GB/T 47495-2026Logistics robots - Test methods for electrical safety (English PDF)

6.1 General Requirements Test Methods

6.1.1 Equipotential bonding The operational observation inspection method was used to check whether the protective connection circuit of the sample met the corresponding technical requirements. When observation and inspection methods cannot determine the cause, the logistics robot (hereinafter referred to as "the robot") should be completely powered off, and three connections should be randomly sampled. Connect a current of at least 24V and 10A to test the impedance between any connection points and record the DC resistance value between any connection points.

6.1.2 Anti-static grounding The test shall be conducted in accordance with the method in section

18.2 of GB/T 5226.1-2019.

6.1.3 Insulation Insulation resistance was tested using a megohmmeter. The megohmmeter output voltage was 500V DC, and the test voltage was applied for 1 minute. This is performed while the robot is powered off. During testing, the battery should be disconnected from the circuit. Components unsuitable for withstanding a 500V test voltage (such as semiconductor devices, communication devices) should not be tested. Interfaces, etc., and surge protection devices that may activate during testing should be disconnected or short-circuited from the test circuit. Measure the insulation resistance between all electrical lines (excluding the battery) and the robot chassis (or protective grounding terminal), and record the measured resistance. Resistance value.

6.1.4 Dielectric Strength Conduct the test according to section

5.4.9 of GB 4943.1-2022.Record whether breakdown, flashover, or arcing occurs during the test.

6.1.5 Protection against electric shock Visually inspect whether the robot has external structural protection or electrical isolation protection devices. After disconnecting the robot's power switch and removing the power connection, measure the voltage between each pin of the power interface within 5 seconds and record the measured values. The voltage value.

6.1.6 Overcurrent Protection Visually inspect the robot's overcurrent protection components for markings, ratings, and installation locations. Jam the robot's wheels and observe whether the robot can stop safely and sound an alarm. At the same time, observe whether a fire or smoke occurs. The robot short-circuit fault test is performed according to the following steps. only one component is short-circuited at a time, and each identified component only withstands [the short-circuit test]. Subjected to a short-circuit test.

a) Use a cable with a cross-sectional area of not less than

2.5 mm^2, and apply a short circuit to the component under test by adding an appropriate switching device. This test should only target one component, and the part most likely to cause the most adverse or dangerous situation should be selected for testing;

b) Keep the equipment powered on until the short-circuit protection circuit trips or the protective device disconnects;

c) After the protection action, wait at least 10 minutes to allow the system to reach steady-state temperature;

d) Observe for signs of fire, smoke, or molten metal spillage, and monitor the cable's temperature during the short circuit using temperature measuring instruments. Does the temperature rise exceed its specified temperature limit?

6.1.7 Electromagnetic Compatibility The test was conducted according to the test method in GB/T 17799.2 to verify whether the robot's safety functions were compromised after being subjected to external electromagnetic interference. Invalid.

6.1.8 Temperature rise The temperature rise of the heating element and its surrounding components shall be measured in accordance with test

9.3 of GB 4943.1-2022.

6.1.9 Protection Level The robot's shell protection capability should be tested according to the following methods.

a) IK level tests are conducted according to Chapter 6 of GB/T 20138-2023;

b) IP rating shall be tested in accordance with Chapters 13 and 14 of GB/T 4208-2017;

6.2 Power Supply Test Method

6.2.1 Power Supply Voltage Measure and record the power supply voltage according to the manufacturer's stated specifications. Low voltage may indicate a problem. To check for risks, examine the electrical connection drawings provided by the manufacturer, and check the description of the low-voltage protection function in the drawings.

6.2.2 Charging Interface

6.2.2.1 Docking The robot charging docking should be tested according to the following steps.

a) During the test, except when continuous charging is required during operation, confirm that the robot is in a state where it is prohibited from moving;

b) Repeat the docking process 100 times, observing for potential ignition sources such as electric arcs and sparks throughout each docking and separation process;

c) After 100 docking cycles, check the charging docking structure for mechanical deformation and test its electrical functions to ensure they are normal.

6.2.2.2 Reverse Connection Protection Reverse the positive and negative electrodes of the robot charging system's output port to the charger's output port, and connect a multimeter to the circuit. When the circuit is open, observe the ammeter reading. After maintaining the connection for 15 seconds, disconnect the circuit, correctly connect the positive and negative electrodes, and record the ammeter reading.

6.2.3 Power off When using a disconnect switch or a detachable connector as a power disconnect device, perform the following tests.

a) Power disconnection test. 1) Connect the switch/connector under test to the test circuit and connect the drive component. Set the power supply voltage to the nominal value and the load to [value missing]. Rated current; 2) Start the system to full load operation, triggering the cut-off device to disconnect the power supply; 3) Use a voltmeter to measure the voltage at the input terminals of each component, confirm that the voltage has dropped to a safe range, and verify that it cannot be restored without manual operation. powered by; 4) Operate the manual reset device to check if the power supply has been restored and if the drive components are functioning normally; 5) Repeat the above steps 10 times, recording the success rate of the reset and any abnormal phenomena each time; 6) If the voltage of the drive component is <=60VDC after power failure, the reset device has no automatic recovery function, and there is no failure after 10 cycles, then it is considered as... Test passed.

b) Maximum nominal current cutoff test. 1) Set the load to the nominal maximum continuous current; 2) Trigger the disconnection action and record the contact temperature and disconnection time; 3) Perform three consecutive disconnection operations and check the contact condition (visually or under a microscope to observe welding and ablation marks); use after disconnection. An insulation resistance tester measures the insulation resistance between contacts; 4) If the breaking time is <=50ms, the contact temperature rise is <=40K, and the insulation resistance after 3 breaks is >=10MOmega, then the test is considered passed.

c) Main power disconnect switch test. 1) Labeling inspection. Verify that the switch labeling includes symbols for rated voltage, current, and breaking capacity; 2) Mechanical life test. Perform 10,000 interruption operations to check if the function is normal; 3) Breaking current measurement. Break

1.25 times the rated current at

1.1 times the rated voltage, repeat 10 times, and record whether a continuous interruption occurs. Arcing or damage.

6.2.4 Power Outage Recovery The robot power outage recovery test shall be performed according to the following steps.

a) Add a remote power-off switch at the battery interface and set the robot's working path;

b) After the robot has traversed back and forth between the starting point and the target point 50 times, the power is cut off using a remote power-off switch;

6.3 Wiring and Layout Testing Methods

6.3.1 Conductors Based on the drawings provided by the manufacturer, test the following.

a) Visually inspect the wires and cables to ensure the model meets the requirements;

b) Use tools to measure wire diameter and dimensions, and record the measured values and mechanical strength test results.

6.3.2 Electrical Connections Based on the electrical connection drawings provided by the manufacturer, randomly sample connectors and wires were inspected. The following tests were performed.

a) For the main power circuit connectors, use a tensile tester to slowly and evenly apply a tensile force of 30N, and record whether the connectors are... Loosening;

b) For screw tightening, randomly select 3 connection points using a torque wrench to ensure that the torque applied by the wrench conforms to the connector manufacturer's specifications. According to regulations, record whether the wiring terminals are loose;

c) For welded connection cables, visually inspect the weld joints to ensure they meet acceptance requirements.

6.3.3 Wiring Based on the drawings provided by the manufacturer, visually inspect each wiring section to ensure it meets the requirements.

6.3.4 Installation Layout Based on the drawings provided by the manufacturer, use visual inspection to check whether the installation layout of each electrical component meets the requirements.

7.1 Driver System Testing Methods

7.1.1 Motor The motor shall be tested in accordance with the test methods in GB/T 39553.

7.1.2 Driver The drive shall be tested in accordance with the test methods in GB/T 12668.502-2013.

7.1.3 Integrated Unit The integrated unit is tested along with the complete machine. If there are special requirements, testing should be conducted according to the corresponding standards.

7.2 Control System Test Methods

7.2.1 Controller Maintain the operating voltage at 90% and 110% of the rated voltage respectively, and operate for 15 minutes to observe whether the robot continues to operate normally. In specific application scenarios with high reliability requirements, check whether there is a dual power supply redundancy design based on the design drawings provided by the supplier.

7.2.2 Navigation Sensors/Obstacle Avoidance Sensors The electrical safety testing methods for navigation sensors/obstacle avoidance sensors are as follows:

a) Enclosure protection rating test. According to GB/T 4208-2017, under the test environment, if the robot can operate normally... If the test is completed within 24 hours, it is considered passed.

b) Laser radiation limit test. The laser radiation limit of the navigation sensor and obstacle avoidance sensor shall be determined in accordance with the test method in GB/T 7247.1. The method was used to conduct experiments.

7.2.3 Control Loop The electrical safety testing method for external control circuits is as follows:

a) Electrical safety test method for power supply circuit. Use instruments to test the voltage of the control circuit, and record the measured voltage value and the positive voltage value of the control circuit. Check whether the voltage is consistent during operation.

b) Electrical safety testing methods for protection circuits. 1) Apply the maximum test voltage, twice the rated electrical voltage, to the power circuit conductors and protective connection circuit. Every 1 second, use a withstand voltage tester to monitor and determine whether a breakdown discharge has occurred; 2) Short-circuit the power circuit wires and the control circuit ground for 1 second, monitor the current change using an ammeter, and verify the control. Does the circuit protection device automatically cut off the power supply to the circuit or equipment within 5 seconds?

7.3 Battery System Test Methods

7.3.1 Battery (pack) The batteries should be supplied by the supplier in accordance with GB/T 7403.1, GB/T 22084.2, GB 40165, GB/T 37669, and SJ/T 11852. The test report verifies the relevant parameters of the battery pack. The thermal runaway of the battery pack was tested according to the GB 44240 test method. All tests... All activities should be carried out in an environment with adequate safety protection.

7.3.2 Battery Box The battery box should be tested according to the following methods, and all tests should be conducted under environmental conditions with adequate safety protection.

a) Visually inspect whether the battery box structure meets electrical safety requirements;

b) The ventilation capacity of lead-acid batteries shall be tested according to the method in GB/T 7403.1.For other batteries, the specification sheet should be checked to ensure that... Ventilation measures will not pose a danger;

c) For non-metallic lids, the flammability rating shall be tested according to GB/T 5169.44;

d) For non-metallic lids, take a complete shell or a portion representing the largest unreinforced area and support it in its normal position. A steel ball with a diameter of 100 mm and a mass of

4.11 kg is dropped freely onto the sample from a distance of

3.3 m from rest. If the battery is located under the overhead support frame, a steel ball with a diameter of 100mm and a mass of 4.11kg is dropped from a height of 1.65m. Conduct tests and record whether live parts are exposed and whether the battery suffers physical damage after the tests.

7.3.3 Battery Management System According to the battery system test report provided by the supplier, and in accordance with GB/T 38661, GB/T 39086 and GB/T 2423.18-2021 Environmental testing standards connect the battery management system to the corresponding host computer, and read the battery voltage and charge via communication methods such as RS485 or CAN. The data includes current, temperature, state of charge, protection status, alarm information, and self-status. All tests should be conducted in an environment with adequate safety protection. This will be carried out under the following circumstances.

7.4 Auxiliary Component Testing Methods Electrical components are tested along with the complete machine. If there are special requirements, the components shall be tested in accordance with the corresponding standards.

8.Marking Requirements Test Method Each item should be inspected visually.