1. Research on REESS Vibration Test Method
FAW , China
2015.9

2. 1 2 3 Outline REESS vibration test standards introduction
FAW-A class EV road load data collection and analysis 3
Conclusion

3. 1 REESS vibration test standards introduction
Overview
Now, IEC, ISO, SAE, GB/T and other standards contain the REESS vibration test method .
According to the different load characteristics, the vibration test could be divided into:
(1) Sweep frequency vibration test;
(2) Random vibration test.

4. Sweep frequency vibration test
1 REESS vibration test standards introduction
REESS vibration test standards
Items
Standards
Application
Sweep frequency vibration test
ECE R100 Uniform Provision Concerning the Approval of Battery Electric Vehicles with regard to Specific Requirements for the Construction and Functional Safety
REESS
UN38.3 UN Lithium Battery Tests, UN Manual Tests and Criteria
Cell、Module、Pack
GB The safety requirement of the transporting Lithium primary and secondary battery
（锂原电池和蓄电池在运输中的安全要求）
Random vibration
UL2580 Batteries for Use in Electric Vehicles
Module、Pack
SAE J2380 Vibration Testing of Electric Vehicle Batteries
Pack
ISO Electrically propelled road vehicles-Test specification for lithium-ion traction battery packs and systems-Part3：Safety performance requirements
GB/T Lithium-ion power battery pack and system used in electric vehicle Part3: Safety requirement and test methods.
（电动汽车用锂离子动力蓄电池包和系统 第3部分：安全性要求与测试方法）

5. 1 REESS vibration test standards introduction
Comparison of different standards
Items
Standard No.
Frequency
Acceleration
Test time
SOC
Sweep frequency vibration test
UN38.3
7-200Hz
Max.8gN 3h
Not stated
ECER100
7-50Hz
Max.10gN
≥50%
GB21966/IEC62281:2004 9h
Random vibration
UL2580
10-190Hz
Z:1.9&0.75(N)/0.95Gms(A)
Y:1.5&0.4(N)/0.75Gms(A)
X:1.5&0.4(N)/0.75Gms(A)
≈93h
100%
SAEJ2380
20%~100%
ISO12405
5-200Hz
X:0.96Gms
Y1:1.23Gms
Y2:0.95Gms
Z:1.44Gms
X:21h
Y:21h
Z:21h
50%
GB/T
Full charged

6. 2 FAW-A class EV road load data collection and analysis
We collected the FAW-A class EV’s road load data , then, we will compare the test results with ISO (Random vibration) and ECE R100 (Sweep frequency vibration).
Vehicle parameter
Vehicle type
FAW A class EV
Manufacturer
FAW
Tires
195/65R15
Tire pressure (bar)
Front tire pressure 220KPa
Rear tire pressure  230KPa
Curb weight（kg）
1420

7. 2 FAW-A class EV road load data collection and analysis
Introduction of the acceleration data collection
Test sensor installation position
Reference car road reliability test standard
FAW standard 《A-class car bearing system reliability test specification》
Acceleration sensor g
Test equipment
CRONOS Compact
Sampling frequency
2000Hz
No.
Channel name
Positive direction
Position 1
A1X
Rear
Right front side of the battery fix position（as the pic A1）
A1Y
Right
A1Z Up 2
A2X
Right side of the battery fix position（near the front）
（as the pic A2）
A2Y
A2Z 3
A3X
Right side of the battery fix position（in the middle）
（as the pic A3）
A3Y
A3Z 4
A4X
Right side of the battery fix position（near the rear）
（as the pic A4）
A4Y
A4Z 5
A5X
Right rear side of the battery fix position（as the pic A5）
A5Y
A5Z
The acceleration sensor installation position

8. 2 FAW-A class EV road load data collection and analysis
Test condition
Vehicle Weight (kg)
condition
The left front wheel
The Right front wheel
The left rear wheel
The right rear wheel
Front axle load
Rear axle load
Total weight
Empty
319.5
316
390
392.5
635.5
782.5
1418
Half load
353.5
359.5
421
427
713
848
1561
Full load
378.5
379.5
546
547
758
1093
1851
Reliablity road
Road section
Regulating speed (km/h)
big hunch curve 20
1#chuckholes 50
big chuckholes 55
1#torsion
5～10
concrete road unevenness 10
2#middle cobble road
45（full load）
40（half load）
girder crossing
2#slanting wash road
small hunch curve
2#beigian road
1#slanting wash road
2#chuckholes
1#middle cobble road
55（full load）
50（half load）
2#torsion
1#beigian road 35

9. 2 FAW-A class EV road load data collection and analysis
Test results
The acceleration time series signal (point 1 to point 3)
The acceleration time series signal (point 4 to point 5) and vehicle speed

10. 2 FAW-A class EV road load data collection and analysis
FAW analysis method
Using damage equivalent and the envelope method to create test profiles for accelerated random and sweep frequency vibration bench tests.
Consumer vehicle equivalent
2.4×105km
S/N Slope 4
 Safety factor
1.5
Frequency
5~200Hz
According to
ISO 12405
Vibration duration hours
x-axis 21h、y-axis 21h、z-axis 21h
7~50Hz
ECE R100
z-axis 3h

11. 2 FAW-A class EV road load data collection and analysis
Comparison of power spectrum density curve between vehicle test and ISO 12405
X-axis

12. 2 FAW-A class EV road load data collection and analysis
Comparison of power spectrum density curve between vehicle test and ISO 12405
Y-axis

13. 2 FAW-A class EV road load data collection and analysis
Comparison of power spectrum density curve between vehicle test and ISO 12405
Z-axis

14. 2 FAW-A class EV road load data collection and analysis
Comparison of Sweep frequency vibration between vehicle test and ECE R100
Z-axis

15. 3 Conclusion
To sum up， the FAW A class EV test results are different from ISO (Random vibration) and ECE R100 (Sweep frequency vibration).
when you do the REESS vibration test，you’d better input the test data according to the real vehicle’s road load data.

16. Thank you for your attention!16 16

17. 3 Conclusion
Comparison of power spectrum density curve between vehicle test and ISO 12405
Comparing ISO12405 bench vibration power spectrum density with the vehicle test, the ISO12405 bench vibration power in X axis is similar to the vehicle test, and the ISO12405 bench vibration power in Y and Z axis is significantly higher than that of the real vehicle test.
Comparing ISO12405 bench vibration power spectrum density with vehicle test, their vibration frequency distribution trend is similar.
Considering the safety, we suggest using ISO12405 PSD in the REESS vibration test.
Comparison of sweep frequency vibration between vehicle test and ECE R100
Comparing ECE R100 bench vibration with the vehicle test, within 7 to 24Hz the ECE R100 bench vibration is similar to vehicle test, and at 24 to 50 Hz the ECE R100 bench vibration is smaller than the vehicle test.
Considering the safety, we suggest using the vehicle test in the REESS vibration test.