Codeofchina.com is in charge of this English translation. In case of any doubt about the English translation, the Chinese original shall be considered authoritative.
All technical contents of this standard are compulsory.
This standard is developed in accordance with the rules given in GB/T 1.1-2009
This standard was proposed by and is under the jurisdiction of the Ministry of Industry and Information Technology of the People's Republic of China.
Introduction
This standard is formulated on the basis of GB 18384 and GB 38031, for the purpose of improving the safety technology of electric buses, perfecting the special waterproof and dustproof, fire prevention, rechargeable energy storage system, charging and other safety requirements and test methods of electric buses.
In the process of formulation, this standard refers to the existing traditional bus standards and the relevant standards of the complete electric vehicle and its parts. The main reference standards are GB/T 31467.3-2015, GB/T 18487.1-2015 and UN GTR No.20.
Electric buses safety requirements
1 Scope
This standard specifies the safety requirements and test methods for electric buses.
This standard is applicable to electric buses of Category M2 and Category M3, including battery electric buses and hybrid electric buses.
This standard is not applicable to fuel cell electric buses.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2408-2008 Plastics - Determination of burning characteristics - Horizontal and vertical test
GB 4208 Degrees of protection provided by enclosure (IP code)
GB 8624-2012 Classification for burning behavior of building materials and products
GB/T 10295 Thermal insulation - Determination of steady-state thermal resistance and related properties - Heat flow meter apparatus
GB 13094 The safety requirements for light bus construction
GB/T 15089 Classification of power-driven vehicles and trailers
GB 17578 Requirements and test methods of strength for the superstructure of bus
GB/T 18384 Electric vehicles safety requirements
GB/T 19596 Terminology of electric vehicles
GB 20071-2006 The protection of the occupants in the event of a lateral collision
GB/T 31498-2015 The safety requirement of electric vehicle post crash
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB 13094, GB/T 15089, GB/T 19596 and the following apply.
3.1
minimum management unit of battery system
minimum battery unit monitored by the battery management system
4 Safety requirements
4.1 General
The general safety of electric buses shall comply with the requirements of GB 18384.
4.2 Waterproof and dustproof performance
4.2.1 Wading requirement of complete vehicle
Carry out the complete vehicle wading test according to the test method specified in 5.1.1. Within 10min after completion of the vehicle wading test, the insulation resistance of the complete vehicle shall be greater than 1MΩ.
4.2.2 Protection degree requirements for Class B voltage components
Carry out the protection degree test according to the test method specified in 5.1.2. The insulation resistance of the complete vehicle shall be greater than 1MΩ, and the protection degree of the following components shall not be lower than IP67:
a) Class B voltage electrical equipment with lowest point below the cabin floor and 500mm above the ground and connectors connected to Class B voltage components;
b) Class B voltage electrical equipment installed on the roof and without protective devices (except those for receiving electricity).
4.2.3 Flooding requirement of complete vehicle
Carry out the flooding test of complete vehicle according to the test method specified in 5.1.3, and the vehicle will not catch fire or explode within 2h after the test is completed.
4.3 Fire resistance
4.3.1 Flame retardant performance of Class B voltage components
Carry out the flame retardant performance test for Class B voltage components according to the test method specified in 5.2.1. The flame retardant performance of the insulation materials used for Class B voltage components shall meet the requirements specified in Table 1.
Table 1 Flame retardant performance requirements of insulation materials used for
Class B voltage components
No. Component assembly Component name Standard requirement
Horizontal combustion meets the requirements of GB/T 2408-2008, Class HB Vertical combustion meets the requirements of GB/T 2408-2008, Class V-0.
1 Drive motor system Enclosure √ √
2 Cable insulation layer √ √
3 PCB circuit board √ √
4 Insulating plate √ √
5 Insulating paper √ —
6 Insulation film √ —
7 Motor driven compressor Enclosure √ √
8 Cable insulation layer √ √
9 Electric heater Enclosure √ √
10 Cable insulation layer √ √
11 DC/DC converter Enclosure √ √
12 Cable insulation layer √ √
13 PCB circuit board √ √
14 Distribution box Enclosure √ √
15 Cable insulation layer √ √
16 Charging socket Enclosure √ √
17 Cable insulation layer √ √
18 Double-wall heat-shrinkable tube Double-wall heat-shrinkable tubes (all sizes) √ √
19 Bellow Bellows (all sizes) √ √
Note: "—" means that the part does not need to meet this requirement.
4.3.2 Flame retardant and thermal insulation performance between rechargeable energy storage system (or installation cabin) and passenger cabin
The rechargeable energy storage system (or installation cabin) shall be separated from the passenger cabin by flame retardant and thermal insulation materials and shall be subjected to flame retardant and thermal insulation performance test according to the test methods specified in 5.2.2. The combustion performance of the flame retardant and thermal insulation material shall comply with the Class A requirements specified in GB 8624-2012, and the thermal conductivity shall be less than or equal to 0.04W/(m•K) at 300°C.
4.4 Safety requirements for rechargeable energy storage system
4.4.1 Requirements for thermal runaway of minimum management unit of battery system
The thermal runaway test for minimum management unit of battery system shall be carried out according to the test methods specified in 5.3.1. The test object shall not cause fire or explosion.
4.4.2 Fire retardant requirements for part materials of rechargeable energy storage system
Except for battery cells, other non-metallic parts in the rechargeable energy storage system shall be subjected to flame retardation test for part materials in the rechargeable energy storage system according to the test method specified in 5.3.2. The following flame retardation requirements shall be met:
a) for parts that meet any of the following conditions, the flame retardant grade of their materials shall reach the horizontal combustion grade HB and the vertical combustion grade V-0:
— the mass of a single part ≥50g;
— the total mass of parts of the same model in a single rechargeable energy storage system >200g.
b) for other non-metallic parts, the flame retardant grade of their materials shall reach the horizontal combustion grade HB 75 and the vertical combustion grade V-2.
4.4.3 Isolation requirements for installation cabin
The installation cabin of the rechargeable energy storage system shall be isolated from the passenger compartment (except the ventilation device) to ensure that passengers cannot touch the rechargeable energy storage system. If the air is taken from the passenger compartment to adjust the temperature for the rechargeable energy storage system, the air inlet shall be equipped with a smoke control device to ensure that harmful gases cannot enter the passenger compartment from the air inlet when safety problems occur in the rechargeable energy storage system.
4.4.4 Requirements for disconnecting devices
Manual maintenance switches and fuses shall be installed for the rechargeable energy storage system.
4.4.5 Requirements for pressure relief and venting devices
The rechargeable energy storage system shall be provided with pressure relief and pressure-balanced devices, and the relief pressure shall not exceed 50kPa.
4.4.6 Requirements for abnormality alarm
The rechargeable energy storage system shall send a thermal event alarm signal 5min before any passenger compartment hazard caused by the thermal propagation resulting from thermal runaway of single cell.
4.5 Safety requirements for control system
4.5.1 Priority requirement for braking signal
When the braking signal and acceleration signal occur simultaneously, the complete vehicle control system shall only respond to the braking signal.
4.5.2 Control requirements for driving power system
In the process of driving, when the vehicle is in abnormal condition that requires the failure of Class B high voltage power supply of the complete vehicle, if the vehicle speed is greater than 5km/h, the steering system shall be maintained in the power assist state or keep this state for at least 30s.
4.6 Safety requirements for charging
4.6.1 Safety requirements for charging interface
When the complete vehicle has multiple charging interfaces, the charging interfaces that do not perform charging works shall be de-energized.
4.6.2 Temperature monitoring requirements for charging socket
The charging socket of the vehicle shall be equipped with a temperature monitoring device, which shall be able to transmit the corresponding signal to the vehicle according to the temperature change, for realizing the temperature monitoring and over-temperature protection functions of the vehicle charging interface.
4.7 Safety requirements for vehicle collision and rollover
4.7.1 Safety requirements for vehicle collision
If the lowest point of a rechargeable energy storage system is no more than 1m above the ground (the vehicle is in no-load state), the vehicle shall be subjected to the collision test according to the test methods specified in 5.5.1. After the collision test, the vehicle shall meet the requirements of GB/T 31498-2015, 4.2 to 4.4.
4.7.2 Safety requirements for vehicle rollover
If the superstructure strength test is required for the electric bus, it shall be carried out according to the test methods specified in 5.5.2 under the conditions that the SOC of the rechargeable energy storage system is kept at 30% to 50% and in the state of Class B voltage. After the test, the vehicle shall meet the requirements of GB/T 31498-2015, 4.2 to 4.4.
4.7.3 Exemptions for vehicle collision and rollover tests
When it is necessary to assess the vehicle collision safety requirements, if the vehicle meets one of the following two conditions, it shall be regarded as meeting the requirements of 4.7.1.
a) When compared with the models that have passed the collision test, the following five conditions are met at the same time:
— the same manufacturer and type of rechargeable energy storage system (unit or assembly);
— the energy of the rechargeable energy storage system is the same or reduced;
— the cabinet structure is the same or strengthened;
— the installation structure of the cabinet is the same or strengthened;
— the structure of the vehicle body in the battery pack installation area is unchanged or strengthened (the opening size of the structure is the same or smaller).
b) When compared with the models that have passed the collision test and have no mechanical damage to the battery pack after the collision, the following requirements are met:
— the structure of the vehicle body in the battery pack installation area is unchanged or strengthened (the opening size of the structure is the same or smaller).
Foreword i
Introduction ii
1 Scope
2 Normative references
3 Terms and definitions
4 Safety requirements
4.1 General
4.2 Waterproof and dustproof performance
4.3 Fire resistance
4.4 Safety requirements for rechargeable energy storage system
4.5 Safety requirements for control system
4.6 Safety requirements for charging
4.7 Safety requirements for vehicle collision and rollover
5 Test methods
5.1 Waterproof and dustproof
5.2 Fire resistance
5.3 Safety of rechargeable energy storage system
5.4 Functional safety protection
5.5 Safety requirements for vehicle collision and rollover
6 Implementation date
Annex A (Normative) Thermal runaway test method
Annex B (Normative) Collision test method
Bibliography
Codeofchina.com is in charge of this English translation. In case of any doubt about the English translation, the Chinese original shall be considered authoritative.
All technical contents of this standard are compulsory.
This standard is developed in accordance with the rules given in GB/T 1.1-2009
This standard was proposed by and is under the jurisdiction of the Ministry of Industry and Information Technology of the People's Republic of China.
Introduction
This standard is formulated on the basis of GB 18384 and GB 38031, for the purpose of improving the safety technology of electric buses, perfecting the special waterproof and dustproof, fire prevention, rechargeable energy storage system, charging and other safety requirements and test methods of electric buses.
In the process of formulation, this standard refers to the existing traditional bus standards and the relevant standards of the complete electric vehicle and its parts. The main reference standards are GB/T 31467.3-2015, GB/T 18487.1-2015 and UN GTR No.20.
Electric buses safety requirements
1 Scope
This standard specifies the safety requirements and test methods for electric buses.
This standard is applicable to electric buses of Category M2 and Category M3, including battery electric buses and hybrid electric buses.
This standard is not applicable to fuel cell electric buses.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2408-2008 Plastics - Determination of burning characteristics - Horizontal and vertical test
GB 4208 Degrees of protection provided by enclosure (IP code)
GB 8624-2012 Classification for burning behavior of building materials and products
GB/T 10295 Thermal insulation - Determination of steady-state thermal resistance and related properties - Heat flow meter apparatus
GB 13094 The safety requirements for light bus construction
GB/T 15089 Classification of power-driven vehicles and trailers
GB 17578 Requirements and test methods of strength for the superstructure of bus
GB/T 18384 Electric vehicles safety requirements
GB/T 19596 Terminology of electric vehicles
GB 20071-2006 The protection of the occupants in the event of a lateral collision
GB/T 31498-2015 The safety requirement of electric vehicle post crash
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB 13094, GB/T 15089, GB/T 19596 and the following apply.
3.1
minimum management unit of battery system
minimum battery unit monitored by the battery management system
4 Safety requirements
4.1 General
The general safety of electric buses shall comply with the requirements of GB 18384.
4.2 Waterproof and dustproof performance
4.2.1 Wading requirement of complete vehicle
Carry out the complete vehicle wading test according to the test method specified in 5.1.1. Within 10min after completion of the vehicle wading test, the insulation resistance of the complete vehicle shall be greater than 1MΩ.
4.2.2 Protection degree requirements for Class B voltage components
Carry out the protection degree test according to the test method specified in 5.1.2. The insulation resistance of the complete vehicle shall be greater than 1MΩ, and the protection degree of the following components shall not be lower than IP67:
a) Class B voltage electrical equipment with lowest point below the cabin floor and 500mm above the ground and connectors connected to Class B voltage components;
b) Class B voltage electrical equipment installed on the roof and without protective devices (except those for receiving electricity).
4.2.3 Flooding requirement of complete vehicle
Carry out the flooding test of complete vehicle according to the test method specified in 5.1.3, and the vehicle will not catch fire or explode within 2h after the test is completed.
4.3 Fire resistance
4.3.1 Flame retardant performance of Class B voltage components
Carry out the flame retardant performance test for Class B voltage components according to the test method specified in 5.2.1. The flame retardant performance of the insulation materials used for Class B voltage components shall meet the requirements specified in Table 1.
Table 1 Flame retardant performance requirements of insulation materials used for
Class B voltage components
No. Component assembly Component name Standard requirement
Horizontal combustion meets the requirements of GB/T 2408-2008, Class HB Vertical combustion meets the requirements of GB/T 2408-2008, Class V-0.
1 Drive motor system Enclosure √ √
2 Cable insulation layer √ √
3 PCB circuit board √ √
4 Insulating plate √ √
5 Insulating paper √ —
6 Insulation film √ —
7 Motor driven compressor Enclosure √ √
8 Cable insulation layer √ √
9 Electric heater Enclosure √ √
10 Cable insulation layer √ √
11 DC/DC converter Enclosure √ √
12 Cable insulation layer √ √
13 PCB circuit board √ √
14 Distribution box Enclosure √ √
15 Cable insulation layer √ √
16 Charging socket Enclosure √ √
17 Cable insulation layer √ √
18 Double-wall heat-shrinkable tube Double-wall heat-shrinkable tubes (all sizes) √ √
19 Bellow Bellows (all sizes) √ √
Note: "—" means that the part does not need to meet this requirement.
4.3.2 Flame retardant and thermal insulation performance between rechargeable energy storage system (or installation cabin) and passenger cabin
The rechargeable energy storage system (or installation cabin) shall be separated from the passenger cabin by flame retardant and thermal insulation materials and shall be subjected to flame retardant and thermal insulation performance test according to the test methods specified in 5.2.2. The combustion performance of the flame retardant and thermal insulation material shall comply with the Class A requirements specified in GB 8624-2012, and the thermal conductivity shall be less than or equal to 0.04W/(m•K) at 300°C.
4.4 Safety requirements for rechargeable energy storage system
4.4.1 Requirements for thermal runaway of minimum management unit of battery system
The thermal runaway test for minimum management unit of battery system shall be carried out according to the test methods specified in 5.3.1. The test object shall not cause fire or explosion.
4.4.2 Fire retardant requirements for part materials of rechargeable energy storage system
Except for battery cells, other non-metallic parts in the rechargeable energy storage system shall be subjected to flame retardation test for part materials in the rechargeable energy storage system according to the test method specified in 5.3.2. The following flame retardation requirements shall be met:
a) for parts that meet any of the following conditions, the flame retardant grade of their materials shall reach the horizontal combustion grade HB and the vertical combustion grade V-0:
— the mass of a single part ≥50g;
— the total mass of parts of the same model in a single rechargeable energy storage system >200g.
b) for other non-metallic parts, the flame retardant grade of their materials shall reach the horizontal combustion grade HB 75 and the vertical combustion grade V-2.
4.4.3 Isolation requirements for installation cabin
The installation cabin of the rechargeable energy storage system shall be isolated from the passenger compartment (except the ventilation device) to ensure that passengers cannot touch the rechargeable energy storage system. If the air is taken from the passenger compartment to adjust the temperature for the rechargeable energy storage system, the air inlet shall be equipped with a smoke control device to ensure that harmful gases cannot enter the passenger compartment from the air inlet when safety problems occur in the rechargeable energy storage system.
4.4.4 Requirements for disconnecting devices
Manual maintenance switches and fuses shall be installed for the rechargeable energy storage system.
4.4.5 Requirements for pressure relief and venting devices
The rechargeable energy storage system shall be provided with pressure relief and pressure-balanced devices, and the relief pressure shall not exceed 50kPa.
4.4.6 Requirements for abnormality alarm
The rechargeable energy storage system shall send a thermal event alarm signal 5min before any passenger compartment hazard caused by the thermal propagation resulting from thermal runaway of single cell.
4.5 Safety requirements for control system
4.5.1 Priority requirement for braking signal
When the braking signal and acceleration signal occur simultaneously, the complete vehicle control system shall only respond to the braking signal.
4.5.2 Control requirements for driving power system
In the process of driving, when the vehicle is in abnormal condition that requires the failure of Class B high voltage power supply of the complete vehicle, if the vehicle speed is greater than 5km/h, the steering system shall be maintained in the power assist state or keep this state for at least 30s.
4.6 Safety requirements for charging
4.6.1 Safety requirements for charging interface
When the complete vehicle has multiple charging interfaces, the charging interfaces that do not perform charging works shall be de-energized.
4.6.2 Temperature monitoring requirements for charging socket
The charging socket of the vehicle shall be equipped with a temperature monitoring device, which shall be able to transmit the corresponding signal to the vehicle according to the temperature change, for realizing the temperature monitoring and over-temperature protection functions of the vehicle charging interface.
4.7 Safety requirements for vehicle collision and rollover
4.7.1 Safety requirements for vehicle collision
If the lowest point of a rechargeable energy storage system is no more than 1m above the ground (the vehicle is in no-load state), the vehicle shall be subjected to the collision test according to the test methods specified in 5.5.1. After the collision test, the vehicle shall meet the requirements of GB/T 31498-2015, 4.2 to 4.4.
4.7.2 Safety requirements for vehicle rollover
If the superstructure strength test is required for the electric bus, it shall be carried out according to the test methods specified in 5.5.2 under the conditions that the SOC of the rechargeable energy storage system is kept at 30% to 50% and in the state of Class B voltage. After the test, the vehicle shall meet the requirements of GB/T 31498-2015, 4.2 to 4.4.
4.7.3 Exemptions for vehicle collision and rollover tests
When it is necessary to assess the vehicle collision safety requirements, if the vehicle meets one of the following two conditions, it shall be regarded as meeting the requirements of 4.7.1.
a) When compared with the models that have passed the collision test, the following five conditions are met at the same time:
— the same manufacturer and type of rechargeable energy storage system (unit or assembly);
— the energy of the rechargeable energy storage system is the same or reduced;
— the cabinet structure is the same or strengthened;
— the installation structure of the cabinet is the same or strengthened;
— the structure of the vehicle body in the battery pack installation area is unchanged or strengthened (the opening size of the structure is the same or smaller).
b) When compared with the models that have passed the collision test and have no mechanical damage to the battery pack after the collision, the following requirements are met:
— the structure of the vehicle body in the battery pack installation area is unchanged or strengthened (the opening size of the structure is the same or smaller).
Contents of GB 38032-2020
Foreword i
Introduction ii
1 Scope
2 Normative references
3 Terms and definitions
4 Safety requirements
4.1 General
4.2 Waterproof and dustproof performance
4.3 Fire resistance
4.4 Safety requirements for rechargeable energy storage system
4.5 Safety requirements for control system
4.6 Safety requirements for charging
4.7 Safety requirements for vehicle collision and rollover
5 Test methods
5.1 Waterproof and dustproof
5.2 Fire resistance
5.3 Safety of rechargeable energy storage system
5.4 Functional safety protection
5.5 Safety requirements for vehicle collision and rollover
6 Implementation date
Annex A (Normative) Thermal runaway test method
Annex B (Normative) Collision test method
Bibliography
