T/CSAE 79-2018Performance requirements and bench test methods for energy-regeneration automobile hydraulic anti-lock braking system (English PDF)

Foreword

This standard is based on GB/T 1.1-2009 "Standardization Work Guide Part 1. Standard Structure and Preparation" Then write.

1 Scope

This standard specifies the basic parameters, requirements and test methods of the energy feedback type automotive anti-lock brake system (EABS).

This standard applies to energy-feedback hydraulic anti-lock braking systems of various switch valve types for M1 and M2 electric vehicles.

A type of energy feedback hydraulic anti-lock brake system can be implemented by reference.

2 Normative references

The following documents are indispensable for the application of this document. For dated references, only the dated version applies.

This document. For undated references, the latest edition (including all amendments) applies to this document.

GB/T 2423.37-2006 Test L. sand dust test GB/T 10125 artificial atmosphere corrosion test salt spray test GB 10830 Technical conditions for the use of brake fluids for motor vehicles GB 12676 Technical requirements and test methods for brake systems for commercial vehicles and trailers GB/T 13594 Anti-lock braking performance and test method for motor vehicles and trailers GB/T 30038 road vehicle electrical and electronic equipment protection level (IP code) Technical requirements and bench test method for hydraulic electromagnetic regulator of QC/T 1005 automobile anti-lock brake system

3 Terms and definitions

The following terms and definitions apply to this standard, and the terms and definitions referred to in QC/T 1005 apply equally to this standard.

3.1 Energy feedback automotive anti-lock braking system (EABS) Energy-regeneration Antilock Brake System

4 Requirements

5 Rated working voltage DC9.5V ~ 16V

6 Working withstand voltage DC18V 1h 100 °C

4.2 General requirements

4.2.1 EABS should meet the requirements of GB 12676.

4.2.2 When EABS is working normally, its performance requirements shall comply with the provisions of GB/T 13594.

4.2.3 EABS consists of a hydraulic control unit (HCU) and an electronic control unit (ECU).

4.3 Hydraulic Control Unit Performance Requirements

4.3.1 Sealing requirements the sealing of each channel of the tested product shall meet the requirements of Table 2.

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Table 2 Sealing requirements

Test project pressure drop (liter) value (MPa) High pressure sealing <= 0.6 Low pressure sealing <= 0.1 Vacuum tightness <= 100×10-6 Pressure tightness <= 0.3 Low pressure accumulator cavity sealing <= 0.1 Medium pressure accumulator cavity sealing performance <= 0.1

4.3.2 Dynamic characteristics requirements

4.3.2.1 The ABS dynamic characteristics of the product shall be implemented in accordance with the requirements of 4.5.1, 4.5.2, 4.5.3, 4.5.4 and 4.5.5 of QC/T 1005.

4.3.2.2 During the pressure switching test, the pressure at the output of the left front and right front wheels is between (0 and 0.02) MPa, left rear the pressure at the output of the wheel and the right rear wheel should be (6 ± 0.3) MPa, and the pressure at the interface of the medium-pressure accumulator should be (6 ± 0.3) MPa.

4.3.2.3 Open the pressure regulating valve, the output flow of the two front wheel output ports should be greater than 2.7mL/s.

4.3.3 Working noise requirements the working noise of the sample to be tested should be less than 73dB.

4.3.4 Environmental test requirements

4.3.4.1 Low temperature resistance test requirements After the test, the performance of the product to be inspected shall meet the requirements of 4.3.1, 4.3.2, and 4.3.3.

4.3.4.2 Low temperature operation test requirements During the test, the sample shall have no functional damage and other guiding phenomena. After the test, the product performance shall meet the requirements of 4.3.1.

Requirements for 4.3.2.1, 4.3.2.1, 4.3.3 and Table 3.

Table 3 Characteristics and parameter requirements after environmental test

Characteristic parameter technical requirements Boost time (ms) <= 195 Buck time (ms) <= 125 Maximum pressure difference (MPa) <= 6.2 Boost lag time (ms) <= 11 Buck lag time (ms) <= 9 5T/CSAE 79 -.2018

4.3.4.3 High temperature resistance requirements After the test, the performance of the product to be inspected shall meet the requirements of 4.3.1, 4.3.2, and 4.3.3.

4.3.4.4 High temperature operation performance requirements During the test, the sample shall have no functional damage and other guiding phenomena. After the test, the product performance shall meet the requirements of 4.3.1.

Requirements for 4.3.2.1, 4.3.2.1, 4.3.3 and Table 3.

4.3.4.5 Temperature cycle resistance requirements During the test, the sample shall have no functional damage and other guiding phenomena. After the test, the product performance shall meet the requirements of 4.3.1.

Requirements for 4.3.2.1, 4.3.2.1, 4.3.3 and Table 3.

4.3.4.6 Humidity and heat resistance requirements During the test, there shall be no functional damage and other guiding phenomena in the water inside the sample. After the test, the product performance shall be Meet the requirements of 4.3.1, 4.3.2.1, 4.3.2.1, 4.3.3 and Table 3.

4.3.4.7 Waterproof performance requirements After the test, the sample shall not be filled with water and the performance of the product to be inspected shall meet the requirements of 4.3.1, 4.3.2 and 4.3.3.

4.3.4.8 Dustproof performance requirements After the test, there shall be no dust inside the sample to enter the sealing area of the test sample and the performance of the tested product shall meet the requirements of 4.3.1.

4.3.2, 4.3.3 requirements.

4.3.4.9 Liquid compatibility requirements After the test, the sample should meet the following requirements.

a) no liquid shall enter the sealing area of the test sample;

b) EABS assembly has no cracks and deformation;

c) electrical faults are not allowed in the test;

d) The performance requirements of each channel of the sample shall meet the requirements of 4.3.1, 4.3.2, 4.3.3.

4.3.4.10 Liquid immersion requirements After the test, the sample meets the following requirements.

a) no water shall enter the sealing area of the test specimen after the test;

b) There must be no electrical faults during the test;

c) The performance of the product under inspection shall meet the requirements of 4.3.1, 4.3.2, 4.3.3.

4.3.4.11 Salt spray resistance performance requirements After the salt spray test was carried out for 72 hours, no white rust appeared on the surface of the product, and no red rust appeared on the exposed surface of the product after 128 hours.

4.3.5 Strength test requirements

4.3.5.1 Pressure resistance requirements After the pressure resistance test, the sample piece shall have no effect on the damage and deformation of the function, and no external leakage. The sealing performance of the sample should meet the requirements of 4.3.1 Requirements.

4.3.5.2 Vibration resistance requirements During the test, the sample shall be free of functional damage and other anomalies. After the test, the products to be inspected should meet Table 4 and Table 5 requirements.

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Table 4 Sealing requirements after vibration durability

Test project pressure drop (liter) value (MPa) High pressure sealing <= 0.7 Low pressure sealing <= 0.18 Vacuum tightness <= 150×10-6 Pressure tightness <= 0.35 Low pressure accumulator cavity sealing performance <= 0.15 Medium pressure accumulator cavity sealing performance <= 0.15

Table 5 Dynamic characteristics parameter requirements after vibration endurance

Characteristic parameter technical requirements Boost time (ms) <= 210 Buck time (ms) <= 135 Maximum pressure difference (MPa) <= 6.5 Boost lag time (ms) <= 11 Buck lag time (ms) <= 9

4.3.6 Insulation resistance performance requirements the insulation resistance of the connection plug of the ECU and the metal (body) of the HCU was measured before and after the test, and the resistance was greater than 10 Mohm.

5 test conditions

5.1 Test equipment requirements

5.1.1 Performance test device

5.1.1.1 The ABS regulation performance test equipment of the product shall be implemented in accordance with the requirements of 5.1.1 of QC/T 1005.

5.1.1.2 The test equipment shall control the on-off state and working time of the isolation valve, the switching valve and the pressure regulating valve coil. Working time the control error should be no more than 2%.

5.1.1.3 The test equipment shall be capable of providing a pressure of 0 MPa to 16 MPa, and the control error of the pressure source shall not exceed 2%.

5.1.1.4 Test equipment should be connected to the flow meter at the output port, and the flow rate of the pressure output port should be monitored in real time.

5.1.2 Noise test bench the ambient noise in the noise detection station should be less than 40dB; the pickup of the sound level meter is installed 700mm directly above the sample.

5.1.3 high and low temperature test chamber the error between the actual temperature of the test box and the set temperature shall not exceed 2 °C. The test box shall have a passage connecting the air pipe, the brake pipe and the cable.

It has sealing measures for heat insulation and moisture insulation, and has space for accommodating the durability test device of the gantry.

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5.1.4 Salt spray test chamber the salt spray test chamber shall meet the requirements of the neutral salt spray test in GB/T 10125.

5.1.5 constant temperature and humidity test chamber the control box can control the temperature range from -40 °C to 120 °C, the error between the actual temperature and the set temperature should not exceed 1 °C, the actual relative the error between humidity and set relative humidity should not exceed 2%.

5.1.6 Vibration test bench the vibration test rig can perform random vibration, and the total rms indication error of acceleration should not exceed 3%, and the acceleration power spectral density indication value the error should not be greater than 3%.

5.2 Sample requirements

5.2.1 The prototype shall be a product manufactured in accordance with a technical document approved by the prescribed procedures.

5.2.2 The number of samples and test items should be selected according to Table 6 according to different test purposes.

Table 6 Sample quantity and test items

test

order

Pilot projects

Sample number

8 Humidity and heat resistance test - - - * * * -

9 Water resistance should be tested - - - * * * -

10 Dustproof performance test - - - * * * -

11 Liquid immersion test - - - * * *

12 Liquid compatibility test - - - * * * -

13 Pressure resistance test - - - - - - *

14 Salt spray resistance test* * * - - - -

15 Vibration endurance test* * * - - - -

Note. "*" indicates the test item to be performed, and "-" indicates the test item not to be performed.

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6 Test methods

6.1 Sealing test

6.1.1 High pressure tightness test

6.1.1.1 The sample is in the normal state (the inlet valve, the outlet valve, the isolation valve, the switching valve, the pressure regulating valve, and the return pump motor are not energized, the sample is in the boost state or the normal braking state, the same as below), blocking the output port, and inputting the hydraulic pressure of the input port (20±0.5) MPa.

The test is started after the pressure is stabilized.

6.1.1.2 Detect the pressure drop of each channel of the tested product within 60s.

6.1.2 Low pressure tightness test

6.1.2.1 When the sample is in the normal state, the output port is blocked, and the input port is input with a pressure of (0.5±0.3) MPa, and the pressure is stable.

Close the input pressure source after setting.

6.1.2.2 Detect the pressure drop of each channel of the tested product within 5s.

6.1.3 Vacuum tightness test

6.1.3.1 When the sample is in the normal state, the output port is blocked, and the input port starts to vacuum, when the absolute pressure inside the sample reaches at 300 Pa, the vacuum source is turned off and stabilized for 5 s.

6.1.3.2 Detect the pressure rise of each channel of the tested product within 5s.

6.1.4 Pressure sealing test

6.1.4.1 Input the hydraulic pressure of (12±0.5) MPa from the input port of the sample. After the pressure is stabilized, energize the inlet valve, and the outlet valve and the pressure source of the input port is closed when the return pump motor is not energized.

6.1.4.2 Measure the pressure drop of the input and output ports of each channel within 30 s.

6.1.5 Low-pressure accumulator chamber sealing test

6.1.5.1 The sample outlet valve coil is energized, blocking the output port, and the input port inputs (12±0.5) MPa hydraulic pressure, waiting for pressure Start testing after stabilization.

6.1.5.2 Detect the pressure drop of each channel of the tested product within 5s.

6.1.6 Medium pressure accumulator sealing test

6.1.6.1 The sample isolation valve and the switching valve coil are energized at the same time, blocking the output port, and the input port input (12±0.5) MPa Hydraulic pressure, start testing after the pressure is stable.

6.1.6.2 Detect the pressure drop of each channel of the tested product within 5s.

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6.2 Dynamic characteristics test

6.2.6.1 Dynamic characteristics The ABS test method is tested in accordance with 6.5 of QC/T 1005.

6.2.6.2 First open the switching valve and close the isolation valve, then fill the input port with (6 ± 0.5) MPa oil pressure and test four the pressure at the output port and the intermediate pressure accumulator interface.

6.2.6.3 Add (6 ± 0.5) MPa oil pressure to the medium pressure accumulator interface, and open the two pressure regulating valves until the pressure of the two front wheel outlets when (6 ± 0.5) MPa is reached, the flow rate of the left front output port and the right front output port is detected.

6.3 Working noise test

6.3.6.1 Simulate the actual vehicle state installation sample (with mounting bracket and damping pad), control circuit and analog controller or real vehicle controller Connected; installed in the noise detection station.

6.3.6.2 Operation controller, simulating the boosting, holding pressure and depressurization process of conventional braking, the test pressure is (12±0.5) MPa;

Record the working noise of the sample.

6.4 Environmental test

6.4.1 Low temperature resistance test

6.4.1.1 Place the sample in the cryostat at room temperature and place the test piece in the actual vehicle assembly state (or simulate the actual vehicle assembly state).

Gradually reduce the temperature in the low temperature box to (-40 ± 2) °C, so that the sample is kept in a non-energized state (96 ± 2) h in the low temperature chamber.

Remove the sample from the cryostat; leave it at room temperature for more than 2 hours.

6.4.1.2 After the test, the samples shall be tested according to 6.1, 6.2 and 6.3.

6.4.2 Low temperature operation test

6.4.2.1 Place the sample in the cryostat at room temperature and place the test piece in the actual vehicle assembly state (or simulate the actual vehicle assembly state).

Gradually reduce the temperature in the cryostat to (-40 ± 2) °C conditions. Keep the sample in the running state (72±2)h in the low temperature box, Remove the sample from the cryostat; leave it at room temperature for more than 2 hours.

6.4.2.2 After the test, the samples shall be tested according to 6.1, 6.2 and 6.3.

6.4.3 High temperature resistance test

6.4.3.1 Place the sample in the high temperature box at room temperature and place the test piece in the actual vehicle assembly state (or simulate the actual vehicle assembly state).

Gradually increase the temperature in the high temperature chamber to (120 ± 2) °C, so that the sample is kept in a non-energized state (96 ± 2) h in the high temperature chamber.

Remove the sample from the oven and leave it at room temperature for more than 2 hours.

6.4.3.2 After the test, the samples shall be tested according to 6.1, 6.2 and 6.3.

6.4.4 High temperature operation test

6.4.4.1 Place the sample in the high temperature box at room temperature and place the test piece in the actual vehicle assembly state (or simulate the actual vehicle assembly state).

Gradually increase the temperature in the high temperature chamber to 120 ± 2 ° C conditions. Keep the sample in the power state and run it in the high temperature chamber (72±2)h.

Remove the parts from the high temperature chamber; leave at room temperature for more than 2 hours.

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6.4.4.2 After the test, the samples shall be tested according to 6.1, 6.2 and 6.3.

6.4.5 Temperature cycle test

6.4.5.1 The product under test is filled with brake fluid, plugging the input port and the output port, and putting the product into a low temperature box with a temperature of -40 °C.

After 2 hours of placement, the product was quickly placed in a 120 ° C high temperature chamber for 2 h, and the intermediate conversion time was between 2 min and 3 min.

6.4.5.2 The above test procedure constitutes a cycle for a total of 50 cycles.

6.4.5.3 After the test, the samples shall be tested according to 6.1, 6.2 and 6.3.

6.4.6 Heat and humidity resistance test

6.4.6.1 Pre-aging treatment according to 6.4.4.1 before test.

6.4.6.2 Place the sample in the hot and humid chamber at room temperature and place the test piece in the actual vehicle assembly state (or simulate the actual vehicle assembly state).

Control the ambient temperature and humidity in the test chamber, change according to the curve of Figure 1, repeat 5 cycles

6.4.6.3 After the test, the samp...