QC/T 792-2022 English PDF (QCT792-2022)

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QC/T 792-2022: Motors and controllers for electric motorcycles and electric mopeds
QC/T 792-2022
QC
AUTOMOBILE INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 43.140
CCS T 85
Replacing QC/T 792-2007
Motors and controllers for electric motorcycles and electric mopeds
ISSUED ON: APRIL 08, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: Ministry of Industry and Information Technology of PRC
Table of Contents
Foreword ... 6
1 Scope ... 9
2 Normative references ... 9
3 Terms and definitions ... 10
4 Product model compilation ... 12
5 Requirements ... 14
6 Test method ... 23
7 Inspection rules ... 34
Motors and controllers for electric motorcycles and electric mopeds
1 Scope
This document specifies the product model compilation, requirements, test methods,
inspection rules for motors (including motors including reducers) and controllers for
electric motorcycles and electric mopeds.
This document applies to the motors for electric motorcycles and electric mopeds
(hereinafter referred to as motors) and controllers.
2 Normative references
The contents of the following documents constitute the essential provisions of this
document through normative references in the text. Among them, for dated reference
documents, only the version corresponding to the H issue is applicable to this document;
for undated reference documents, the latest version (including all amendments) is
applicable to this document.
GB/T 755 Rotating electrical machines - Rating and performance
GB/T 1184-1996 Geometrical tolerancing - Geometrical tolerance for features
without individual tolerance indications
GB/T 2423.5-2019 Environmental testing - Part 2: Test methods - Test Ea and
guidance: Shock (IEC 60068-2-27:2008; IDT)
GB/T 2423.17-2008 Environmental testing for electric and electronic products - Part
2: Test method - Test Ka: Salt mist (IEC 60068-2-11:1981, IDT)
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code)
GB/T 4942-2021 Degrees of protection provided by the integral design of rotating
electrical machines (IP code) - Classification
GB/T 5171.21-2016 Small power motors - Part 21: General test methods
GB/T 10069.1-2006 Measurement of airborne noise emitted by rotating electrical
machines and the noise limits - Part 1: Method for the measurement of airborne
noise emitted by rotating electrical machines (ISO 1680:1999, MOD)
GB/T 10069.3-2008 Measurement of airborne noise emitted by rotating electrical
machines and the noise limits - Part 3: Noise limits
GB/T 13202-2015 Series of motorcycle rims (ISO 4249-3:2010, ISO 5995-2:1988,
ISO 6054-2:1990, MOD)
GB/T 18387 Limits and test method of magnetic and electric field strength from
electric vehicles
GB/T 18488.1-2015 Drive motor system for electric vehicles - Part 1: Specification
GB/T 18488.2-2015 Drive motor system for electric vehicles - Part 2: Test methods
GB 34660 Road vehicles - Requirements and test methods of electromagnetic
compatibility
ISO 11898.1 Road vehicle - Controller Area Network (CAN) - Part 1: Data link layer
and physical signaling
ISO 11898.2 Road vehicle - Controller Area Network (CAN) - Part 2: High-speed
medium access unit
ISO 14229.2 Road vehicles - Unified Diagnostic Services (UDS) - Part2 : Session
layer services
ISO 15765.2 Road vehicles - Diagnostics on Controller Area Networks (CAN) - Part
2: Network layer services
ISO 16845.1 Road vehicles - Controller Area Network (CAN) conformance test plan
- Part 1: Data link layer and physical signaling
3 Terms and definitions
The following terms and definitions apply to this document.
3.1
Wheel with the outer shell of motor integrated
The motorcycle driving wheel, whose wheel hub and motor casing are made into an
integral part.
3.2
Continuous torque
The specified maximum torque that can work continuously for 30 minutes.
ZK - Brushed DC motor controller;
ZWK- Brushless DC motor controller;
YCK - Permanent magnet synchronous motor controller;
JYK - AC asynchronous motor controller;
KCK - Switched reluctance motor controller.
4.2.2 Voltage level
The controller adopts DC voltage input. The voltage level is indicated by the nominal
voltage value of the DC bus of the controller. If it is less than three digits, add a 0 in
front.
4.2.3 Current level code
The current level of the controller is indicated by the integer value (three Arabic
numerals) of the maximum DC input current of the controller. If there are less than three
digits, add a 0 in front.
4.2.4 Derivative code
The derivative codes are A, B...
Note: The letters I, N, O, Y are not used.
5 Requirements
5.1 General requirements
The motor shall be idling flexibly, without fixed-rotor friction or abnormal noises (such
as periodic abnormal noises, abnormal noises caused by damaged bearings, or abnormal
noises caused by foreign objects stuck in the rotating parts, etc.). The controller shall
have safety management functions, such as communication, fault diagnosis, calibration
and program refresh, which meet the whole vehicle requirements.
5.2 Environmental conditions for use
The motor and controller shall be able to work normally under the following conditions:
- Ambient temperature: -25 °C ~ 60 °C;
- Relative humidity: 0% ~ 100%.
5.3 Rated voltage
The rated voltage shall be the nominal voltage of the DC bus of the controller.
5.4 Appearance
The surface of the motor and controller shall be free of rust, bruises, cracks, peeling of
the coating. The fasteners shall be firmly connected. The lead wires shall be intact. The
contents of nameplate of the motor and controller shall be correct; the words shall be
clear; the background color shall not fade.
5.5 External dimensions and installation dimensions
The external dimensions and installation dimensions of the motor and controller shall
comply with the provisions of the technical documents of the enterprise.
5.6 Assembly requirements
5.6.1 Motor's axial clearance
The axial clearance of the power output end of the direct drive motor, non-direct drive
independent motor, motor and reducer integrated machine shall not be greater than 0.3
mm.
5.6.2 Radial circular runout
The radial circular runout of the output shaft of the inner rotor motors, such as direct
drive motors and non-direct drive independent motors, shall meet the tolerance
requirements of level 6 in GB/T 1184-1996. For the motor and reducer integrated
machine, the radial circular runout of the output shaft of the reducer shall meet the
tolerance requirements of level 6 in GB/T 1184-1996 standard.
5.6.3 End face runout
The end face runout of the outer edge of the integrated wheel-mounted motor wheel
shall not exceed 1 mm.
5.7 Sealing performance of cooling circuit in liquid cooling system
For liquid-cooled motors and controllers, there shall be no leakage, when subjected to
a pressure not lower than 200 kPa.
5.8 Lead wires and connectors
5.8.1 Color of lead wire
Among the three-phase main winding wires of brushless DC motors, permanent magnet
synchronous motors, switched reluctance motors, the U phase wires shall have obvious
blue marks; the V phase wires shall have obvious green marks; the W phase wires shall
have obvious yellow marks.
5.14 Direction of rotation of the motor rotor
The direction of rotation of the motor rotor shall comply with the provisions of the
product technical documentation.
5.15 No-load current
The motor runs at the rated voltage and at the speed specified in th...