Power in electrical safety Electrical safety for hybrid and electric vehicles
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1 Power in electrical safety Electrical safety for hybrid and electric vehicles Bender Germany Draft H. Sellner 4 March 2009 No. 1
2 Overview 1. General 2. Drive concepts 3. Standards 4. Bender solutions Bender Germany Draft H. Sellner 4 March 2009 No. 2
3 The reliable and safe supply of power Electrical safety in vehicles and mobile units Vehicles Mobile units Land Water Water Land Air next pages Road Rail Electrical installations on ships Mobile and fixed offshore units Elec. systems in vehicles or transportable units Mobile generators Rail applications DIN EN (VDE ) rolling stock IEC DNV, GL..., LR..., DIN VDE yachts IEC DNV, GL..., LR..., DIN VDE IEC DIN VDE IEC Railway signalling systems DIN VDE 0831 (VDE 0831) DIN VDE yachts, boats, caravans, moorings Bender Germany Draft H. Sellner 4 March 2009 No. 3
4 Electrical vehicles with varying drive concepts, requirements and applications Electric motor drive Comb. engine / elec. motor drive (hybrid) Comb. engine drive / elec. loads Electricital grid / solar Fuel Elec. equip. Fuel Generator Elec. grid Charger 3 AC Battery Comb. engine Energy storage Vehicle elec. sys. Generator Inverter Generator Transf ormer Elec. motor Comb. engine Elec. motor Vehicle elec. system Electrical loads Bender Germany Draft H. Sellner 4 March 2009 No. 4
5 Hybrid principle Bender Germany Draft H. Sellner 4 March 2009 No. 5
6 Hybrid unit Toyota Prius Bender Germany Draft H. Sellner 4 March 2009 No. 6
7 Hybrid variants Architectural approaches Micro hybrid Mild hybrid Medium hybrid Full hybrid Functionality Boosting passive active yes yes Recuperation limited / overload yes yes yes Electric driving no no limited yes Start / stop yes yes yes yes Vehicle elec. sys. Voltage level(s) 12 V V V V Elec. machines Power rating 5 kw 10 kw 15 kw 15 kw Bender Germany Draft H. Sellner 4 March 2009 No. 7
8 Overview 1. General 2. Drive concepts 3. Standards 4. Bender solutions Bender Germany Draft H. Sellner 4 March 2009 No. 8
9 Electric vehicle with traction battery High voltage link circuit Propulsion motor Gearbox Charger Battery Vehicle elec. sys. Air cond. compressor (high voltage) Bender Germany Draft H. Sellner 4 March 2009 No. 9
10 Electrical system (example for electric forklift truck) Hydraulics for truck functions Propulsion drive Battery 24 /48 80 V Vehicle chassis Ground Bender Germany Draft H. Sellner 4 March 2009 No. 10
11 Hybrid vehicle High voltage link circuit Clutch Gearbox Electrical energy store vehicle elec. sys. High power loads (e.g. air cond.) Loads connected externally Bender Germany Draft H. Sellner 4 March 2009 No. 11
12 Electrical system (serial diesel-electric vehicle) Combustion engine Hydraulics for truck functions Propulsion motor Control unit Battery Vehicle chassis Earth Bender Germany Draft H. Sellner 4 March 2009 No. 12
13 Vehicle with fuel cells High voltage link circuit Gearbox Buffer battery Air conditioning (high voltage) Fuel cell Vehicle elec. sys. Bender Germany Draft H. Sellner 4 March 2009 No. 13
14 Faults and protective measures Insulation fault Short-circuit Fault Reason Effect Direct contact with high voltage (vehicle not in operation) Thermal or mechanical damage to the insulation, accident Mechanical fault, accident Mechanical fault, maintenance, repair, incorrect operation Electric shock, battery discharge Failure of control units Electric shock Passive protective measures Double insulation, insulation monitoring Emergency stopping, compliance with EMC regulations, watchdog for monitoring control unit Active protective measures Disconnection of power sources Disconnection of power sources Discharge capacitors, disconnection of power sources Contact with high voltage (vehicle in operation) Mechanical fault Insulation monitoring Alarm, disconnection of power sources Overvoltage Electrostatic charging, transients during switching, electromagnetic effect Damage to components Overvoltage protection Connection of the vehicle to earth during refuelling and battery charging Bender Germany Draft H. Sellner 4 March 2009 No. 14
15 Overview 1. General 2. Drive concepts 3. Standards 4. Bender solutions Bender Germany Draft H. Sellner 4 March 2009 No. 15
16 High voltage safety in vehicles EUROPE ECE R 100 USA / CANADA FMVSS 305 CMVSS 305 JAPAN Attachment 101 Attachment 110 Attachment 111 International standards ISO 6469 part ISO Bender Germany Draft H. Sellner 4 March 2009 No. 16
17 Overview of standards Germany DIN VDE 0122: Elektrische Ausrüstung von Straßenfahrzeugen (Electric equipment of electrical road vehicles) DIN EN (VDE 0122 T1): Konduktive Ladesysteme für Elektrofahrzeuge - Teil 1: Allgemeine Anforderungen DIN EN (VDE 0122 T 2-1): Konduktive Ladesysteme für Elektrofahrzeuge AC/DC-Versorgung DIN EN (VDE 0122 Teil 2-2): Konduktive Ladesysteme für Elektrofahrzeuge AC-Ladestation DIN EN (VDE 0117 T1): Sicherheit von Flurförderfahrzeugen Elektrische Anforderungen DIN EN : Elektrisch angetriebene Straßenfahrzeuge - Besondere Festlegungen für die Sicherheit Teil 3: Schutz der Benutzer gegen elektrische Gefahren Bender Germany Draft H. Sellner 4 March 2009 No. 17 International - IEC : Electric vehicle conductive charging system Part 1: General requirements IEC : Electric vehicle conductive charging system Part 21: EV requirements for conductive connection to an ac/dc supply IEC : Electric vehicle conductive charging system Part 22: AC electric vehicle charging station EN : Safety of industrial trucks Electrical requirements Part 1: General requirements for batt. powered trucks EN :1998 Electrically propelled road vehicles Specific requirements for safety Part 3: Protection of users against electrical hazards UL : Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: General requirements UL Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits: Particular Requirements for Protection Devices for Use in Charging systems
18 Overview of standards Germany International SAE J1766: Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Integrity Testing SAE J2578: Recommended Practice for General Fuel Cell Vehicle Safety SAE J 2344 Guideline for Electrical Vehicle Safety SAE J 1772 Electric vehicle Conductive Charger ISO : Fuel cell road vehicles Safety specifications Part 3: Protection of persons against electric shock ISO Electric road vehicles Safety specifications Part 3: Protection of persons against electric hazards TP : U.S. Department of Transportation FMVSS305: Electric powered vehicles: Electrolyte Spillage and Electrical shock protection Regulation No. 100 Agreement concerning the adoption of uniform conditions technical prescriptions for wheeled vehicles Bender Germany Draft H. Sellner 4 March 2009 No. 18
19 Overview 1. General 2. Drive concepts 3. Standards 4. Bender solutions Bender Germany Draft H. Sellner 4 March 2009 No. 19
20 A-ISOMETER iso-f1 for electric/hybrid vehicles Bender Germany Draft H. Sellner 4 March 2009 No. 20
21 Example of possible insulation faults in electric/hybrid vehicles Bender Germany Draft H. Sellner 4 March 2009 No. 21
22 Vielen Dank Thank you Merci beaucoup Bender Incorporated Tel.: (800) ; (610) Fax: (610) info@bender.org Sources for image material: Bender archives, The images and illustration provided in this document are copyright protected. Reproduction, translation, microfilming and storage in electronic systems, in particular for commercial purposes, are prohibited without the publisher s consent. We Provide no warranty or guarantee for erroneous or omitted entries. All data is based on manufacturer s information. A-ISOMETER is a registered trademark of Dipl.-Ing. W. Bender GmbH & Co. KG. Bender Germany Draft H. Sellner 4 March 2009 No. 22
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