1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2008 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgJ2289 JUL2008 SURFACEVEHICLEINFORMATIONREPORTIssued 2000-11Revised 2008-07 Superseding J2289 NOV2000 Electric-Drive Battery Pack System: Functional Guidelines RATIONALEThis document provides guidance in designing batte
5、ry systems for electric vehicles and hybrid electric vehicles. The document is basically an extensive checklist of design considerations for battery packs: mounting, operation, environment, durability, safety, etc. These design considerations have not changed appreciably since the standard was issue
6、d in 2000.This document should be revised only for corrections of minor typographical errors. FOREWORDThe mission of this document is to provide guidance in designing vehicle level battery systems for Electric Vehicles and Hybrid Electric Vehicles using electrically rechargeable battery modules. Ite
7、ms addressed include battery system content, component and system safety and reliability, improving system performance of the battery, and optimizing battery life.The term battery used throughout this document implies the complete energy storage system and its auxiliaries, which are used to deliver
8、power and energy to an electric vehicle traction system.Design of aqueous electrolyte battery modules and cells as to electrochemical performance and design are defined in SAE J1797, and referenced here. An electric drive battery system as described here may be designed to meet the safety and crash
9、requirements of SAE J1766 and SAE J2344. The requirements outlined in this document are intended to guide the vehicle manufacturers in understanding the environmental conditions that a well designed battery pack should be able to withstand. It is at the manufacturers discretion as to what tests and
10、test limits to implement. 1. SCOPE This SAE Information Report describes common practices for design of battery systems for vehicles that utilize a rechargeable battery to provide or recover all or some traction energy for an electric drive system. It includes product description, physical requireme
11、nts, electrical requirements, environmental requirements, safety requirements, storage and shipment characteristics, and labeling requirements. It also covers termination, retention, venting system, thermal management, and other features. This document does describe guidelines in proper packaging of
12、 the battery to meet the crash performance criteria detailed in SAE J1766. Also described are the normal and abnormal conditions that may be encountered in operation of a battery pack system 1.1 Purpose This document provides the guidelines for designing a battery system to package into manufacturer
13、s electric drive vehicles. It lays the foundation for electric vehicle battery systems and provides information to assist in developing a robust battery system. SAE J2289 Revised JUL2008 - 2 -1.2 Field of Application This document applies to vehicles using electrically rechargeable storage traction
14、batteries that provide energy and power to an electric drive system for propulsion, namely Electric Vehicles and some Hybrid Electric Vehicles. This document does not fully address all guidelines for mechanically rechargeable battery systems. Users of mechanically recharged batteries should evaluate
15、 applicability of individual sections of this document. 1.3 Product Classification The battery system is a vehicle subsystem that provides all or some of the traction power and energy for vehicles using electric drive systems. This document does not apply to low voltage non-traction battery supply s
16、ystems. 1.4 Product Description A battery system is the complete set of assemblies required to supply traction power and energy to an electric vehicle drive system. A battery pack is a single assembly with batteries that is part of a Battery System. In some cases a single pack may comprise the compl
17、ete Battery System. Electric Drive vehicles may require an electrically rechargeable secondary battery to provide motive traction power and energy as well as power and energy for incidental loads like power steering, heating and air conditioning, FMVSS mandated exterior lighting, controls, customer
18、convenience features, etc. The battery can also represent a significant physical load to the vehicle in terms of mass, volume, and controls complexity. Consequently, the battery exerts a significant factor in vehicle design. 2. REFERENCES 2.1 Applicable Publications The following publications form a
19、 part of this specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 5096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-49
20、70 (outside USA), www.sae.org.SAE J551 Performance Levels of Methods of Measurement of Electromagnetic Radiation from Vehicles and Devices SAE J1211 Recommended Environmental Practices for Electronic Equipment Design SAE J1555 Recommended Practice for Optimizing Automotive Damagability SAE J1654 Hig
21、h Voltage Primary Cable SAE J1673 High Voltage Automotive Wiring Assembly Design SAE J1715 Electric Vehicle Terminology SAE J2289 Revised JUL2008 - 3 -SAE J1718 Measurement of Hydrogen Gas Emission from Battery-Powered Passenger Cars and Light Trucks During Battery Charging SAE J1742 Connections for
22、 High Voltage On-Board Road Vehicle Electrical Wiring HarnessesTest Methods and General Performance Requirements SAE J1766 Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Integrity Testing SAE J1772 SAE Electric Vehicle Conductive Charge Coupler SAE J1773 SAE Elec
23、tric Vehicle Inductively Coupled Charging SAE J1797 Recommended Practice for Packaging of Electric Vehicle Battery Modules SAE J1798 Recommended Practice for Performance Rating of Electric Vehicle Battery Modules SAE J1850 Class B Data Communications Network Interface SAE J2184 Vehicle Lift Points f
24、or Service Garage Lifting SAE J2288 Life Cycle Testing of Electric Vehicle Battery Modules SAE J2293-2 Energy Transfer System for Electric VehiclesPart 2: Communication Requirements and Network Architecture SAE J2344 Guidelines for Electric Vehicle Safety SAE J2380 Vibration Testing of Electric Vehi
25、cle Batteries 2.1.2 Battery Council International (BCI) Publication Available from Battery Council International, 401 North Michigan Avenue, 24th Floor, Chicago, IL 60611-4267, Tel: 312-644-6610, www.batterycouncil.org.UL 1244 UL Standard for Safety Electrical and Electronic Measuring and Testing Eq
26、uipment 2.1.3 NHTSA Publication Available from NHTSA, 1200 New Jersey Avenue, SW, Washington, DC 20590, Tel: 1-888-327-4236, www.nhtsa.gov.NHTSA FMVSS 305 Electric-powered Vehicle: electrolyte spillage and electrical shock protection 2.1.4 National Electric Code Available from National Fire Protecti
27、on Agency, 1 Batterymarch Park, Quincy, MA 02169-7471, Tel: 617-770-3000, www.nfpa.org.National Electric Code 625 SAE J2289 Revised JUL2008 - 4 -2.2 Related Publications The following publications are for information purposes only and are not a required part of this document. 2.2.1 SAE Publications
28、Available from SAE International, 400 Commonweatlh Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J2223-1 Connections for On-Board Road Vehicle Electrical Wiring HarnessesPart 1: Single-Pole ConnectorsFlat Blade TerminalsDi
29、mensional Characteristics and Specific Requirements SAE J2284 High Speed CAN (HSC) for Passenger Vehicle Applications SAE J2464 Electric Vehicle Battery Abuse Testing 2.2.2 Battery Council International (BCI) Publication Available from Battery Council International, 401 North Michigan Avenue, 24th F
30、loor, Chicago, IL 60611-4267, Tel: 312-644-6610, www.batterycouncil.org.Battery Council International Data Book 3. DEFINITIONS Reference SAE J17154. SYMBOLS Not used. 5. PHYSICAL REQUIREMENTS 5.1 Mechanical Retention A retention system to attach components and the battery system to the vehicle shoul
31、d provide for retention in the three mutually perpendicular axes. The restraint need not contact the entire surface in the axis being restrained, i.e., small areas of contact are satisfactory as long as no damage is done to the components. 5.1.1 Physical/Mechanical Performance Requirements a. Any re
32、straining system used shall not inhibit the normal electrical operation or ventilation of the module(s) through either physical or electrical obstructions. If an air draft system is used for thermal management or hydrogen gas emissions, the retention system should not hinder airflow around the modul
33、e(s) needed for proper thermal management or venting of the entire battery system. b. The restraints should retain the orientation and position of the modules during vehicle operations. Crash performance as described in SAE J1766, is recommended to ensure that the retention system remains intact. It
34、 should also not directly damage modules, which could result in electrolyte leakage.c. Any retention system should maintain electrical isolation during a crash as referenced in SAE J1766. The retention system should prevent current leakage and should be protected against electrolyte corrosion. The r
35、etention system should not allow damage to sensor wiring, vent tubes, thermal management components, or primary traction wiring leads under all but extreme conditions. SAE J2289 Revised JUL2008 - 5 -5.1.2 Retention of Components in a Battery Pack System It is recognized that there are a multitude of
36、 methods by which to restrain both single modules and multiple modules connected together in a system. Although electrical cables and connections may seem to provide some form of retention and restraint of modules in relation with one another, this is not considered to be a part of an acceptable ret
37、ention system that provides restraint in normal and some safety critical situations. Fasteners, used to mount components to the structure should consider the strength over time and corrosion due to the emission (leakage or spillage) of electrolyte, or other contaminants that may enter the battery sy
38、stem. Use of high stress clamping retention should be evaluated in the light of not exceeding the force required to damage thermal welds of plastic structures or stress the electrical isolation of metal cans or to cause deformation of the module/cell surface. 5.1.3 Retention of Battery Pack to Vehic
39、le Sufficient structural strength is required to withstand severe contact loads from FMVSS Crash conditions and rollover without ejecting modules or while providing clearance to the vehicle body. Retention should be sufficient to prevent damage to the batteries by repetitive motion contact. In addit
40、ion it is necessary to provide retention to protect the battery and the vehicle from damage or affect overall pack reliability. 5.2 Installation/Removal for Service Battery pack design should consider installation and removal by service personnel. One consideration is structural support of the batte
41、ry tray during installation and removal after it has been disconnected from the vehicle. During this time, some additional structure (pallet or other) may be needed to support the battery pack to preclude damage and enable movement by fork lift trucks or cranes to move a battery pack from the servic
42、e bay to a transport truck in instances of swapping or offsite servicing of a battery pack. Clearances on the vehicle that are adequate to enable easy installation or removal of a battery pack should be verified during vehicle design to simplify service operations. SAE J1555 and SAE J2184 may need t
43、o be evaluated to prevent interferences with the battery systems. The vehicle manufacturer should offer detailed service information and training to service personnel. It should include safety procedures due to high voltage potentials in battery systems. 5.3 Clearance 5.3.1 Ground Clearance Ensuring
44、 adequate ground clearance may be required to protect the structural integrity and durability of some battery systems mounted under the vehicles structure. This is to verify that departure angles for a vehicles beginning or ending grade climbs or passing over bumps or other obstacles is not compromi
45、sed. The amount of ground clearance is left to the discretion of the vehicle manufacturer based on vehicle mission and image.5.3.2 Body Clearance Body clearance spacing may be required to provide adequate protection of the battery system components movement to preclude contact of the battery pack or
46、 components to the vehicle. These limits are specified as part of the manufacturers design for manufacture/assembly/service guidelines to assist in developing a robust design. Battery packs should be located to reduce probability of damage. Locating battery packs in susceptible locations should cons
47、ider use of additional crash structure to protect the battery. SAE J2289 Revised JUL2008 - 6 -5.3.3 NVH Compatibility (noise vibration harshness) Battery packs should have sufficient retention to provide structural rigidity and separation from the body. Retention should also be sufficient to prevent
48、 vibrations/low frequency noises that may reduce structural reliability or be objectionable to passengers. Some designs may also include isolation mounts to reduce NVH. 5.4 Durability Requirements 5.4.1 Mechanical Shock Battery systems and components should withstand automotive shock effects. This i
49、ncludes shock induced by shipping and handling, component installation, in-use operation, and crash. Battery modules may have additional shock limitations as described by the battery manufacturer. Section 4.8 of SAE J1211 may be an acceptable standard. Also reference SAE J1555. Battery packs may be exposed to the underside of the vehicle, which could result in ground contact or other impacts such as road debris. 5.4.2 Vibration The bat
