QC/T 1152-2021 English PDF (QCT1152-2021)

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QC/T 1152-2021: Specification of DC/DC converter for electric motorcycles and electric mopeds
QC/T 1152-2021
QC
AUTOMOBILE INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 43.140
CCS T 85
Specification of DC/DC converter for electric motorcycles
and electric mopeds
ISSUED ON: AUGUST 21, 2021
IMPLEMENTED ON: FEBRUARY 01, 2022
Issued by: Ministry of Industry and Information Technology of PRC
Specification of DC/DC converter for electric motorcycles
and electric mopeds
1 Scope
This document specifies the product model compilation, requirements, test methods,
markings of DC/DC converter for electric motorcycles and electric mopeds.
This document applies to DC/DC converters for electric motorcycles and electric
mopeds.
2 Normative references
The contents of the following documents constitute essential provisions of this
document through normative references in the text. Among them, for dated references,
only the version corresponding to the date applies to this document; for undated
references, the latest version (including all amendments) is applicable to this document.
GB/T 2423.1 Environmental testing - Part 2: Test methods - Tests A: Cold
GB/T 2423.2 Environmental testing - Part 2: Test methods - Tests B: Dry heat
GB/T 2423.5 Environmental testing - Part 2: Test methods - Test Ea and guidance:
Shock
GB/T 2423.17 Environmental testing for electric and electronic products - Part 2:
Test method - Test Ka: Salt mist
GB/T 2423.34-2012 Environmental testing - Part 2: Test methods - Test Z/AD:
Composite temperature/humidity cyclic test
GB/T 4208 Degrees of protection provided by enclosure (IP code)
GB 34660 Road vehicles - Requirements and test methods of electromagnetic
compatibility
QC/T 680-2014 General technical specifications for voltage regulators for
motorcycles and mopeds
QC/T 792-2007 Motors and controllers for electric motorcycles and electric mopeds
3.6
Rated power
Under the specified environmental conditions, rated voltage, continuous operation,
the maximum power at which the DC/DC converter can work continuously, after
reaching thermal stabilization under the temperature rise limit.
3.7
Peak power
The maximum power that the DC/DC converter can work continuously, under the
specified environmental conditions and within the specified time.
3.8
Thermal equilibrium
The state under which the temperature rise of the heating part of the DC/DC
converter casing does not change by more than 1 K within 0.5 h.
Note: Thermal equilibrium can be defined by a time-temperature rise diagram, that is, the
connecting line -- between the start and end points of adjacent intervals of 0.5 h has a
gradient of 1 K or less than 1 K every 0.5 h, OR a gradient of 2 K or less than 2 K every 1
h.
3.9
Ripple factor
Ratio -- of half the difference between the peak value and the valley value of the
pulsating DC power TO the absolute value of the DC component.
3.10
Dynamic response time
The time it takes for the system to change from a stable working state to another
stable working state, after being stimulated.
4 Compilation of product model
4.1 General
The model of the DC/DC converter shall be composed of two parts: product name code
and performance parameter code.
The model nomenclature of the DC/DC converter is as shown in Figure 1:
Figure 1 -- Schematic diagram of model nomenclature
4.2 Product name code
DC/DC converter product name code is ZB; if necessary, an extended name code can
be added, after the basic name code; the two are separated by the symbol "-". The
extended name code is:
G - Isolated type.
4.3 Performance parameter code
4.3.1 The performance parameter code includes four parts: rated power code, nominal
input voltage code, rated output voltage code, one-way and two-way code. The voltage
unit indicated in the model name is V; the power unit is W.
4.3.2 The rated power, nominal input voltage, rated output voltage in the performance
parameter code are all integer digits, of which the nominal input voltage and rated
output voltage are 3 integer digits, the rated power is 4 integer digits; 0 is added in front,
if its digit is insufficient.
4.3.3 For DC/DC converters with multiple outputs, all rated output voltage values shall
be marked and separated by "/".
4.3.4 For two-way DC/DC converters, all nominal input voltage values and rated output
voltage values shall be identified and separated by "/".
4.4 Example of product model
Examples of product models are as follows:
Example 1: ZB 0120-072-012 A: Indicates a one-way non-isolated DC-DC converter,
which has a rated power of 120 W, a nominal input voltage of 72 V, a rated output
voltage of 12 V.
Example 2: ZB-G 1000-072-012/005 B: Indicates two-way isolated DC-DC converter,
which has a rated power of 1000 W, a nominal input voltage of 72 V, a rated output
voltage of 12 V/5 V, two-way, isolated.
The two letters A and B represent one-way and two-way respectively
Three Arabic numerals indicate rated output voltage
Three Arabic numerals indicate nominal input voltage
Four Arabic numerals indicate rated power
ZB-G stands for isolated DC/DC converter
5.4 Environmental adaptability
5.4.1 Low temperature
After the DC/DC converter is tested, according to the provisions of 6.5.1, under the
environment of -25 °C ± 1 °C, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.2 High temperature
After the DC/DC converter is tested according to the provisions of 6.5.2, under the
environment of 60 °C ± 1 °C, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.3 Combined temperature/humidity cycle
After the DC/DC converter is subjected to 2 cycles of combined temperature/humidity
cycle test as specified in 6.5.3, the insulation resistance shall meet the requirements of
Table 1; the electrical performance shall meet the requirements of 5.3.2 and 5.3.3,
appearance rust shall not affect normal work.
5.4.4 Salt spray
The DC/DC converter shall be subjected to the salt spray test as specified in 6.5.4. After
the test is completed and allowed to stand, the electrical performance shall meet the
requirements of 5.3.2 and 5.3.3.
5.4.5 Vibration
The DC/DC converter shall be subjected to the vibration test, in accordance with the
provisions of 6.5.5. The parts shall not be loose or damaged during the test. After the
test, the electrical properties shall meet the requirements of 5.3.2 and 5.3.3.
5.4.6 Shock
The DC/DC converter shall be subjected to the shock test, in accordance with the
provisions of 6.5.6. The parts shall not be loose or damaged during the test. After the
test, the electrical performance shall meet the requirements of 5.3.2 and 5.3.3.
5.4.7 Degree of protection
The product's degree of protection of the DC/DC converter shall meet the requirements
of IP55 in GB/T 4208.
5.5 Protection function
5.5.1 Output current limit protection
The DC/DC converter shall have the output current limiting protection function. When
the output load increases to the current limiting state, which is specified in the technical
documents of the enterprise, the converter shall be able to enter the protection state. The
output current shall be limited to the current limiting value range, which is specified in
the technical documents of the enterprise, AND no longer increase.
5.5.2 Input undervoltage pro...