This standard specifies the use conditions, technical requirements and test requirements of DC choppers (hereinafter referred to as choppers) for battery vehicles (industrial vehicles and other road vehicles using batteries as energy). This standard applies to choppers for battery vehicles, which are used as speed regulators for the main traction (travel) motors of battery vehicles. In principle, it is also applicable to choppers for auxiliary (oil pump and steering) motors on battery vehicles. JB/T 6481-1992 DC choppers for battery vehicles JB/T6481-1992 Standard download decompression password: www.bzxz.net

Mechanical Industry Standard of the People's Republic of China
JB6481-92
DC Chopper for Battery Vehicles
Published on August 6, 1992
Implementation of the Ministry of Machinery and Electronics Industry of the People's Republic of China on January 1, 1993
Mechanical Industry Standard of the People's Republic of China
DC Chopper for Battery Vehicles
This standard adopts the subject content and scope of application of IEC411-4 (1986) "DC Chopper Converter for Vehicles"
JB6481-
This standard specifies the use conditions, technical requirements and test requirements of DC choppers (hereinafter referred to as choppers) for battery vehicles (industrial vehicles and other road vehicles with batteries as energy). This standard applies to choppers for battery vehicles, which are used as speed control for the main traction (travel) motor of battery vehicles. In principle, it is also applicable to choppers for auxiliary (oil pump and steering) motors on battery vehicles. 2·Referenced standards
GB6104
GB2900.33
GB7677
JB3974
ZBK63002
ZBK63003
JB3136
JB3137
JB3085
Use conditions
Rated current of electrical equipment
Terms of motor-driven industrial vehicles
Terms of electrical engineering·Converter||tt ||Semiconductor direct current converter
Basic technical conditions for DC appliances for battery vehiclesBasic environmental test procedures for electrical and electronic productsTest Db: Alternating damp heat test methodBasic technical conditions for traction appliances
Basic test methods for traction appliances
Technical specifications for printed circuit board assembly and welding for electric drive devicesTechnical conditions for printed circuit boards for electric drive control devicesProduct packaging and transportation regulations for electric drive control devices equipped with electronic devicesNormal use conditions
The chopper should be able to work normally in the following environment. 3.1.1 The altitude shall not exceed 1200m.
3.1.2 The ambient temperature shall be -25~40℃, and the annual average temperature shall not exceed 25℃: 3.1.3 The average maximum relative humidity of the wettest month shall be .90%, and the average minimum temperature of the month shall not exceed 25℃. The short-term maximum relative humidity is allowed to reach 100%.
3.1.4 Corresponding to the vertical, lateral and longitudinal directions of the battery vehicle, the battery vehicle has a sinusoidal vibration with a frequency of 1 to 50 Hz, and its amplitude is not greater than A, where A is:
3.1.5 Maximum impact acceleration
Longitudinal (vehicle travel direction)
Approved by the Ministry of Machinery and Electronics Industry in 1992-08-06 When f is: 1 to 10 Hz
When f is 10 to 50 Hz
1993 —01-01 Implementation
*3—1
10m/st
JB6481-92
Vertical direction
3.1.6 When used in the following environments, the chopper should be protected; a.
Corrosive gas or conductive dust;
Rain or dripping water site;
Radio interference source or radioactive dose sufficient to cause damage to electronic devices and system out of control. e
3.1.7 The fluctuation range of battery power supply voltage is 70%~110% of the rated voltage. 3.2 The use conditions that exceed the normal use conditions in 4.1 shall be agreed upon by the user and the manufacturer. 4 Technical requirements
4.1 Rated input voltage value level
The rated value of the battery power supply voltage is the rated input voltage value of the chopper, i.e. 24, 48, 72 (80), 96V. The voltage beyond the above range shall be agreed upon by the user and the manufacturer. 4.2. Rated output current value level
The rated output current value of the chopper is 50, 100, 160, 200, 250, 315A. The rated current value beyond the above range shall be agreed upon by the user and the manufacturer. And selected from GB762. 4.3 Overload capacity
The overload capacity of the chopper is in accordance with the data in Table 1.
Overload duration
Instantaneous (5s)
Note: le—Rated output current value of the chopper, the value in brackets is limited to old products. 4.4 Chopper frequency
The chopper frequency is specified by the product technical conditions. 4.5: Output voltage (voltage regulation) range
Overload multiple
1.6Te;(1.4 le),(1.2 le)
3Ies(2.5Te):(2 Te)
5 le;(4 Te)
The ratio of the output voltage to the input voltage of the chopper (i.e., the voltage regulation ratio) shall not be less than 10% to 90% and shall be continuously adjustable. 4.6 The chopper shall have short circuit and loss of control protection functions. When other functions are required, the user and the manufacturer shall agree. 4.7 The mean trouble-free working time of the chopper shall be specified by the product technical conditions, but shall not be less than 3000h. 4.8 When the chopper is running under rated load, its audio noise shall not be greater than 60dB(A). The minimum electrical clearance and minimum creepage distance of the chopper device shall be implemented in accordance with ZBK63002. 4.9
4.10 The electrical connection points and fasteners of the new chopper must be firm. The installation dimensions and spare parts (accessories) of the same type of chopper are interchangeable. 4.12 The main electrical components of the chopper must comply with the relevant provisions of JB3974. At the same time, they should also meet the corresponding professional technical standards. 4.1
The design and manufacture of the control unit circuit board of the chopper must comply with the relevant provisions of JB3137 and JB3136. 5 Test requirements
5.1 Light load test
This test is carried out at rated voltage and not less than 10% of the rated current. The purpose is to verify whether the wiring of the chopper is correct and whether its static control performance meets the requirements.
5.2 Output voltage (voltage regulation) range test
JB6481--92
For this test, the input and output ends of the chopper are connected to a 0.5-level DC voltmeter and ammeter. 5.2.1 Minimum input voltage test
Input 70% rated voltage and output the maximum current specified in item 2 of table 1 of clause 4.3. The output voltage value of the chopper shall not be less than 90% of the input voltage value
5.2.2 Maximum input voltage test
Input 110% rated voltage and output 10% rated current. The output voltage value of the chopper shall not be greater than 10% of the input voltage value. 5.3 Repeated start test
Under rated load, input 70% rated voltage and repeat the start 5 times, each time with an interval of 3$. 5.4 Temperature rise test
The test is run to the equilibrium temperature under the specified load, equivalent working conditions and specified cooling conditions (specified by the product technical conditions). The temperature rise limit values ​​of the electrical components of the chopper are shown in Table 2. Item
Name of conductive heating element
Electrical contact part connected by screws (aluminum)Electrical contact part connected by burst nails (copper)Power semiconductor device housing
Electronic control unit
Commutation inductor (line diagram) (red copper)
Temperature rise limit
5.5 Commutation capacity (short-term overload) test
After the chopper reaches the equilibrium temperature, input 70% of the rated voltage, output the maximum current specified in item 2 of table 1 of Article 4.3 and the pulsation rate is the largest. Duration 1min. The commutation capacity test requirements of the chopper composed of gate turn-off transistors (GTO) and giant power transistors (GTR) are specified by the product technical conditions.
5.6 Long-term overload test
This test is used to check the chopper's ability to withstand long-term overload. After the chopper reaches the equilibrium temperature, input the rated voltage and output the current specified in item 1 of table 1 of clause 4.3 for 5 minutes, and the voltage regulation ratio is 90%.
5.7 Audio noise test
The audio noise of the chopper when running under rated load should not be greater than 60dB(A). The audio noise transmitted by the chopper should be measured at a horizontal distance of 1m from the chopper housing.
5.8 High temperature test
The chopper is placed in a high temperature box, and the temperature is gradually increased from ambient temperature to 40±2℃. The heating time is not less than 0.5h. After maintaining at 40±2℃ for 2h, the chopper is connected to the power supply for testing. The chopper should meet the requirements of clauses 5.3 and 5.5. 5.9 Low temperature test
The chopper is placed in a low temperature box and the temperature in the box is gradually reduced to -25±2°C for no less than 0.5h. The temperature is kept at -25±2°C for 2h and then the power is turned on for testing. The chopper should meet the requirements of 5.3 and 5.5. 5.10 Vibration shock test
The chopper is tested in 3.1.4 and 3.1.5. Under the vibration and impact conditions, there should be no mechanical damage, loose fasteners, etc., and the chopper should be able to work normally.
5.11 Short-circuit test
The input voltage of the chopper is 1.1 times the rated voltage, equivalent load, and the output current is the specified maximum value. After 1 minute of power-on, the short-circuit contactor connected in parallel with the resistance 33
JB6481-92
load is closed, and the protection link should operate reliably. After the short circuit is eliminated, the chopper should be able to restart. 5.12 Failure protection testbzxZ.net
If the chopper fails to control during operation, its failure protection link should be able to reliably disconnect the power supply of the controlled motor within 200ms, and it can restart after the fault is eliminated.
5.13 Moisture resistance test
The chopper is tested at a high temperature of 40℃C according to GB2423.4 for 6 days. After the test, the insulation performance of the product should meet the following requirements: the insulation resistance of the chopper shall not be less than 0.5Ma; a.
The withstand voltage performance shall meet 85% of the value specified in Article 5.14 and Table 3; b.
Parts shall not have obvious rust spots, coating shedding, or blistering. c.
5.14 Insulation withstand voltage test
The insulation of the chopper shall be able to withstand the AC 50Hz sinusoidal test voltage (effective value) specified in Table 3 for 1min, and there shall be no breakdown or flashover. Table 3
Rated voltage
31~300
Position where voltage is applied
Between mutually insulated live parts and to groundTest voltage between mutually insulated live parts and to ground
5.15 Instantaneous overload test
The chopper is input with rated voltage and outputs the instantaneous maximum current specified in item 3 of table 1 of clause 4.3, with an instantaneous value of 55 and a voltage regulation ratio of 90%.
6 Test acceptance rules
The chopper test is divided into type test and factory test. 6.1 Type test
6.1.1 Part or all of the type test must be carried out in the following cases. a.
Trial production of new products and trial production of conversion;
When the changes in the structure, process or material of the product are sufficient to affect its basic performance; b.
Mass-produced choppers should be subject to type tests regularly for a period not exceeding five years. c.
6.1.2 There shall be no less than 2 type test prototypes, and each prototype and each test shall be qualified. When conducting the test of item C in 6.1.1, randomly select 2 prototypes from the qualified products in the batch. If there are unqualified test items in the test, double the number of products shall be retested for this item. If one product still fails this item in the doubled test, the batch of products shall be considered unqualified.
6.2 Factory test
6.2.1 Each product shall be tested by the manufacturer before leaving the factory. 6.2.2 When the user makes a request, some or all of the type test items may be selected to assess the product, and the specific matters involved shall be negotiated by the supply and demand parties.
6.3 Test method
Except for the specific provisions in this standard, the rest of the test method shall be carried out in accordance with ZBK63003. 6.4 Type test and factory test shall be carried out in accordance with Table 4. 3—4
Test items
General inspection
Light load test
Output voltage range test
Repeated start test
Temperature rise test
Commutation capacity test
Long-time overload test
Noise test
High temperature test
Low temperature test
Vibration and shock test
Short circuit test
Failure protection test
Moisture resistance test
Insulation withstand voltage test
Instantaneous overload test
JB6481—92
Type test
5.6 (recommended)
Factory test
Some special requirement test items, such as reliability enhancement test, shall be negotiated by the user and the manufacturer for test or installation assessment. Marking
7.1 Product marking
The product must be equipped with a fixed, reliable and durable brand name: The product brand name should be installed in a position that is easy to observe. 7.2
Product brand name content
Product name, model;
Rated voltage, rated current;
Standard number;
Factory serial number:
Product weight;
Manufacturer name;
Manufacture year and month.
Product packaging, transportation, storage and warranty period 8.1 The chopper is packaged in single units. The packaging box must comply with the provisions of JB3085 to adapt to various transportation methods and transportation environments to ensure that the product is intact.
8.2 Under the condition that the user complies with the storage and use methods of the product, within one year from the date of shipment from the manufacturer, if the product is damaged or cannot work normally due to poor quality, the manufacturer shall repair or replace parts for the user free of charge. 3—5
Documents to be attached to the product
Product certificate,
Product use and maintenance instructions.
JB6481—92
Additional notes:
This standard is proposed and managed by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. Participating drafting units: Changzhou Switch Factory, Beijing Hoisting and Transportation Machinery Research Institute, Shenyang Automatic Control Research and Design Institute, Shenyang Electrical Special Equipment Research Institute.
The main drafters of this standard are Zhu Xinhe and Zhao Junku.4 Type tests and factory tests shall be carried out in accordance with Table 4. 3—4
Test items
General inspection
Light load test
Output voltage range test
Repeated start test
Temperature rise test
Commutation capacity test
Long-time overload test
Noise test
High temperature test
Low temperature test
Vibration and shock test
Short circuit test
Failure protection test
Moisture resistance test
Insulation withstand voltage test
Instantaneous overload test
JB6481—92
Type test
5.6 (recommended)
Factory test
Some special requirement test items, such as reliability enhancement test, shall be negotiated by the user and the manufacturer for testing or installation assessment. Marking
7.1 Product marking
The product must be equipped with a fixed, reliable and durable brand name: The product brand name should be installed in a position that is easy to observe. 7.2
Product brand name content
Product name, model;
Rated voltage, rated current;
Standard number;
Factory serial number:
Product weight;
Manufacturer name;
Manufacture year and month.
Product packaging, transportation, storage and warranty period 8.1 The chopper is packaged in single units. The packaging box must comply with the provisions of JB3085 to adapt to various transportation methods and transportation environments to ensure that the product is intact.
8.2 Under the condition that the user complies with the storage and use methods of the product, within one year from the date of shipment from the manufacturer, if the product is damaged or cannot work normally due to poor quality, the manufacturer shall repair or replace parts for the user free of charge. 3—5
Documents to be attached to the product
Product certificate,
Product use and maintenance instructions.
JB6481—92
Additional notes:
This standard is proposed and managed by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. Participating drafting units: Changzhou Switch Factory, Beijing Hoisting and Transportation Machinery Research Institute, Shenyang Automatic Control Research and Design Institute, Shenyang Electrical Special Equipment Research Institute.
The main drafters of this standard are Zhu Xinhe and Zhao Junku.4 Type tests and factory tests shall be carried out in accordance with Table 4. 3—4
Test items
General inspection
Light load test
Output voltage range test
Repeated start test
Temperature rise test
Commutation capacity test
Long-time overload test
Noise test
High temperature test
Low temperature test
Vibration and shock test
Short circuit test
Failure protection test
Moisture resistance test
Insulation withstand voltage test
Instantaneous overload test
JB6481—92
Type test
5.6 (recommended)
Factory test
Some special requirement test items, such as reliability enhancement test, shall be negotiated by the user and the manufacturer for testing or installation assessment. Marking
7.1 Product marking
The product must be equipped with a fixed, reliable and durable brand name: The product brand name should be installed in a position that is easy to observe. 7.2
Product brand name content
Product name, model;
Rated voltage, rated current;
Standard number;
Factory serial number:
Product weight;
Manufacturer name;
Manufacture year and month.
Product packaging, transportation, storage and warranty period 8.1 The chopper is packaged in single units. The packaging box must comply with the provisions of JB3085 to adapt to various transportation methods and transportation environments to ensure that the product is intact.
8.2 Under the condition that the user complies with the storage and use methods of the product, within one year from the date of shipment from the manufacturer, if the product is damaged or cannot work normally due to poor quality, the manufacturer shall repair or replace parts for the user free of charge. 3—5
Documents to be attached to the product
Product certificate,
Product use and maintenance instructions.
JB6481—92
Additional notes:
This standard is proposed and managed by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by Xiangtan Traction Electrical Equipment Research Institute of the Ministry of Machinery and Electronics Industry. Participating drafting units: Changzhou Switch Factory, Beijing Hoisting and Transportation Machinery Research Institute, Shenyang Automatic Control Research and Design Institute, Shenyang Electrical Special Equipment Research Institute.
The main drafters of this standard are Zhu Xinhe and Zhao Junku.
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