1、Page 1 LV215-1: Revision Date 02-2009 Electrical/Electronic Requirements of HV Connectors Edition 1 Feb. 2009 This SR 215-1 was created by WG 4.3.3 of the German car manufacturers. Page 2 LV215-1: Revision Date 02-2009 Content Page 1 Introduction 5 1.1 Scope of application . 5 1.2 References. 5 1.3
2、Glossary, Definitions, and Abbreviations. 7 1.4 Legal stipulations 9 2 Requirements Development Framework 10 2.1 Quality 10 2.1.1 General. 10 2.1.2 Delivery quality . 10 2.1.3 Reliability 10 2.1.3.1 Full functional fulfilment . 10 2.1.3.2 Warranty and goodwill . 10 2.1.4 Maintenance intervals. 10 2.
3、2 Operating and environmental conditions. 10 2.3 Environmental compatibility and emissions. 11 2.3.1 Environmental compatibility 11 2.4 Operating reliability and product safety. 11 2.4.1 Operational reliability 11 2.4.2 Product safety. 11 2.5 Requirements Protection against electrical hazards. 11 2.
4、5.1 Additional measures for deenergising the HV electric circuit 11 2.5.2 IP degree of protection 11 2.5.3 Protection against direct contact of active components 11 2.5.3.1 General . 11 2.5.4 Protection against direct contact. 12 2.5.4.1 General. 12 2.5.5 Contacting system 12 2.5.6 HV interlock (HVI
5、L). 12 2.5.6.1 General. 12 2.5.6.2 Design 12 2.6 Component identification of HV connectors 12 2.6.1 Functional models and prototypes 13 2.6.2 Production parts . 13 2.7 Design of electrical system/electronics . 13 2.7.1 Electromagnetic compatibility . 13 2.8 Documentation 13 2.9 Corrosion resistance.
6、 13 3 Requirement Integration Framework. 14 3.1 Geometric requirements 14 3.2 Thermal requirements. 14 3.3 Mechanical requirements 14 3.3.1 Electrical requirements . 14 3.3.1.1 Current-carrying capacity 14 3.3.1.2 Electric, insulating strength . 15 3.3.1.3 Shield connexion 15 4 Requirements Function
7、ality 16 4.1 Overall functionality 16 4.2 Functional features . 6 Page 3 LV215-1: Revision Date 02-2009 4.2.1 Contact cover . 16 4.2.1.1 Pin-socket contact . 16 4.2.1.2 Front contact 16 4.2.2 Contact arrangement 16 4.2.2.1 Insertion forces. 16 4.2.3 Contact locking device . 16 4.2.4 Contact lock 16
8、4.2.4.1 Lock in the contact cavity 16 4.2.4.2 Disassembly of contact component 16 4.2.4.3 Holding forces 16 4.2.4.4 Holding force of primary locking device. 17 4.2.4.5 Holding force of secondary locking device . 17 4.2.5 Function of secondary locking elements . 17 4.2.5.1 Active secondary locking sy
9、stem 17 4.2.6 Polarisation/keying . 17 4.2.6.1 Keying . 17 4.2.6.2 Polarisation 18 4.2.7 Housing pre-guide . 18 4.2.7.1 Housing guide. 18 4.2.7.2 Angled housing connection. 18 4.2.7.3 Push-on safeguarding. 18 4.2.8 Housing lock/locking device 18 4.2.8.1 Locking. 18 4.2.9 CPA 18 4.2.10 Crimps 18 4.2.
10、11 Crimping pull-out forces 19 4.3 Assembly forces . 19 4.3.1 Insertion force . 19 4.3.2 Separation force . 19 4.4 IP protection classes (tightness/contact protection) 19 4.4.1 Contact protection . 19 4.4.1.1 Uninserted state 19 4.4.1.2 Inserted state . 19 4.4.1.3 HVIL system 19 4.4.1.4 HVIL system,
11、 mechanism . 19 4.4.2 Tightness 20 4.4.2.1 Inserted state. 20 4.4.2.2 Design of sealing elements and sealing surfaces 20 4.4.2.3 Seal at conductor side 21 4.4.3 Operational reliability 21 4.5 Customizability . 21 4.6 EMC requirement . 21 4.6.1 Shielding . 21 4.6.1.1 In the HV connector. 21 4.6.1.2 F
12、rom HV cable set to HV connector. 21 4.6.2 Shroud 22 4.6.2.1 Geometric design . 22 4.6.3 Shield connexion 22 4.6.3.1 Shield connexion between receptacle housing and cable . 22 4.6.3.2 Shield connexion between receptacle housing and unit connection . 22 4.7 Electrical requirements . 22 Page 4 LV215-1
13、: Revision Date 02-2009 4.7.1 Electric strength 22 4.7.2 Insulating strength . 22 4.8 Housing identification and labelling. 23 4.8.1 Housing chamber . 23 4.8.2 Component identification 23 4.9 Housing colour 23 4.10 Material selection 23 5 Test and protection. 24 5.1 Test and inspection requirements
14、on the component 24 5.2 Inspections and execution 24 5.2.1 Measurement of insulating resistance of component 24 5.2.2 Identification of HV components . 25 5.2.3 Protection against direct contact of active components 25 5.2.4 Electric strength 26 5.2.5 HV interlock 27 5.2.6 Shield transfer . 27 5.2.7
15、 Air gaps and creepage distances 27 Preface This standard was put together in its present version by representatives from the car manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG and Volkswagen AG. This standard is deposited as a Word file in the Standardization department of Audi AG. This stan
16、dard does not claim to be complete. Car manufacturers are always free to require additional inspections according to the respective state of the art. Since the individual car manufacturers can make changes, if necessary, inspections may not be performed using this standard. Instead, the supplier mus
17、t ensure that the currently valid internal standard of the car manufacturer is at his disposal. Deviations from the present standard are represented in italics in the internal standards. If modifications of individual inspection points should become necessary in individual cases, they must be coordi
18、nated separately between the responsible technical department and the corresponding manufacturer. The inspection reports of the cable manufacturers are recognized provided that the inspections have been performed by an independent institute accredited in accordance with DIN EN ISO/IEC 17025. Accepta
19、nce of the inspection reports does not give rise to an automatic release. Page 5 LV215-1: Revision Date 02-2009 1 Introduction 1.1 Scope of application The present supply regulation (SR 215-1) describes the technical and functional requirements on HV systems (electrical connector systems) that are u
20、sed in HV electrical systems. This SR applies solely to new designs and is applied only for the initial registration by the OEM. Reference can be made to the established data for further application approvals (PPAP, ISTR, etc.). HV systems that are already in production series are not changed. 1.2 R
21、eferences Table 1 lists the documents referenced in these performance specifications. In principal, the relevant valid version of these documents must be used if the validity has not been explicitly restricted by specifying a date of publication. Table 1: References ID Document number Title, Author
22、1 IEC 60 664-1 International Electrotechnical Commission Part 1: Principles, requirements and tests 2 VDA series of papers; Quality management in the automotive industry, volume 3 part 2, Reliability provision for car manufacturers and suppliers; reliability methods and auxiliaries; Verband der Auto
23、mobilindustrie e.V. (VDA) 3 ISO 6469-3 Electric road vehicles Safety specifications Part 3: Protection of persons against electric hazards 4 2000/53/EG; Directive of the European Parliament and Council for the disposal of motorcars, incl. appendices; European Union 5 ISO 20653 Road vehicles - Degree
24、s of protection 6 LV 214-1 WG inspection guideline for automotive connectors, edition 2009 7 DIN 40050-9 Road vehicles; degrees of protection (IP code); protection against foreign objects, water and contact; electrical equipment 8 SAE J1742 SURFACE VEHICLE RECOMMENDED PRACTICE Connections for High V
25、oltage On-Board Road Vehicle Electrical Wiring Harnesses Test Methods and General Performance Requirements 9 SAE J 2223 SURFACE VEHICLE RECOMMENDED PRACTICE Connections for On-Board Road Vehicle Electrical Wiring Harnesses Part 2: Tests and General Performance Requirements 10 IEC 60529 Degrees of pr
26、otection through housing 11 ECE R 100 United Nations Regulation, Uniform Provisions Concerning the Approval of: Battery Electric Vehicles with Regard to Specific Requirements for the Construction, Functional Safety and Hydrogen Emission 12 VG88720 Terminal ends for crimp connections, technical suppl
27、y requirements 13 VG9514-11 Inspection of components Part 11: Measuring principle for coupling resistance and shield attenuation, coupling resistance of shielded components (parallel wire principle, KS 11B) Page 6 Page 6 LV215-1: Revision Date 02-2009 1.3 Glossary, Definitions, and Abbreviations Abb
28、reviations: Abbreviation Explanation HV High voltage PS Performance specifications SR Supply regulation PPAP Production Part Approval Process ISTR Initial sample test report DC Direct current AC Alternating current EMC Electromagnetic compatibility HVIL High voltage interlock AT-PZEV Advanced Techno
29、logy Partial Zero Emission Vehicle PTR Prototype release DR Design regulation LV Low voltage Vmax Max. voltage Vrated Operating voltage CPA Connector Position Assurance Overview of internal standards Standard Audi/VW BMW Daimler Porsche LV214-1 VW75174-1 GS 95006-7 MBM 10384 PTL 12100-1 LV214-2 VW75
30、174-2 GS 95006-7-2 PTL 12100-2 Definition of HV system: All of the HV electrical circuits, including cabling (cables, connectors) and components (consumers, generator, storage) form the HV system. Regardless of their function, all components connected directly or indirectly to the HV electrical circ
31、uit are referred to as HV components. The HV systems (connector systems) ensure the transfer of energy for components 60 V. Definition of active components: All conductors or conductive components to which a voltage is applied in normal usage. Page 7 LV215-1: Revision Date 02-2009 Definition of oper
32、ating voltage: The greatest root-mean-square value of the voltage of an electrical circuit specified by the manufacturer that can be measured with any insulation, non-closed electrical circuit or under normal operating conditions. Definition of direct contact: The contact of persons and animals (pet
33、s and livestock) with active components. Definition of crimp: The connection between contact element and line is generally made by means of crimping. For alternate joining techniques, such as welding or even soldering, the inspection conditions and requirements apply logically. If required, deviatio
34、ns must be coordinated with the purchaser. For reasons of clarity and simplification, this connection is referred to as crimp in the present document. Definition of electrical mass: A set of conductive components that are connected electrically (metallically) and all other conductive components that
35、 are electrically (metallically) connected with them and using its potential as reference value. The HV circuit does not use this potential as reference value, except for the shielding and potential equalisation. Definition of exposed conductive component (also unprotected conducting component): Eve
36、ry conductive component that can easily be touched and is generally not energized, but can be energised in case of a fault. Definition of HV electrical system: Infrastructure for the electrical energy supply of the HV system, but without components for consumption, storage and generation of electric
37、al energy and without controls. Definition of indirect contact: People or animals (pets or livestock) touching exposed conductive components. Definition of creepage distance: According to 1, the shortest distance along the surface of an insulating material between two conducting components. Definiti
38、on of conducting component: A conducting component is a component that is capable of conducting a current, even though it is not necessarily energised under normal operating conditions. Definition of air gap: Shortest spatial distance between two conducting components. Definition of energised compon
39、ent: An energised component is any conductor or component that is energised during normal operation. Definition of unprotected conducting component: An unprotected conducting component is a component that can easily be touched and is not energised in regular use, but can be energized under fault con
40、ditions (insulation fault). This term is referenced to a specific electrical circuit, e.g. a vehicle body can be an energised part of the auxiliary circuit, but an unprotected conducting part of the drive electrical system. Page 8 LV215-1: Revision Date 02-2009 Voltage class B The HV system must be
41、assigned to voltage class B according to the specified voltage ranges (cp. 3): 60 V_DC V 1500 V_DC The following voltage range is defined for alternating voltages of voltage class B: 15 Hz 150 Hz 25 V_AC V_rms 1000 V_AC The information about alternating voltage is relevant to the electrical circuits
42、 of the HV system in which AC or DC components, e.g. the electrical drive, are used. 1.4 Legal stipulations Safety regulations, country regulations and similar provisions are imposed on the references. They must be adhered to for the product development and the creation of the release drawings. If l
43、egal requirements take effect during or after the product development, they must be implemented immediately. If the contractor should know or learn in the course of the development work that stipulations of these performance specifications should lead to non-compliance of one or several of these reg
44、ulations, the purchaser must be informed about it immediately and in writing. Page 10 LV215-1: Revision Date: 02-2009 2 Requirements Development Framework 2.1 Quality 2.1.1 General The attempted quality goal is zero faults. To ensure the attempted quality goal, the supplier must create a design and
45、a process failure mode and effects analysis (FMEA) on his own responsibility and present upon demand. 2.1.2 Delivery quality The delivery quality is defined as zero faults. The limit values of the delivery quality must be defined with the respective quality offices of the individual OEMs. 2.1.3 Reli
46、ability 2.1.3.1 Full functional fulfilment The object of the development must be designed so that the full operational capability is ensured for at least 15 years or 240,000 km under consideration of the listed operating conditions. The reliability requirements must be verifiably satisfied. For this
47、 purpose, fatigue strength tests must be performed prior to the start of series production and the results (failures over mileage) statistically analysed, e.g. via Weibull analysis according to 2, VDA series of papers volume 3 part 2, “Reliability provision for car manufacturers and suppliers.” The
48、tests must be designed so that they allow conclusions about the failure behaviour in the field. A representative number of tests must be used for this purpose. When selecting the test specimens, ensure that they represent the expected production dispersion. 2.1.3.2 Warranty and goodwill The maximum
49、granted warranty period must be specified by the supplier. The resulting complaint rate from warranty and goodwill cases within this warranty period must be defined with the corresponding quality figures. This definition is carried out separately via the responsible quality offices of the individual OEMs. 2.1.4 Maintenance intervals The system must be designed so that its operational capability is ensured across the entire vehicle life cycle without maintenance. 2.2 Operating and environmental conditions The operational reliability must
