SAE J 1797-1997 Recommended Practice for Packaging of Electric Vehicle Battery Modules.pdf

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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 entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro

2、m, 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.QUESTIONS REGARDING THIS DOCUMENT: (412) 772-8512 FAX: (412) 776-0243TO PLACE A DOCUMENT

3、 ORDER; (412) 776-4970 FAX: (412) 776-0790Copyright 1997 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001RECOMMENDEDPRACTICEJ1797ISSUEDJAN97Issued 1997-01RECOMMENDED PRACTICE FOR PACKAGING OF ELECTRIC VEHICLE B

4、ATTERY MODULESForewordThe mission of this document is to provide direction for standardization in packaging of secondarybattery modules for Electric Vehicles. Some of the incentives for this standardization effort include componentsafety, compatibility, availability, and economics. The term battery

5、module used throughout this document impliessecondary battery modules.The document addresses the external features of a battery module and how they interface to a battery pack system,or vehicle system, with a major emphasis on safety. Only commercially available aqueous battery systems whichcan be m

6、odularized within the recommendations of this document will be considered.This document also provides for the definition of additional package sizes as new vehicle battery systemrequirements are identified or new battery technologies become commercially available. Module sizes containedherein are ag

7、reed upon by vehicle and battery manufacturers and can serve as the basis for Battery CouncilInternational Group Sizes and other international standards.The procedure for acceptance of a new SAE EV battery standard is as follows:a. A letter to the EV Battery Systems Standards Committee Chairperson m

8、ust be submitted by a vehiclemanufacturer and one battery manufacturer proposing a new SAE EV battery size and documentationshowing compliance to SAE J1797.b. A letter of agreement with another vehicle manufacturer, other than that in Step a, is necessary toapprove proposing a new draft to the Recom

9、mended Practice.c. SAE will review for compliance (technical and commercial) and ballot the proposal in the EV BatterySystems Standards Committee to revise SAE J1797.TABLE OF CONTENTS1. Scope. 31.1 Purpose . 31.2 Field of Application 31.3 Product Classification 31.4 Form 32. References 32.1 Applicab

10、le Documents . 32.1.1 SAE Publications . 32.1.2 Other Publications . 3COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-2-2.2 Related Publications 43. Definitions 44. Symbols .45. Product Description45.1 Type of Electrochemistry45.2 Module

11、 Voltage 55.2.1 Nominal Voltage .55.2.2 Maximum Voltage.55.2.3 High-Voltage Considerations55.3 Package Envelope55.3.1 Dimensional .55.4 Capacity .165.5 Mass.166. Systems Interfaces.166.1 Mechanical Interfaces 166.1.1 Retention of Module in Battery Pack System.166.1.2 Retention Location and Features

12、.166.1.3 Top/Intermediate Retention166.1.4 Bottom Retention .166.1.5 Clamping Area and Force 176.1.6 Installation/Removal.176.1.7 Performance Connection Requirements 176.2 High-Power Connection Requirements 176.3 Dielectric 176.4 Vented Emissions Interfaces176.4.1 Flame/Flash Arrestor System Perform

13、ance Standards176.4.2 Venting System 176.4.3 Hydrogen Gas Emissions.176.4.4 Tube Connection RequirementsSize and Retention.186.4.5 Electrolyte Containment.186.4.6 Temperature Sensing Interface 186.5 High Power Electrical Interfaces.186.5.1 Termination.186.5.2 Terminal Location and Features.186.4.3 T

14、erminal Type.187. Physical Pick-Up Features Interface 198. Monitoring/Control Interfaces .198.1 Voltage .198.2 Temperature .198.3 Thermal Management Interfaces .198.3.1 Cooling.208.3.2 Heating.209. Marking and Labeling.209.1 Safety .209.1.1 Principal Hazards.209.1.2 Poison/Danger219.2 Polarity .21CO

15、PYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-3-9.3 Information .219.3.1 Battery Module and Group Size Designation.219.3.2 Battery Performance Ratings .219.3.3 Type of Battery Electrochemistry .219.3.4 Recycling219.3.5 Manufacturers Info

16、rmation.219.3.6 Country of Origin219.3.7 Date of Manufacture.2210. Shipping and Handling.2210.1 Packaging and Stackability 2211. Durability 221. ScopeThis SAE Recommended Practice provides for common battery designs through the description ofdimensions, termination, retention, venting system, and ot

17、her features required in an electric vehicleapplication. The document does not provide for performance standards. Performance will be addressed bySAE J1798. This document does provide for guidelines in proper packaging of battery modules to meetperformance criteria detailed in J1766.1.1 PurposeThis

18、document provides the guidelines for designing a battery module to effectively package intomanufacturers electric vehicles. It will lay the foundation for electric vehicle battery modules and serve as anindustry guideline.1.2 Field of ApplicationElectric Vehicles.1.3 Product ClassificationElectroche

19、mical Storage Devices.1.4 FormA modular unit consisting of electrochemical cell(s) configured to met the guidelines of this documentto provide a component which can be assembled into a battery pack system for electric vehicle applications.2. References2.1 Applicable PublicationsThe following publica

20、tions form a part of this specification to the extent specifiedherein. Unless otherwise indicated, the latest issue of SAE Publications shall apply.2.1.1 SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAE J1715Electric Vehicle TerminologySAE J1718Recommended Pr

21、actice for Measurement of Hydrogen Gas Emission from Battery PoweredPassenger Cars and Light Trucks During Battery ChargingSAE J1766Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems CrashIntegrity TestingSAE J1798Recommended Practices for Performance Rating of Electric Ve

22、hicle Battery Modules2.1.2 UNDERWRITERS LABORATORIES INC.Available from Underwriters Laboratories, Inc., 333 Pfingsten Road,Northbrook, IL 60062-2096.UL 1244COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-4-2.2 Related PublicationsThe fo

23、llowing publications are provided for information purposes only and are not arequired part of this document.2.2.1 SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAE TSB 0001SAE Technical Standards Board Rules and RegulationsSAE TSB 002SAE Preparation of SAE Tec

24、hnical ReportsSAE TSB 003Rules for the SAE Use of SI (Metric) UnitsSAE ReportFormat Guidelines for Electronic Capture of SAE DocumentsSAE Committee Guidelines ManualSAE J1115Guidelines for Developing and Revising SAE Nomenclature and DefinitionsSAE J1495Test Procedure for Battery Flame Retardant Ven

25、ting SystemsSAE J1654Recommended Practice for High-Voltage WiringSAE J1673Recommended Practice for High-Voltage Terminals and ConnectorsSAE J1742Recommended Practice for High-Voltage ConnectorsSAE J2288Recommended Practice for Life Cycle Testing of Electric Vehicle Battery ModulesSAE J2289Recommende

26、d Practice for Electric Vehicle Battery Pack Design and Performance2.2.2 BATTERY COUNCIL INTERNATIONAL (BCI)Available from Battery Council International, 401 North MichiganAvenue, Chicago, IL 60611.Battery Council International Data Book3. DefinitionsSee SAE J1715.4. SymbolsPbA = Lead Acid Batteries

27、NiCd = Nickel Cadmium BatteriesNiMH = Nickel Metal Hydride Batteries“+” = Positive Charged Electrode Polarity“” = Negative Charged Electrode Polarity“L” = Length“W” = Width“H” = Height5. Product Description5.1 Type of ElectrochemistryThis specification applies only to the commercially available aque

28、ous electrolytesystems listed in Table 1 which are packageable into the dimensional constraints specified in this document.COPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-5-5.2 Module Voltage5.2.1 NOMINAL VOLTAGEThe battery module unit i

29、s targeted for a nominal 12 V, or other designated modulevoltages as specified by the vehicle manufacturer.5.2.2 MAXIMUM VOLTAGEExceeding maximum voltage of 60 V direct current at a single battery modulesterminals during any state, including charging, is considered likely to increase the risk of ele

30、ctric shock, perUL 1244, Section 10.5.2.3 HIGH-VOLTAGE CONSIDERATIONSWhenever handling modules (installing, charging, etc.) due care isnecessary to avoid shock or spark hazard. Reference UL 1244, Section 10 for further guidance.5.3 Package Envelope5.3.1 DIMENSIONALThe packaging envelope for battery

31、modules contained in this document are described inTable 2.5.3.1.1 Pictorial RepresentationThe isometric and orthorhombic views of the external envelope are shown inFigures 1A through 4F and correspond to the module form factors detailed in Table 2.TABLE 1AQUEOUS ELECTROLYTE SYSTEMSElectrochemicalCo

32、upleLabelBackgroundColorElectrolyteTypeIdentificationLabel AcronymLead Acid Black Sulfuric Acid PbANickel Cadmium Blue Potassium Hydroxide NiCdNickel Metal Hydride Gray Potassium Hydroxide NiMHTABLE 2PACKAGING ENVELOPE FOR BATTERY MODULESSAEDesignationH (Height)mmW (Width)mmL (Length)mmMass(kg)Figur

33、eReferenceSAE EV1 175 2 116 2 388 2 21 1A-1FSAE EV2 223 2 173 2 306 2 30 2A-2ESAE EV3 260 2 123 1 246 2 13 3A-3FSAE EV4 170 2 165 2 197 2 15 4A-4FCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-6-FIGURE 1AISOMETRIC VIEWFIGURE 1BORTHORHOM

34、BIC VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-7-FIGURE 1CORTHORHOMBIC SIDE VIEWFIGURE 1DORTHORHOMBIC END VIEWFIGURE 1EEND VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Iss

35、ued JAN97-8-FIGURE 1FTOP VIEWFIGURE 2AISOMETRIC VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-9-FIGURE 2BORTHORHOMBIC TOP VIEWFIGURE 2CORTHORHOMBIC SIDE VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Han

36、dling ServicesSAE J1797 Issued JAN97-10-FIGURE 2DORTHORHOMBIC END VIEWFIGURE 2ETERMINAL TOP VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-11-FIGURE 3AISOMETRIC VIEWFIGURE 3BORTHORHOMBIC TOP VIEWCOPYRIGHT Society of Automotive Engin

37、eers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-12-FIGURE 3CORTHORHOMBIC SIDE VIEWFIGURE 3DORTHORHOMBIC END VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-13-FIGURE 3ETERMINAL END VIEWFIGURE 3FTERMINAL TOP

38、VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-14-FIGURE 4AISOMETRIC VIEWFIGURE 4BORTHORHOMBIC TOP VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-15-FIGURE 4CORTHRO

39、HOMBIC SIDE VIEWFIGURE 4DORTHORHOMBIC END VIEWFIGURE 4ETERMINAL END VIEWCOPYRIGHT Society of Automotive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-16-FIGURE 4FTERMINAL TOP VIEW5.4 CapacityThe capacity is determined by the Baseline Capacity Test as defined in SAE J

40、1798.5.5 MassThe maximum mass of the modular unit is found in Table 2 and excludes peripheral systems interfacecomponents, i.e., thermistors, cables, terminal protectors, etc. Ergonomic considerations must be made by thepack manufacturers to ensure due care is used when handling individual modules d

41、uring installation andservicing of packs.6. Systems InterfacesSystems interfaces shall include all peripheral device(s), component(s) or sub-system(s) which interact with the battery module unit(s).6.1 Mechanical Interfaces6.1.1 RETENTION OF MODULE IN BATTERY PACK SYSTEMIt is recognized that there a

42、re a multitude of methods bywhich to restrain both single modules and multiple modules connected together in a system. Althoughelectrical cables and connections may seem to provide some form of retention and restraint of modules inrelation with one another, this is not considered to be a part of an

43、acceptable retention system that providesrestraint in normal and some safety critical situations. Any method used shall consider the following areasand features of the module(s). Use SAE J1766 for retention performance standards.6.1.2 RETENTION LOCATION AND FEATURESThe retention system used shall pr

44、ovide for retention in the threemutually 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 modules and the system canmeet SAE J1766 performance standards.Any retention s

45、ystem should maintain electrical isolation during a crash as referenced in J1766. Theretention system should prevent current leakage and should be protected against electrolyte corrosion. If anair draft system is used for thermal management or hydrogen gas emissions, the retention system should noth

46、inder air flow around the module(s) needed for proper thermal management or venting of the entire batterysystem. The retention system should not interfere with the vent system or high-voltage wiring.6.1.3 TOP/INTERMEDIATE RETENTIONIf applicable, all remaining area on the top surface may be contacted

47、 forrestraint and should be available to the restraint system. If there is a heat seal area of the intermediate coverto top cover, it should not be used to provide edges by which to clamp or connect a restraining system.However, the top surface of the module may be used as a contact surface for the

48、restraint system and shouldprovide as much surface area as possible for maximum usage in retention.6.1.4 BOTTOM RETENTIONThe bottom surface of the module shall provide a level plane for placement in theretention and restraining system. Other retention features are optional.COPYRIGHT Society of Autom

49、otive Engineers, Inc.Licensed by Information Handling ServicesSAE J1797 Issued JAN97-17-6.1.5 CLAMPING AREA AND FORCEThe clamping area and force should be designed and specified to comply withbattery manufacturers performance requirements. The clamping area and force applied shall not damagethe battery module, particularly in consideration of material creep.6.1.6 INSTALLATION/REMOVALThe retention system should be designed for easy removal and installation ofbattery modules for service.6.1.7 P