QC/T 1241-2025Specifications and test methods for hybrid electric drive system of electric vehicles (English PDF)

3.1 Hybrid electric drive system

A device capable of obtaining power from at least the following two types of onboard energy storage:

a) Consumable fuel;

b) Electrical energy storage device.

NOTE: The structure includes, but is not limited to, a system consisting of a drive motor, generator, dynamic coupling device, and motor controller, etc.

3.2 Dynamic coupling device

A device for implementing control strategies to achieve power coupling in a hybrid power system.

NOTE: The structure includes, but is not limited to, gear transmission mechanisms, cooling and lubrication mechanisms, mode switching actuators, and control units.

3.3 System efficiency

The percentage of total output power to total input power in a hybrid electric drive system, including both mechanical and electrical energy.

3.4 Pure electric mode

A mode in which energy is provided solely by an electrical energy storage device, and driving force is provided by a drive motor.

3.5 Series mode

The mode in which engine, generator, and drive motor all operate, with the drive motor providing the driving force, and the engine driving the generator to generate electricity.

3.6 Parallel mode

The mode in which engine, generator, and drive motor can all participate in the operation, and there can be at least two power sources providing driving force at the same time.

3.7 Direct drive mode

The mode in which neither generator nor drive motor participates in driving, the engine is the sole power source providing driving force.

4.1 General items

4.1.1 Component materials

The raw materials used in the system shall meet the requirements of GB/T 30512.

4.1.2 Appearance

4.1.2.1 The outer surface of the system shall be free from obvious damage or deformation, and the coating shall be undamaged.

4.1.2.2 The system's leads or terminals shall be intact and undamaged, and fasteners shall be securely connected without loosening.

4.1.2.3 The color markings and routing of high-voltage wiring harnesses shall be clearly identifiable, and the arrangement of low-voltage wiring harnesses shall be neat and orderly.

4.1.2.4 If a nameplate is installed, the system nameplate shall be installed upright and securely, with clear lettering.

4.1.3 Insulation resistance

The insulation resistance shall be tested according to the method specified in 5.2.1, and shall meet the requirements of 5.1.4 in GB/T 18488-2024.

4.1.4 Withstand voltage

The withstand voltage shall be tested according to the method specified in 5.2.2, and shall meet the requirements of 5.1.5 in GB/T 18488-2024.

4.1.5 General performance requirements

4.1.5.1 Shaft voltage

The shaft voltage shall be tested according to the method specified in 5.2.4; and the peak-to-peak value of the shaft voltage of each motor in the system under steady-state and dynamic operating conditions shall meet the requirements of the product technical documents.

4.1.5.2 Torque loss

The torque loss shall be tested according to the method specified in 5.2.5; when the oil temperature reaches 60 °C, the maximum torque loss at the drive end in each operating mode shall not exceed 15 N·m, or meet the requirements of the product technical documents.

4.1.5.3 Overspeed performance

The overspeed performance shall be tested according to the method specified in 5.2.6; and the system shall be able to withstand speeds no less than 1.1 times the maximum operating speed of the motor for a duration of no less than 2 min. After the test, the system performance shall meet the requirements of the product technical documents.

4.1.5.4 Ripple immunity performance

The ripple immunity performance shall be tested according to the method specified in 5.2.7, and the system operating condition shall meet the relevant requirements of ISO 21498.

4.2 Input/Output characteristics

4.2.1 Peak output torque

The peak output torque shall be tested according to the method specified in 5.3.1, and the maximum continuous output torque of the system shall meet the requirements of the product technical documents.

4.2.2 Peak output power

The peak output power shall be tested according to the method specified in 5.3.2, and the maximum continuous output power of the system shall meet the requirements of the product technical documents.

4.2.3 Efficiency test

The efficiency test shall be conducted according to the method specified in 5.3.3, and the system efficiency in each mode shall meet the requirements of the product technical documents.

4.3 Thermal balance and lubrication performance

4.3.1 Thermal balance performance

4.3.1.1 It shall be tested according to the method specified in 5.4.1; under rated operating conditions, the system should reach thermal balance, and the thermal balance temperature shall not exceed the temperature limit specified in the product technical documents.

4.3.1.2 The thermal balance judgment condition is that the motor stator temperature fluctuation does not exceed ±1°C within 15 min, or does not exceed the temperature limit within 30 min.

4.3.1.3 It shall be tested according to the method specified in 5.4.2; and the system shall operate continuously for no less than 10 s under all peak operating conditions. During this period, the thermal performance shall meet the requirements specified in the product technical documents.

4.7 Electromagnetic compatibility

4.7.1 Electromagnetic radiation emission

Radiated emission limits shall meet the requirements of 5.5.1 in GB/T 18488-2024.

4.7.2 Electromagnetic radiation immunity

The radiated immunity shall meet the requirements of 5.5.2 in GB/T 18488-2024.

4.7.3 Power line transient conducted immunity

Power line transient conducted immunity shall meet the requirements of 5.5.3 in GB/T 18488-2024.

4.8 Vibration and noise performance

It shall be tested according to the method specified in 5.9, and the system's vibration and noise performance shall meet the requirements of the product technical documents.

5.1 Test preparation

The test environment conditions, selection of test instruments, measurement process errors, test power supply, wiring, cooling, signal shielding, safety, etc., unless otherwise specified, shall meet the relevant test requirements in GB/T 18488.

5.2 General test items

5.2.1 Insulation resistance test

The insulation resistance test shall be conducted according to the requirements of 6.2.4 in GB/T 18488-2024.

5.2.2 Withstand voltage test

The withstand voltage test shall be conducted according to the requirements of 6.2.5 in GB/T 18488-2024.

5.2.3 Break-in test

If the system has multiple speeds, each speed should be broken in separately. The break-in conditions are shown in Table 1. The lubricating oil shall be replaced after the break-in period.