New energy vehicles have been plagued with a range of problems, such as thermal diffusion of battery, functional safety, the consistency among charging pile communication protocol, verification of motor functional performance and controller accuracy. Manufacturers face many challenges, such as:
1. Thermal diffusion of battery, functional safety and other fundamental safety issues have always been put under the compulsory inspection and test in China. Therefore, the safety of battery has a direct bearing on the sales volume of automobile enterprises and the personal and property safety of consumers;
2. It is a major challenge for governments and enterprises to try to realize cascade utilization, disassembly and recycling of batteries after their service life comes to an end.
3. The requirements for battery energy density get increasingly higher, it is imperative to develop new batteries. However, the corresponding testing technology and standard evaluation system for new batteries are outdated, thus failing to meet the current needs for application and development.
Product Scope:
Battery and its management system: battery/module/system (battery pack), battery management system and radiator
Micromotor: sunroof/side window/wiper
Motor: single motor/dual motors/three motors/four motors/power assembly
Motor controller unit (MCU): MCU for passenger vehicles/MCU for commercial vehicle
Charging pile: AC charging pile/DC charging pile/charging coupler/charging cable
On-board OBC/DCDC
Test Item:
(I)Power battery test
| Test Item |
Category |
Test Standard |
| Capacity and energy, tests of power and internal resistance, non-load capacity loss, storage capacity loss, energy efficiency |
Electrical performance |
GB/T 31467.1&2、GB/T 31486、 |
| Room temperature power |
Electrical performance |
GB/T 31484 |
| Vibration, mechanical shock |
Safety & reliability |
GB/T 31467.3、GB/T 31486 |
| Temperature shock, thermal-humidity cycle, seawater immersion, salt fog, low pressure, over-temperature, heating, overcharge protection, over discharge protection |
Safety |
GB/T 31467.3、GB/T 31485 |
| The operating cycle life of standard cycle life, power batteries for passenger vehicles with hybrid power/power batteries for commercial vehicles with hybrid power/energy batteries for passenger vehicles with pure electric/energy batteries for commercial vehicles with pure electric/batteries for plug-in and extended-range electric vehicles |
Cycle life class |
GB/T 31484 |
| Radiation emission - ALSE method, conducted emission - voltage method, conducted emission - voltage method |
Electromagnetic compatibility (EMC) |
CISPR25，GB/T 18655 |
| Transient conduction emission |
Electromagnetic compatibility (EMC) |
ISO7636-2，GB/T21437.2 |
| Magnetic field emission |
Electromagnetic compatibility (EMC) |
MIL-STD-461F，GJB151，GJB152 |
| Electromagnetic radiation immunity - ALSE method, high current injection method |
Electromagnetic compatibility (EMC) |
ISO11452-2，GB/T33014 |
| Immunity to interference of handheld transmitter |
Electromagnetic compatibility (EMC) |
ISO11452-9 |
| Magnetic field immunity level |
Electromagnetic compatibility (EMC) |
ISO11452-8，MIL-STD-461F，GJB151，GJB152 |
| Immunity to interference of transient conduction - power line |
Electromagnetic compatibility (EMC) |
ISO7636-2，GB/T21437.2 |
| Immunity to interference of transient conduction - signal line |
Electromagnetic compatibility (EMC) |
ISO7636-3，GB/T21437.3 |
| Electrostatic discharge |
Electromagnetic compatibility (EMC) |
ISO10605，GB/T19951 |
| Low frequency electro-magnetic field radiation emission test |
Electromagnetic compatibility (EMC) |
GB/T18387, SAE J551-5 |
| Electrical fast transient immunity |
Electromagnetic compatibility (EMC) |
IEC61000-4-4，GB/T17626.4 |
| Immunity to interference of surge (impact) |
Electromagnetic compatibility (EMC) |
IEC61000-4-5，GB/T17626.5 |
| System Internal conducted emission、System internal Conducted immunity、Radiated emission、Conducted emission on external ports |
Electromagnetic compatibility (EMC) |
CEVT8888790454-1 |
(II) Test of motors and electronic control
| Test Item |
Category |
Test Standard |
| Main test items of driving motors |
| Operating voltage range, torque - turning feature, continuous torque, continuous power, peak torque, peak power, locked-rotor torque, maximum working speed, the highest efficiency of the system, high efficient working area, speed/torque control accuracy, response time |
Electrical performance |
GB/T 18488.1&2、SOR |
| Safety ground |
Safety |
GB/T 18488.1&2、SOR |
| High and low temperature work/storage, thermal-humidity, dustproof and waterproof |
Environmental suitability |
GB/T 18488.1&2、SOR |
| Sweep frequency vibration, random vibration |
Reliability |
GB/T 18488.1&2、SOR |
| Salt fog |
Corrosion resistance |
GB/T 18488.1&2、SOR |
| Main test items of controllers |
| Working voltage, overvoltage, voltage frequency change, voltage drop, working current, quiescent current, impact current, short circuit protection |
Electrical performance |
ISO 16750、SOR |
| Thermal limit value |
Safety |
ISO 16750、GB/T 2423 |
| High and low temperature test, temperature-humidity cycling, temperature variation, thermal shock |
Environmental suitability |
ISO 16750、GB/T 2423 |
| The communicative function of CAN bus |
Electrical performance |
SOR |
(III) Testing of charging couplers and charging piles
| Test Item |
Category |
Test Standard |
| DC charging pile |
General inspection |
Manual inspection |
NB/T 33001-2010
NB/T 33008.1-2013
GB/T 27930-2015
Q/GDW 1233-2014
Q/GDW 1591-2014
Q/GDW 1235-2014
GB/T 18487.1-2015 |
| Function check |
Inspection of charging setting mode, communication function test, display function test, input function test and metering function test |
| Insulation performance test |
Insulation resistance test |
| Charging output test |
Output voltage error test, output current error test, stabilized voltage precision test, stabilized current precision test, ripple factor test, voltage limiting characteristic test, current limiting characteristic test, efficiency and power factor test, output current control time test and output current stop rate test |
| Low-voltage auxiliary power supply test |
|
| Harmonic current test |
|
| Safety requirements test |
Input overvoltage protection test, input undervoltage protection test, output overvoltage protection test, emergency stop function test, impact current test, soft start test, battery polarity reverse test and battery voltage detection test |
| Comparability test |
Charging coupler comparability test, charging control comparability test and charging communication comparability test |
| AC charging pile |
General inspection |
Basic composition inspection, charging connection inspection, pile inspection |
NB/T 33002-2010
NB/T 33008.2-2013
Q/GDW 1485-2014
Q/GDW 1592-2014
GB/T 18487.1-2015 |
| Functional test |
Display function test, manual input test, metering function test, card swiping and payment function test and communication function test |
| Safety protection test |
Emergency stop function test, on-load circuit ON/OFF test, overload protection test, short circuit protection test and locking function test |
| Comparability test |
Charging coupler comparability test, charging control comparability test |
(IV) High voltage wire harness test
| Test type |
Test Item |
| High voltage wire harness test EMC test |
Shielding effectiveness test of cables and connectors (IEC62153-4-4, IEC62153-4-5, IEC62153-4-6 and CEVT88887904541 Part5, Part6) |
| Mechanical performance test |
vibration test, mechanical shock test, drop test and insertion/pulling-out force test |
| Electrical performance test |
contact resistance, voltage drop test, temperature-rise test, withstand voltage test and insulation test |
| Environmental test: |
high and low temperature, damp heat test, salt spray test, dustproof and waterproof, reagent resistance, gas corrosion test and ozone resistance test |
| Chemical test |
ELV, VOC and smell |
| Other tests |
dimensional measurement, air tightness test and combustion test |
(V) Technical schemes
Evaluation of battery life cycle functional performance: Battery life cycle and mission profile analysis, screening of environmental impact factors and compilation of functional performance evaluation criteria Solve the problems related to adaptability, reliability and safety of battery environment in each life cycle
EMC point-to-point rectification plan evaluation of BMS: In case of any ineligible test items, GRG Test analyzes and finds out the potential factors that might cause the failure from the aspects of structure, schematic diagram, PCB and cable technology, etc. based on the BMS characteristics and test principle, and delivers effective rectification plans to customers for success in passing the test.
Research on new battery testing technology: Characteristic analysis of functional performances of new battery, test method development, R&D of new equipment, and research on electrical performance of new battery. Solve the problems such as R&D of new batteries without testing criteria and technical means.
R&D of health management and remote monitoring system: Development of health state characteristic parameters and management software and hardware, construction of remote monitoring system, and research on high-precision fault diagnosis algorithm Solve the problems of uncontrollable health status, remote test and inaccurate fault location.
