3: 2007;
- Test arrangement:
Capacitive coupling clamp method (CCC) test arrangement, refer to ISO7637-3;
-Test requirements:
Test on all input and output lines;
Specimen working mode: C (fan duty cycle 50%);
Test pulses a and b:
The fast transient test pulse is an electrical transient that simulates a switching process. The characteristics of electrical transients are affected by the distributed capacitance and inductance of the wiring harness.
Test pulse a, negative pulse:
|
Fast transient test pulse a parameter |
|
|
Us |
－60 V |
|
tr |
5 ns |
|
td |
0.1 μs |
|
t 1 |
100 μs |
|
t 4 |
10 ms |
|
t 5 |
90 ms |
|
Ri |
50 Ω |
Test pulse b, positive pulse:
|
Fast transient test pulse b-parameter |
|
|
Us |
+ 40 V |
|
tr |
5 ns |
|
td |
0.1 μs |
|
t 1 |
100 μs |
|
t 4 |
10 ms |
|
t 5 |
90 ms |
|
Ri |
50 Ω |
Test level requirements:
|
Fast transient test pulse a and b requirements |
|||
|
test pulse |
test level |
Test time |
functional class |
|
pulse a |
－60V |
10min |
A |
|
pulse b |
+40V |
10min |
A |
5.3.9 Voltage Transient Emissions
--Test purposes:
Investigate the size of the transient voltage emission of the working power line of the parts, the test method and test equipment meet the requirements of ISO7637-2:2004;
Components are potential sources of conducted disturbance, and it is necessary to measure the strength of the EUT transient voltage conducted emission of components.
--Test layout:
-Test requirements:
Test separately under the conditions of discharge relay open and closed, fan on and off;
Acquire ten waveforms, and record the waveform containing the largest positive amplitude and the largest negative amplitude (and parameters related to them);
For the layout of slow pulses, see Figure a above, and for the layout of fast pulses, see Figure b above;
See the table below for limit values:
|
Slow Pulse - Positive Polarity |
﹢75V |
|
Slow Pulse - Negative Polarity |
-100V |
|
Fast Pulse - Positive Polarity |
﹢100V |
|
Fast Pulse - Negative Polarity |
-150V |
Appendix A: Example of functional monitoring and inspection items
