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    Vibration Testing of Electric Vehicle Batteries j2380201312 PDF Free

    Uploaded by

    Hemalatha Dwadasi
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    © All Rights Reserved
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    SE SURFACE VEHICLE mvernationat. | RECOMMENDED PRACTICE bration Testing of Electric Vehicle Batteries FOREWORD 5 Year review. ‘This document provides a test procedure for charscierzing the effect of long-term, road.induced vibration and shock on the performance and service Ife of electric vehicle batieries. For mature, procucton-eady batteries, the intent of the Procedure is to qualify the vibration durability of the battery. Either swept sine wave vibration or random vibration is {ypicaly used for the performance of such testing. Random vibration isthe focus of this document. “The vibration tests defined in this procedure are besed on rough-road measurements at locations likely io be appropriate {or mounting of traction balteries in EVs. The data were analyzed to determine an appropriate cumulative number cf ‘ecourrences of chock pulses at various givon G-levels over the Ife of the vehicle. The vibration envelopes shown ia Figue 1 of this procedure correspond to aporoximataly 100 000 miles of usage at ihe 90M percentile. The vibration spectra contained in this procedure have been designed to approximate this cumulative exposure envelope. For testing efficiency, vibration regime is specified 10 allow completion of the test procedure in a minimum of 4136) and a maximum of 92 6 h of testing, depending on the type of shaker table available and the choice af acceleration levels. 3ig Yoome Since ead Rane poe at “Th pr nnd by SAE wats tu ef mined egacing soars Ta as fn po ‘Stet ante mp asm ry pear on ea oon epee say waren seeps os ‘SAE roe ca tcl pot Hest et eyo att eX ay vd, ates, aed, creed SAE Hes yr wn oer ae Stopes (Cer 62013 SAE eat SAE INTERNATIONAL, 32380 Revised DEC2013. Page 2 of 7 (CUMULATIVE EXPOSURE TO VIBRATION FIGURE 1 CUMULATIVE VIBRATION ENVELOPES ‘TABLE OF CONTENTS 1 ‘SCOPE. nan 2 2 REFERENCES. seco i 24 ‘Applicabie Documents. 22 Related Publication DEFINITIONS .. ‘TECHNICAL REQUIREMENTS, Prerequisites ‘Test Equipment. ‘Determination of Test Conditions and Test Termination Criteria. Teet Procedure. nt si Testing Precautons oo Data Acquisition and Reporting = 6. NOTES... 54 ‘Margnal inci... TABLE1 VIBRATION SCHEDULE FOR RANDOM VIBRATION TEST cocoons FIGURE 1 CUMULATIVE VIBRATION ENVELOPES... FIGURE 2 VIBRATION SPECTRA FOR RANDOM VIBRATION TEST... 1. SCOPE, This SAE Recommended Practice describes the vibration durability testing of a single baltery (test unit) consisting of tier an electric vetice battery module or an electric vehicle battery pack. For statistical purposes, multiple samples ‘would namilly be subjected to such tasting. Additionally, some test units may be subjected to life cycle testing (ether ‘after oF during 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 inthis procedure. SAE INTERNATIONAL J2380 Revised DEC2013, Page 3 of 7 2. REFERENCES 2.4. Applicable Documents The following publications form a part of this specification tb the extent specified herein. Uniess otherwise indicated, the {atest issue of SAE publications shal apply 2.1.1 SAE Publications Available from SAE Inierational, 400 Commonwealth Drive, Warrendale, PA 15090-0001, Tel: 877-000-7323 (inside USA ‘and Canada) or 724-776-4970 (outsde USA), wnW.S22.010. SAEJI715 Hybrid Electric Vehicle (HEV) & Electiic Vehicle (EV) Terminology SAEJ1765 Recommended Practice for Electric and Hybrid Elactric Vehicle Battery Systems Crash Integrity Testing SAE J1798-_ Recommended Practice for Perlormance Rating of Electric Vehicle Battery Modules SAE J2288 Life Cycle Testing of Electric Vehicle Battery Modules, SAE J246¢ Electric and Hybrid Vehicle Rechargeable Energy Storage System (RESS) Safety and Abuse Testing SAE J2923 Safety Standard for Electric and Hybrid Vehicle Propulsion Battery Systems Ultiizing Lithium-based Rechargeable Cols 2.2 Related Publication ‘The following publications are provided for information purposes only and are not a required part of this SAE Technical Report 22.1 USABC Publication ‘Available from National Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161, Tet: 703-805-6000, wan. gor. USABC Electric Vehicle Battery Test Procedures Manual, Revision 2, January 1996. Obiainable by mail order as Report No, DOE/ID-10478, Rev. 2. htip//ev.inlgovieneray storage Nib shtml 3. DEFINITIONS. Except as specifically noted in this section, he definitions of SAE J1715 shall apply to this document. DOD - Depth of Discharge where: 0% DOD is a fuly charged battery according to the battery manufacture suggested charging recommendations. 80% DOD is 80% of the rated capacity removed via a C:3 discharge rate from a 0% DOD stan. 4. TECHNICAL REQUIREMENTS: 44 Proroquisites ‘A battery test plan or other test requirements document is normally required for testing using this procedure. The test plan specifies the appropriate tost conditions for the Reference Performance Tesis (see 4.4.1) and certain vibration frequencies to be used, along with testing precautions and any special handiing/testing insirucons specified for the battery by the manufacturer andior the test sponsor. Note that SAE J2464 also describes shock tests (25 g acceleration, half sine wave form with duration of 15 msee) SAB IN TERRA TIRAL 24H Raviedd DECANE Bae 4 of 7 Periornnere: of carton Referee Fetonnonee Tes ‘eondued of vibration esting. For aernplotoncis, Ux. apeciiod in SAF 179A fa neematy roquited boars and after the: omnia within to provera aps in 44, Unies othanwne speeified ing fost plan docamont, the test unit stv te tester! Geriy in its life (Lo. pier te the o mareded BA) SCH 42 Tost Fon 494 eqekax.book118.com 5 oR FRR: F sere: ofthis procedure reques @ one-tothree-axis table capable of praducing accelerations upto 1.9 9 ave th vibration spectra detaled in Figure 2, extending from 10 to approximately 200 Hz. ifthe unt {0 be tested can only bo titra! whi in a paricuar physical oentaion, 2 mult-ais take wil be requted. Adclonel, the Uns rea! to jeomtown me test ean be signiicanty reduced f te longtudhnal and lateral axs vibration (or ai tree ice) ran be ‘oviemed uancumently. Additional equipment should include shielding, spil tank, and/or explosion proof chusnitxrs weir “applies 422° Fetes fintimo are required to property secure the tet unit to lo. The theee fists dopete ‘mito type oi fable used, the test un tel, and any rea PP sit 7s 42:8 Instnamentation max.book118.com ‘Spc! instrumentation hookups capable of withstanding the vibration are. required so that, important baticry cerniition ran be meniiiewed during testing. (See 4.5.) 43 Sbiomination of Test Conlons and Test Termination Citra 484 Flivbical Test Conditions Flot! fost conditions are determined according othe procedures in SAE J1796 which are specified in 4.4.4 4.82 Vivation Frequencies Vibration teat conditions, “Feet pai ls 4 Bis 48 Tost Tarmination - max.book118.com itso toting shel be suspended or terminated # ony component degradation produces concies hits ure ‘mona or nts the opersing ranges ofthe balay 60 bythe manufacturer. Conditons tobe cine See ‘tnd 4 44 Tost Prcedure 4.4.4 Poiformn a sequence of Reference Performance Tests consisting of a C/3 Constant Current discharie, » Hynisnic ‘Sapwcity Test discharge to 100% of rated capacity. and a Peak Power discharge, as defined in SAF 11/98. 4.49 Change the battery fily using the manufacturers recommended charge method. 4.48 For oach of the vertcal, longitudinal, and lateral axes of fine leva from Table 1 and program the shaker table Foquurad for each axis, also in accordance wit Table 1. ( ini 7Hz, so they can be scaled for either set of G-evels. in max.book118.com SAE INTERNATIONAL J2380 Revised DEC2013, Page 5 of 7 ‘TABLE 1 - VIBRATION SCHEDULE FOR RANDOM VIBRATION TEST TEST NORMAL NORMAL NORMAL ALTERNATIVE ALTERNATIVE ALTERNATIVE TESTCONDTIONS CONDIMONS “TEST TEST TEST. TEST TEST TEST VIBRATION SOC Acceleration Time Cummuetive Accelerason Time Cumulaive SPECTRUM, (%) "(gr)" h)__ Time, (gma) wm Timo. Vatical Axe Vibration Vertical tepectum 100, 19 04st, 49 ots ons Vertical ispectum — 100 075 52554 08s 35 385 Vertical 2spectum 100, 18 018855, 13 0.18 38 Vertical 2spectum 100, 075-525 108 085 35 73 Verical Sspectum 2 19 018 10.95 19 0.15 748 Vertical Sepectum 20 075 52862 085 38 10.98 Longitudinal Axis Vibration: Longtutinal spectrum 60 15 009 16.29 15 0.09 1108 Longitudinal soecium 60 04 = 180 35.28 075 67 11.74 Longtutinal spectrum 60, 15 008-3538 15 0.08 1783 Longitudinal spectrum = 60 04 180 B38 075 67 2453 Lateral Axis Vibration: Longtusina spectrum 60 15 009 sear” 13 0.08 2482” Longtudinsl spectrum 60 o4 = 1807347” os 67 3132” Longtuinal spectrum 60 15 0007356" 15 0.08 314i Longiutinal spectrum __60, 04 1909256” 075 67, 3a11"” 1 These cumuatve tines aps ony fal vee axes ae done separately. 10 100 +1000 Frequency (Hz) — Veet —— Vert Vert3 Longitudinal FIGURE 2- VIBRATION SPECTRA FOR RANDOM VIBRATION TEST 444 Mount the est unit so that tw be subjected to vibration long he appropriate axes, based on the manufacturers recommended physical orientation. This procedure permits tre required vibration to be periomed in one, two, OF fl ivee axial drections simultaneously depending on the capablies ofthe shaker table used (but see 4.48 or ther consderatons,) SAE INTERNATIONAL 12380 Revised DEC2013, Page 6 of 7 4.4.5 Pertorm the programmed vibration forthe requied times, while battery dapth-of-discharge is varied from 0% (full charge) to 80% (minimal charge) over the course of the vibration testing of a given battery. Two approaches are permitted to accomplish this: 1a. If one- or two-axis vibration table is used, approximately two-thirds of the vertical axis festing should be dore at full

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