LV216-2 电动汽车高压电缆标准

Design LV 216-2: 2012-05-08 Shielded high-voltage-sheathed cables for motor vehicles and their electric drives Requirements and tests LV 216-2 Tags; Sheathed cables, high voltage cables, electric drives, electric vehicles Continued on Page 2 to31 Application Warning Note Because the intended standard may differ from the draft version, may not in principle be carried out according to standard designs. If, nevertheless, a design applied in exceptional cases, so this must be agreed between the users. Foreword This course was developed in the present version of representatives of the automobile manufacturer AUDI AG, BMW AG, Daimler AG, Porsche AG and Volkswagen AG. This course is stored as a Word file in the Department of Standardization of AUDI AG. This course does not claim to be complete. The car manufacturers are free at any time to require the respective state of the art additional tests. Since the individual automakers make changes if necessary, work should be done according to the liabilities arising from this course work standards of the automobile manufacturers. Deviations to this LV are listed in the factory standards in the cover sheet (in exceptional cases, deviations can be represented in the standard text in italics). If, in individual cases the modification of individual test sections are necessary, they must be agreed separately between the competent departments of the car manufacturer and the supplier. In cross-development projects of automobile manufacturers test reports are accepted, provided that the tests were performed by a 17025 accredited according to DIN EN ISO / IEC, independent institute. The acceptance of test reports does not imply automatic approval. Other reports may be accepted at the discretion of the customer. Open issues are highlighted in green Recent changes are highlighted in yellow. Page 2 Design LV 216-2: 2012-05-08 Contents 1 Scope . 3 2 General . 4 3 Dimensions and Pipe Construction . 4 4 Drawing Entry . 6 5 Materials . 6 5.1 Conductor . 6 5.2 Isolation (Single Core and Cladding) . 6 6 Identification and Delivery specifications . 7 6.1 Coomissioned . 7 6.2 Line Manufacturing Markings . 7 6.3 Color . 7 6.4 Color Coding . 7 6.5 Delivery Specifications . 8 6.5.1 Visual Inspection . 8 6.5.2 Testing for Insulation Failure to the Conductor Insulation and Jacket . 8 6.5.3 Packaging . 8 7 General Test Conditions . 9 7.1 Check Matrix . 9 7.2 Test Conditions . 13 7.3 Practice . 13 7.4 Rounds Of Numerical Values . 13 8 Tests . 13 8.1 Checking Cable Structure . 13 8.1.1 Roundness . 13 8.2 Physical and Chemical Properties of the Jacket . 13 8.2.1 Density . 13 8.2.2 Determination of the Viscosity . 13 8.2.3 Thermogravimetric Analysis (TGA) . 13 8.2.4 Differential Scanning Calorimetry (DSC) . 13 8.2.5 Thermal Stability . 14 8.2.6 Determination of the Infra-Red Spectrum . 14 8.2.7 Determination of Tensile Strength and Elongation at Break. 14 8.2.8 Tear Propagation Resistance . 14 8.2.9 Determination of the Degree of Crosslinking . 14 8.2.10 Microhardness. 14 8.3 Mechanical Properties in the Delivery Condition . 14 8.3.1 Strippability of the Jacket . 14 8.3.2 Abrasion Resistance of the Sheath . 14 8.3.3 Flexural Fatigue Resistance . 14 8.3.4 Sliding The Jacket . 14 8.3.5 Bending Force of the Jacketed Cable . 14 8.3.6 Notch Strength of the Jacket Insulation . 15 8.4 Flame Resistance of the Sheathed Cable . 15 8.5 Electrical Properties of the Components. 15 8.5.1 Volume Resistivity of the Wire Insulation and Jacket Material . 15 8.5.2 30-Minute Withstand Voltage . 15 8.5.3 Measurement of the 1-Minute withstand voltage (only after aging) . 15 8.6 Mechanical and Electrical Properties after Mechanical, Thermal or Chemical Stress . 15 8.6.1 Stress-Test . 15 8.6.2 Shrinkage of the Shell in the Heat . 15 Page 3 Design LV 216-2: 2012-05-08 8.6.3 Pressure Resistance of the Jacket in the Heat . 15 8.6.4 Derating Curve Determination . 15 8.6.5 Thermal Overload . 15 8.6.6 Short-Term Aging (240 h) . 16 8.6.7 Long Term Aging (3 000 h) . 16 8.6.8 Bending Test at Low Temperature (-40 C) . 17 8.6.9 Impact Test at Low Temperature (-15 C) . 17 8.6.10 Wipe Resistance of the Cable (Jacket Marking) . 17 8.6.11 Electrical Characteristics for Water Storage . 17 8.6.12 Damp Heat, Constant . 17 8.6.13 Resistance to Ozone . 17 8.7 Mycological Testing . 17 8.8 Compatibility with other Cable Harness Components . 17 8.8.1 Chemical Resistance according to ISO 6722 . 17 8.8.2 Resistance to Chemicals and Wrapping Tapes . 17 8.8.3 Resistance to Cable Harness Components . 17 9 Test according to LV 213-1 . 18 9.1 High-Frequency characteristics (RF characteristics). 18 9.1.1 Capacitance/Inductance . 18 9.1.2 Mean Impedance . 18 9.1.3 Feedback Resistor . 18 9.1.4 Jacketing Effectiveness . 21 10 Tests Specifically for High-Voltage Cables according to LV 216-2 . 21 10.1 Minimum Allowable Bending Radius for Fixed Installation . 21 10.2 Contact Resistance of the Insulation To+50 C . 22 11 Normative Verweise . 22 A.1 High Voltage Cables Single Core Jacketed- Conductor Copper Type A / B . 23 A.2 High Voltage Cables Single Core Shielded - Conductor Copper Stranded / Flexible Type B . 24 A.3 High Voltage Cables Single Core Shielded-Copper Conductor Stranded / Flexible Type B / Documentation of Existing Lines as of 2010. 25 A.4 High Voltage Cables Single Core Shielded Aluminum Conductor Type B . 26 A.5 High Voltage Conductor Mylticore Shielded - Conductor Type A/B. 27 A.5.1 High-Voltage Cable Multicore Shielded Conductor Copper Type B . 28 A.6 High-Voltage Cables Multicore Shielded Conductor Copper Type A/B . 29 A.6.1 High-Voltage Cables Multicore Shielded Conductor Copper Type B . 30 A.7 High-Voltage Cables Multicore Shielded Conductor Copper Type B / Documentation Existing Lines as of 2010 . 31 Back Issues No Changes: 1 Scope This course describes requirements and tests for sheathed cables of single-core and multicore shielded automotive cables for a rated voltage range 60 V to 600 V DC or AC in the definition according to ISO 6722nd Page 4 Design LV 216-2: 2012-05-08 The test points for the respective requirements of the matrix 7.1 to remove. 2 General This course is only valid for new designs. Are already in serial cables must not be changed. Future changes to material, dimensions, manufacturing processes, etc. are communicated to the respective design agencies that can request a new release. The extent of this course and in the individual case specific test conditions must be established with the relevant development agencies and approved by them. Preferably single cores are to be used, according to the LV 112-1 or LV 112-2 are released. If the individual wires are not approved by LV 112-1 or 112-2, the tests of LV 212-1 Table 1 (in- spection scope A1/A2) must be performed on the individual wires. It can be made of existing insulation material of the test results. 3 Dimensions and Pipe Construction Dimensions and management structure (see Figure 1 and 2) are given in the corresponding sections in the notes . Unspecified details shall be coordinated with the development agencies. Page 5 Design LV 216-2: 2012-05-08 Image 1 Cable construction HV-line 1-core screened according to Tables A.1, A.2, A.3, A.4 Cable design HV cable multi core shielded according to Table A.5 Bild 3 Cable construction HV-cable multi core shielded as shown in Table A.6 Page 6 Design LV 216-2: 2012-05-08 4 Drawing Entry The line designation is according to DIN 76722nd In addition, the color name of the outer sheath according to DIN 72551-7. Example: Designation of a shielded high-voltage low-voltage line (F H L) with thin wall insulation (R), a con- ductor nominal cross section of 16 mm (16), head construction with bare strands max. Diameter 0.21 mm (/ 0.21), (2G) Designation of the insulating material (silicone rubber), (C) braided shield, (B) the shield film (2G) Abbreviation of the jacket (silicone rubber), (OR) color name based on DIN 72551-7 in German or English, continuous use temperature (T O) 180 C: Line - F H LR2GCB2G 16/0 ,21-B OR/T180 (Align with current design stand DIN 76722 / state of discussion 02/28/20 12) 5 Materials 5.1 Conductor SeeLV 112-1 and LV 112-2 5.2 Isolation (Single Core and Cladding) The minimum and maximum continuous use temperature (T U T and O) for a stress period of 3000 h, corresponding to the temperature classes according to Table 1 to select or, in exceptional cases, after drawing. The temperature class of the sheath is determined by the insulation material with the lower temperature class. The operating temperature defines the use of the lines without a ladder warming by the current loads, ie in the non-energized state. Conductor temperature rise can be calculated according to the specifications of the LV 112-3. Table 1 Temperature Classes Class after ISO 6722 Temperature class Continuous operating temperature (3000 h) T U T C to O C Short-term temperature (240 h) (T O + 25) C Temperature for thermal Overload (6 h) (T O + 50) C A T85 -40 to 85 110 2 135 3 B T100 -40 to 100 125 3 150 3 B (105) T105 -40 to 105 130 3 155 3 C T125 -40 to 125 150 3 175 3 D T150 -40 to 150 175 3 200 3 E T175 -40 to 175 200 3 225 3 E(180) T180 -40 to 180 205 3 230 4 F T200 -40 to 200 225 4 250 4 G T225 -40 to 225 250 4 275 4 H T250 -40 to 250 275 4 300 4 Page 7 Design LV 216-2: 2012-05-08 Class after ISO 6722 Temperature class Continuous operating temperature (3000 h) T U T C to O C Short-term temperature (240 h) (T O + 25) C Temperature for thermal Overload (6 h) (T O + 50) C Txyz -40 to xyz xyz + 25 xyz + 50 In special cases Txyz enables the classification of intermediate temperatures as temperature class T135. 6 Identification and Delivery specifications 6.1 Coomissioned The labeling of containers must be 6 Part 1 to VDA Volume and shall be agreed between purchaser and supplier compliant. 6.2 Line Manufacturing Markings On a wire or on the mantle a manufacturer identification must be made, for example by printing or embossing. Alternatively, a tracer can be used. Cables with a conductor cross-section 2.5 mm must also be marked in color on the jacket as follows: Flash (as an icon) - ATTENTION HIGH VOLTAGE MAX 600/900 V AC / DC ISO 6722 - flash (as an icon) It is to choose a legible color in an adequate font size. The distance between the non-printed texts must not exceed 200 mm. NOTE The printing / marking may take the garment maker. 6.3 Color The outer jacket color Orange similar to RAL 2003 should be used. The color of the aged (6h, 240h and 3000h) and unaged line are on a picture to document (see also 8.6.5 , 8.6.6 and 8.6.7 ). 6.4 Color Coding The Au enmantelg about color orange similar (RAL 2003 with a tolerance of RAL RAL 2003 to 2008) should be used. To distinguish multiple HV cables in the electrical system are colored longitudinal stripes allowed. This indelible integrated with in isolation. Preferred colors for the longitudinal strips are as follows: Table: Preferred Color for the Longitudinal Strips Color Red Brown Blue Green Violet Application DC + DC - AC L1 AC L2 AC L3 Example Traction line 3-phase line Page 8 Design LV 216-2: 2012-05-08 For 1-core sheathed cables, the color of the wire insulation may be natural color. In multi-core sheathed cables of the intermediate casing must be natural color. In multi-core sheathed cables the colors of the wire insulation should be favored as follows: green / yellow (red) brownblueblackgray 5-wireXXXXX 4-wireXXXX/ 3-wireXXX/ 2-wireXX/ Other color codes are allowed by arrangement. 6.5 Delivery Specifications Failure to observe these delivery requirements, the goods will be returned at the expense of the supplier. 6.5.1 Visual Inspection The