New Energy Vehicle Special Safety Test System
- It's used for electrical safety testing of electric vehicles, including tests like whole vehicle insulation, charging port insulation, and potential equalization.
- Complies with various international regulations, such as ECE R 100,GTR No.20, GB 18384.
- It can detect vehicles from various countries, like European-standard cars, American-standard cars, Japanese-standard cars, and Chinese-standard cars.
Equipment Introduction
1、Basic Knowledge of New Energy Vehicle Testing
Potential Equalization Test: Potential equalization is achieved by physically connecting the exposed conductive parts of electrical equipment to a reference point or equipotential point on the vehicle body (usually the chassis) to minimize the potential difference between them. This connection ensures that, in the electrical system, especially in high-voltage systems, the conductive parts maintain the same potential, thereby reducing the risk of electric shock and other safety hazards.
Insulation Resistance Test: The electrification level of new energy vehicles is higher than that of traditional cars. Under harsh operating conditions (car vibrations, external environmental humidity and temperature), or in the event of a collision or rollover, the insulation performance between the high-voltage circuit and the vehicle chassis may be reduced, leading to vehicle fires and endangering the safety of drivers and passengers. The higher working voltage of new energy vehicles places higher demands on the insulation performance between the high-voltage electrical system and the vehicle chassis.
Whole vehicle insulation test: The high-voltage components of electric vehicles are a parallel structure, and the insulation resistance of the entire system is the parallel value of all high-voltage component insulation resistances. According to GB-T 18384-2015 Electric Vehicle Safety Requirements, the minimum insulation resistance requirement: DC 100Ω/V, AC 500Ω/V.
Insulation Monitoring Verification: In high-voltage electrical systems of electric vehicles, if insulation failure occurs, it will pose serious safety hazards. To ensure that the vehicle can promptly send an alarm signal to the driver in case of insulation failure, the vehicle should have an insulation resistance monitoring function.
Capacitive Coupling Test: Capacitive coupling refers to the amount of stored charge on the Y capacitor of the vehicle’s high-voltage bus (all B-level voltage circuits of the vehicle) at the maximum battery voltage.
2、Workstation layout:
Safety test system test items can be flexibly configured:
On production lines with high requirements for rhythm, corresponding one or two test items can be assembled at suitable stations according to the vehicle assembly progress;
When the beat requirement is relatively low in non-production lines, more comprehensive test items can be optionally selected.
3、New Energy Testing Project Selection
Test item |
Parameters |
Component potential balancing |
32A DC/600mΩ |
Charging port potential balancing | |
Insulation Resistance of Load |
1000V DC/10GΩ (optional 3GΩ/50GΩ) |
Charging port insulation resistance | |
Leakage current |
300V AC/18mA |
Complete vehicle insulation |
0.2-100MΩ |
Insulation Monitoring Verification |
Resistivity coefficient Rx: 100-1000; |
Capacitive coupling |
1、Calculation method (recommended); 2、Actual measurement (long testing time, not recommended); 1000V DC/2000mJ; |
The above testing project manufacturers can consider the actual needs, production rhythm, etc., for station layout. Yidi testing system can flexibly combine the above testing projects.
