VOLKSWAGEN原版完整文件.docx

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1、VOLKSWAGENAKTi E ng ESE LlschaftGroup standardVW 80300Issue 2016-10Class. No.:8MA40Descriptors:high-voltage, HV1 high-voltage components, HV componentsElectrical and Electronic High-Voltage Components in Motor VehiclesElectrical Requirements, Test Conditions, and TestsContentsPage1 Scope32 Definitio

2、ns 43 Symbols and abbreviations54 General information74.1 Test variables84.1.1 HV voltages and HV currents84.1.2 Standard tolerances84.1.3 Standard values 94.1.4 Sampling rates and measured value resolutions94.2 HV operating voltage ranges94.3 HV test voltages114.4 Functional statuses 124.4.1 Genera

3、l information124.4.2 Functional status A124.4.3 Functional status B124.4.4 Functional status C 124.4.5 Functional status D 124.4.6 Functional status E124.5 Operating modes134.5.1 General information134.5.2 Operating mode I - DUT not electrically connected134.5.3 Operating mode Il - DUT electrically

4、connected (LV) 134.5.4 Operating mode 川一 DUT electrically connected(HV, AC) 144.5.5 Operating mode IV - DUT electrically connected(HV, DC)154.5.6 Example showing operating modes for HV components 164.6 Interface description164.7 Test setup for HV components16Ahvays use the latest version of this sta

5、ndard.H7This electronically generated standard Is authentic and valid wMhout signature.1 The EngIkSh translation is believed to be accurate. In case Of discrepancies, the German version is alone autt)OdtatiVe and controMng.Technical responsibilityThe Standards departmentEEIP/1Markus AustTel.: +49 53

6、61 9 44447l/EE-61Thorsten BluhmTel.: +49 841 89 31134EKDD/2 Dirk BeinkerEKDDEEG4Mark MartinsTel :+49 711 911 84847Tel.: +49 5361 9 32438Thomas BehrensAll rights reserved. No part of this document may be provided Io third parties or reproduced without the prior COnSent of one of the Volkswagen Groups

7、 Standards departments. Volkswagen AktiengesellschaftVWNORM-201 m)7(JPage 87VW 80300: 2016-104.7.1 HV test setup type 1 174.7.2 HV test setup type 2 174.8 Procedure limitations194.9 Temperature conditioning 195 Tests on HV components 195.1 Test sequence 195.2 Parameter test (small)215.3 Parameter te

8、st (big) 215.4 Parameter test (HV function check) 235.5 Continuous parameter monitoring with drift analysis 235.6 Physical analysis 235.7 HV parameter tests 255.7.1 HVPT-1 HV voltage cycle255.7.2 HVPT-2 HV pre-charging *-.,285.7.3 HVPT-3 Passive discharge 305.7.4 HVPT-4 Active discharge 325.7.5 HVPT

9、-5 HV insulation resistance to LV 345.7.6 HVPT-6 HV dielectric strength to LV 365.7.7 HVPT-7 Equipotential bonding contact resistance37578HVPT-8 HV shield contact contact resistance 385.7.9 HVPT-9 Protective earth and touch currents 395.7.10 HVPT-IO Residual torque 406 Electrical HV tests * 416.1 EH

10、V-01 Operation within the regular HVoperating voltage range42611Purpose 426.1,2 Test ， 42613Requirement 436.2 EHVTO2 Operation within theHV overvoltage range44621Purpose 446.2.1 Test 446.2.2 Requirement * 456.3 EHV-03 Operation within theHV undervoltage range466.3.1 Purpose46632Test=,466.3.3 Require

11、ment476.4 EHV-04 Pre-charging486.4.1 Purpose 48642Test 48643Test for HV components 536.5 EHV-O5 Generated HV voltage dynamics 586.5.1 Purpose * 586.5.2 Test 586.5.3 Requirement596.6 EHV-06 SystemHV voltage dynamics606.6.1 Purpose 60662Test 606.6.3 Requirement *616.7 EHV-07 HV voltagedynamics of ener

12、gy storage devices6267.1 Purpose62672Test 6267.3 Requirement 636.8 EHj-O8 GeneratedHV voltage ripple 646.8.1 Purpose .646.8.2 Test 646.8.3 Requirement656.9 EHV-09 System HV voltage ripple 666.9.1 Purpose666.9.2 Test 666.9.3 Requirement696.10 EHV-WLoad dump706.10.1 Purpose706.10.2 Load dump all the w

13、ay to HV voltage limit 706.10.3 Load dump with rapid rateof change716.11 EHV-11 HV voltage offset736.11.1 Purpose73116.11.3 Requirement756.12 EHV-12 HV overcurrent 766.12.1 Purpose766.12.2 Test 766.12.3 Requirement776.13 EHV-13 HV service life (addenda) 786.13.1 Purpose786.13.2 Test 786.13.3 Require

14、ment796.14 EHV-14 On/Off durability testing for HV components 806.14.1 Purpose .80 1 I6.14.3 Requirement806.15 EHV-15 HV interlock, service disconnect, and crash signaling operation816.15.1 Purpose816.15.2 Test 816.15.3 Requirement826.16 EHV-16 HV pulse 836.16.1 Purpose836.16.2 Test 836.16.3 Require

15、ment857 Testing of power modulesand power assemblies 868 Applicable documents 869 Bibliography 86Appendix A Test sequence87A.1Test sequence plan 871 ScopeThis Volkswagen standard (VW) specifies requirements, test conditions, and tests for electrical, electronic, and mechatronic components and system

16、s for use in motor vehicles with a high-voltage (HV) electric system. Unless otherwise noted, the tests are not electrical service life tests.The tests in this standard do not replace any of the HV safety requirements and tests described in the HV Safety Performance Specification.The parameter test

17、contents described in this standard are used to determine, among other things, whether HV safety electrical parameters have changed during component reliability testing.This document is intended to supplement VW 80000 and, accordingly, must not be used as a standalone document for testing HV compone

18、nts or HV systems. This document specifies, among other things, the HV operating voltages, HV-relevant test setup parts, and supplemental HV-rele- vant parameter tests required for the tests in VW 80000.Additional Ordeviating requirements, test conditions, and tests are defined in the corresponding

19、Component Performance Specifications.The contractor prepares a test plan that must be agreed upon with the purchaser.The requirements in this standard are subordinate to HV safety requirements.This standard does not apply to the 48-V electric system.NOTE 1: The tests presented are used to check some

20、 of the required properties of the component and are not used to qualify parts or qualify the production process.2 DefinitionsCircuit carrierSubstrate without mounted parts for electronics in general (unpopulated PCB, ceramic, Ieadframe, flexband, etc.)ComponentComplete device, electronic control un

21、it, or mechatronic control module (with housing)Device under testThe system or component to be testedElectronic assemblyA unit of an electrical/electronic circuit, which consists of electronic components and has a defined basic function/propertyElectronic componentThe smallest basic element of an el

22、ectrical/electronic circuit, which is regarded as a unit and has a defined basic function/propertyFunctionIncludes system-specific and diagnostic functionsHV systemFunctionally connected HV components, e.g., inverter and electric machine (EM) or battery with battery energy management systemOff-grid

23、parkingOperating situation of a vehicle having an alternative drive train that is parked and is not connected to a charging station/outlet.On-grid parkingOperating situation of a vehicle having an alternative drive train that is parked and is connected to a charging StationZoutIet but is not being c

24、harged. The vehicle can communicate with the charging station.Power userReal use case with maximum conceivable useRelevant to startingComponents that are needed directly or indirectly for a starting process of an internal combustion engineShort circuitA short circuit at a load output is defined with

25、 a load case that has a lower impedance than with the specified load down to the limit case of 0 C. Creeping short circuits (i.e., current just below short circuit detection) are included. A short circuit may be permanently present (component in opera- tion/not in operation).3 Symbols and abbreviati

26、onsaDUTDevice under testFCurrent that flows during a testaICTIn-circuit testAINNominal currentaPTBThe National Metrology Institute of Germany (Physikalisch-Technische Bundesanstalt)aSOCState of charge; physical charge status of an electrical energy storage de viceA TRoom temperatureA T1 cool.maxMaxi

27、mum coolant temperature in the coolant circuitA -T cool.mlnMinimum coolant temperature in the coolant circuitA T1 cool.nomNominal coolant temperature in the coolant circuitA TMaximum operating temperatureA TMinimum operating temperatureA TTest temperatureA VNominal voltageA VMaximum voltage that may

28、 be produced during a testA VMinimum voltage that may be produced during a testAV vopOperating voltageA V vOpmaxUpper operating voltage limitAVV opmtnLower operating voltage limitAV vPPPeak-to-peak value of a voltageAVmSRMS value of a voltageAVteStTest voltageAfFrequencyALActive discharge timeaUPass

29、ive discharge timeT Ath Atr AtteSI HVFall time (e.g., of a voltage curve)Hold time during a testRise time (e.g., of a voltage curve)Test durationHigh voltage; used as a suffix and for identification purposes in the HV electric systemHV HV+/HV-t.1Positive electric potential in HV electric system, gal

30、vanically isolated from all potentials in the LV electric system and from the bodyHV HV-ZHV-t.2Negative electric potential in HV electric system, galvanically isolated from all potentials in the LV electric system and from the bodyHV I1HVHV I N1HVHV IJOPmaX.HVHV pHVHV -r1 opmaxHV current that flows

31、during a testNominal HV currentMaximum HV operating currentInternal resistance of HV source, including the HV supply wiring harnessMaximum operating temperature for components with overload protec- tion/over-temperature protectionHV T1 opminMinimum operating temperature for components with overload

32、protec- tion/low-temperature protectionHVVHVHVVMHV HVMmHV HV /* max.HVHVVi HV VOPmaX,HV HV VOPmgHV VHV HV V/V rms.HVHVfHV voltage at DUTNominal HV voltage, standard HV voltageHV voltage limitMaximum permissible HV voltageMinimum permissible HV voltageMaximum HV operating voltageMinimum HV operating

33、voltagePeak-to-peak value of an HV voltageRMS value of an HV voltage (AC or DC with AC component)Pre-charge time for charging the HV electric system to the HV battery voltageLVLow voltage; stands for the voltage in electric systems with 60 V, e.g., electric systems with 12 VlvGNDDevice ground in the

34、 LV system (terminal 31) without an electrical (galvanic) connection to the HV system; also chassis ground and shield groundt.Terminal designations as per DIN 72552-2 for the LV electric system4 General information7工LegendHVHV electronicsLVLV electronicsADC HV connection1 HV+2 HV-BAC HV connection3

35、E.g., electric machine4 E.g., power gridCLV connector5 LV supply6 I/O and bus signals7 LV ground, t.31DEquipotential bonding8 Chassis, LV groundFigure 1 - HV component diagramNOTE 2: All HV voltages are specified between reference points HV+ and HV-. Potentials HV+ and HV- do not have a galvanic con

36、nection to the body (chassis, LV ground) or to the LV electric system.Unless otherwise specified:All general temperature specifications refer to the DUTs ambient air-All coolant temperature specifications refer to the coolant inlet temperature at the DUTDepending on the type of electrical test, the

37、internal resistance (R HV) must be specified as a purely resistive resistance or as a complex impedance (Zi HV).Unless otherwise specified, the internal resistances in table 1 apply.Table 1 - Internal resistance as a function of temperatureTmlnRlhv = 200 mCTRTRi HV = 100 mQTmaXRi HV = 50 mC4.1 Test

38、variables4.1.1 HV voltages and HV currentsThe specified voltage curves must be interpreted as envelopes. Curves with any contour within the specified test and reference curves must be expected as the actual voltage curves.All voltage and current specifications refer to the component (at its terminal

39、). This does not apply to tests for which the internal resistance Rj is specified. In this case, the voltage and current specifications refer to the source (see figure 2).LegendVsLV voltage sourceVlvLV voltage at DUTRc LV electric system cable and contact resistancesRi Internal resistance observed a

40、t the terminals of the component in the direction of the LV sourceVs hvHV voltage sourceVhvHV voltage at DUTRc hvHV electric system cable and contact resistancesRlhv Internal resistance observed at the terminals of the component in the direction of the HV sourceFigure 2 - Internal resistances4.1.2 S

41、tandard tolerancesUnless otherwise specified, the tolerances in table 2 apply.The tolerances refer to the required measured value.Table 2 Standard tolerancesFrequencies1%Temperatures2 Humidity5%Times+5%; -0%LV voltages2%LV currents2%HV voltages0.2% of VmaX,hv，absoluteHV currents1% or 100 mA, whichev

42、er is greaterResistance2%Inductances and capacitors10%4.1.3 Standard valuesUnless otherwise specified, the standard values in table 3 apply.Table 3 - Standard valuesRoom temperatureTrt = +23 5 HumidityHrei = 25% to 75% relative humidityTest temperatureTIeSt = TRTOperating voltages (for tests)Vop =14

43、 VVnhv (vehicle-specific value)4.1.4 Sampling rates and measured value resolutionsThe sampling rate and bandwidth of the measuring system must be adjusted as required for the respective test. All measured values must be recorded with all maximum values (peaks).The resolution of the measured values m

44、ust be adjusted as required for the respective test. It must be ensured that voltage and current peaks do not lead to an overflow and that there will not be cases in which they cannot be measured due to insufficient resolution. Data reductions/abstrac- tions (e.g., limit monitoring, bus message eval

45、uation) must not suppress irregularities.4.2 HV operating voltage rangesNo generally applicable voltage values are defined for the HV electric system. The HV voltage ranges and voltage limits will depend on the relevant HV vehicle system and must be specified for each vehicle type on a case-by-case

46、basis before the tests in this document are carried out.The specification for the HV voltage supply values, the HV voltage supply limits, and the HV voltage supply ranges is defined for the reliability testing scopes below. The values must be specified in a vehicle-specific manner and used for the reliability testing.If1 for an