GB/T 40032-2021Safety requirements of battery swap for electric vehicles (English PDF)

3.1 Battery swap

a process of realizing the electric energy supplement of electric vehicles through special devices or manual assistance to quickly replace the power battery

3.2 Swappable battery pack

a power battery pack for battery swap of electric vehicle

3.3 Battery swap connector

a connecting device used to connect the battery pack and the vehicle body to transmit electrical energy, electrical signals, communication data and thermal energy media

3.4 Battery swap mechanism

a mechanical device for combining and separating battery pack and vehicle body

4.1 General requirements

4.1.1 Battery swap system

4.1.1.1 The design and manufacture of the battery swap system shall meet the requirements of safe, fast and reliable battery pack swap.

4.1.2 Battery swap mechanism and battery swap connector

4.1.2.1 There shall be no burrs, foreign objects, flashes and similar sharp edges on the surface of the battery swap mechanism and the battery swap connector.

4.1.2.3 The battery swap mechanism shall have both the automatic unlocking function and manual unlocking function of the dedicated device. Two or more steps shall be used to unlock. The process shall be continuous and reliable. Avoid maloperation.

4.1.2.4 The electrical interface shall have the correct electrical connection and disconnection sequence. Avoid unexpected high and low voltage circuit conduction during battery swap.

4.2 Vehicle requirements

4.2.1 Battery swap operation

4.2.1.1 Electric vehicles shall be tested for battery swap operation in accordance with 5.3.2. See Table 1 for the number of battery swap operations.

4.2.1.5 During the test, there shall be no failures such as connection failure at the battery swap connector.

4.2.2 Road driving

4.2.2.1 Electric vehicles shall be tested for road driving in accordance with 5.3.3. The road mileage shall be no less than 15000km.

4.2.2.2 During the test, the assembly state of the battery pack shall meet the requirements of the vehicle manufacturer's technical documents. There shall be no serious faults such as the battery pack falling off, the connection failure.

4.2.3

4.2.3.2 During and after the test, there shall be no insulation failure, sealing failure and other faults in the battery swap connector.

4.2.3.3 After the simulated wading test, the insulation resistance shall meet the requirements of 5.1.4.1 in GB 18384-2020.

4.3 Component requirements

4.3.1 Battery swap system

4.3.1.1 The battery swap system shall be subjected to vibration and mechanical shock tests in accordance with 5.4.1.

4.3.1.2 During the test, the communication of the battery swap system shall be connected normally without interruption.

4.3.2 Battery swap connector

4.3.2.1 The battery swap connector shall be tested in accordance with 5.4.2~5.4.5.

4.3.2.2 Test according to 5.4.2. There shall be no dielectric breakdown or arc phenomenon in the electrical interface.

4.3.2.3 Test according to 5.4.3. The insulation resistance between the conductors, between the conductor and the shell, between the conductor and the shielding layer of the electrical interface shall not be less than 100Mohm.

5.1 General

5.1.1 Unless otherwise required, component tests shall be carried out under the following environmental conditions.

5.1.2 All measuring instruments and equipment shall have sufficient accuracy. The accuracy shall be at least one order of magnitude higher than the accuracy of the measured index or the error shall be less than one-third of the allowable error of the measured parameter.

5.2 Appearance, structure and function inspection

Check the appearance, structure and function by observation or manual operation.

5.3 Vehicle test

5.3.1 Test plan

5.3.2 Battery swap operation test

5.3.2.1 It shall use the battery swap equipment that is in accordance with the vehicle design objectives to carry out the battery swap operation test.

5.3.2.2 The battery swap operation test shall be evenly distributed within the vehicle road test mileage. Multiple tests can be concentrated in one test cycle of battery swap operation. The number of battery swap operations performed in a test cycle shall not be greater than one-tenth of the number specified in 4.2.1.1.

5.3.4 Waterproof test of vehicle

5.3.4.1 The waterproof test of the vehicle shall be carried out after the whole vehicle battery swap operation and road driving test are all finished. Carry out the test according to the vehicle waterproof test method specified in 6.3 of GB 18384-2020.

5.4 Component test

5.4.1 Vibration and mechanical shock test

5.4.1.1 The battery swap system is tested according to the vibration and mechanical shock test methods in 8.2.1 and 8.2.2 of GB 38031-2020. The test shall be able to simulate the actual installation state of the battery swap system on the vehicle.

5.4.2 Withstand voltage test

Carry out the test in accordance with the withstand voltage test method in 9.3 of GB/T 37133-2018.

5.4.4 Protection level test

Perform IPX7 and IPX9K tests in accordance with GB/T 30038.

5.4.5 Temperature rise test

The temperature rise test of the electrical interface is carried out according to the temperature rise test method in 9.5 of GB/T 37133-2018. The electrical interface with temperature monitoring shall be verified for functional effectiveness.

5.4.6 Test description

The tests of 5.4.2~5.4.5 shall be carried out after the vibration test of the battery swap system is completed. The electrical interface shall be removed from the battery swap system. Install it on the test fixture for testing.