GMW GMW15738-2013 Powertrain Cooling and Thermal Performance for Alternative Propulsion Passenger Vehicles Issue 2 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15738 Powertrain Cooling and Thermal Performance for Alternative Propulsion Passenger Vehicles Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 1 of 34 1 Scope Note: Nothing in this standard supercedes applicable laws and

2、 regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To determine the powertrain cooling temperatures (coolant, engine oil, and transmission oil), thermal temperatures (underhood and underbody components affe

3、cted by powertrain generated heat), power electronics temperatures (inverters and converters), motors and Energy Storage System (ESS)/Rechargeable Energy Storage System (RESS) temperatures for the conditions specified in the Vehicle Technical Specifications (VTS), Subsystem Technical Specifications

4、(SSTS), Component Technical Specifications (CTS) and Interface Control Documents (ICD). 1.2 Foreword. This test procedure is intended to be a supplement to GMW14555 for alternative propulsion programs and used along with procedure GMW14555 to validate the powertrain cooling, thermal, power electroni

5、cs, motor, and ESS/RESS capability for an alternative propulsion vehicle program. This procedure shall be run in addition to the applicable GMW14555 conditions as specified in the VTS for all regions where the Alternative Propulsion vehicle will be sold. The temperatures measured are compared agains

6、t the limits defined in the VTS, SSTS, CTS, and ICD documents. 1.3 Applicability. For all alternative propulsion (belt alternator starter (BAS), hybrid electric vehicle (HEV), plug-in hybrid electric vehicle (PHEV), extended range electric vehicle (EREV), fuel cell electric vehicle (FCEV), battery e

7、lectric vehicle (BEV), etc.) passenger vehicles and multipurpose vehicles. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. 40 CFR Part 86 Note 1 Note 1: CFR 86 Federal Schedule (FTP, HWFE, US06, Cold CO, SC03) CF

8、R Part 86. These are the United States Federal tests located at the following link: http:/www.epa.gov/nvfel/testing/dynamometer.htm. An external link to the drive profiles is established at http:/ All programs/tunnels should review this link on a quarterly basis (January, April, July, and October) t

9、o ensure that the drive profile has not been updated. 2.2 GM Standards/Specifications. GMW3202 GMW8697 GMW14555 GMW15845 2.3 Additional References. Electric Safety General Awareness course Vehicle Technical Specifications (VTS) 3.2.1.5.4. 3 Resources This procedure is intended to be a supplement for

10、 GMW14555 for alternative propulsion vehicle programs. All resource information unless otherwise listed is common with GMW14555. Refer to GMW14555 for detailed resource information. 3.1 Facilities. Refer to GMW14555. 3.1.1 Calibration. The test facilities and equipment shall be in good working order

11、 and shall have a valid calibration label. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15738 Copyright 2013 General Motors Company Al

12、l Rights Reserved December 2013 Page 2 of 34 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with respect to their physical definition. 3.2 Equipment. 3.2.1 General. Refer to

13、GMW14555. 3.2.2 Hybrid Specific. Not applicable. 3.3 Test Vehicle/Test Piece. Alternative propulsion passenger vehicles equipped with ESS/RESS battery pack and configured with appropriate vehicle content. 3.4 Test Time. Calendar time: 60 days Test hours: 512 hours Coordination hours: 250 hours 3.5 T

14、est Required Information. Refer to GMW14555 and Appendix B of this document “Required Data”. 3.6 Personnel/Skills. Refer to GMW14555 for basic requirements. All personnel shall be trained in high voltage safety and alternative propulsion vehicle safety protocol. This includes the alternative propuls

15、ion Electric Safety General Awareness course and Electric Safety procedure for the particular vehicle. These courses can be found by searching General Motors University (GMU) for Hybrids or contacting a Subject Matter Team (SMT) manager of alternative propulsion systems. 4 Procedure 4.1 Preparation.

16、 Refer to GMW14555 for basic requirements. Set up the vehicle with the normal GMW14555 and GMW15845 measuring locations and then add the additional measuring locations listed in Appendix A. 4.1.1 Vehicle Pre-Conditioning. 4.1.1.1 Battery Temperature Setting. Unless specified otherwise by the test pr

17、ocedure or by the specific requirements recorded in the VTS, the vehicle shall be conditioned to ensure that the ESS/RESS battery cell skin temperatures, as read by the on board controller, shall be within 3 C of the ambient temperature prior to the start of the vehicle tunnel test (not each test co

18、ndition). The ESS/RESS can be conditioned by blowing air across the battery pack or circulating coolant using the passive cooling loop. 4.1.1.2 Vehicle Temperature Conditioning. Unless specified otherwise by the test procedure or by the specific requirements recorded in the VTS, the vehicle shall be

19、 conditioned to ensure that the temperatures of the Engine Oil (if equipped), Transmission Oil (if equipped), and Seat Rail/Vehicle Structure shall be within 3 C of the ambient temperature prior to the start of the vehicle tunnel test (not each test condition). 4.2 Conditions. Refer to GMW14555 exce

20、pt as follows: 4.2.1 Environmental Conditions. The operating conditions of alternative propulsion vehicles require test in multiple ambient temperatures. Unless specified otherwise by the specific requirements recorded in the VTS, the default values for the required environmental conditions (ambient

21、, solar, and humidity) are defined in the test conditions. To enable on-road testing, a modification to the environmental conditions can be accepted if in the judgment of the responsible engineer it would not affect the test results. Due to vehicle calibrations and hybrid mode transitions, the addit

22、ional environmental conditions for worst case testing may be required. Development testing and knowledge of the system calibrations shall be used to determine any additional environmental conditions. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon

23、. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.2.2.1 ESS/RESS State of Charge (SOC) Setting. The hybrid ESS/RESS Battery State of Charge (SOC) shall be set to the starting State of Charge (SOC) as defined by the test before any Heating, Ventilation o

24、therwise multiple conditions shall be run for validation. In general “Min (minimum) SOC” is used for non-plug-in hybrids and Full SOC is used for plug-in vehicles. For some schedules plug-in vehicles with backup power (PHEV/EREV) will start from the Min SOC (the SOC that determines the onset of char

25、ge sustaining mode). 4.2.2.2 Rear HVAC Module Operation. For vehicles equipped with rear/auxiliary HVAC modules (including heater only, AC only and blower only systems) additional test conditions are required based on multiple rear HVAC settings. Tests shall be run with the rear/auxiliary systems in

26、 “mimic” mode to the front and also operated in “off” position. 4.3 Instructions. A vehicle program may not need to run all of the conditions of this procedure. The required conditions are dictated by the program VTS for the region and vehicle content. Check the condition paragraph to see which ones

27、 are optional based on the region and content. A reference summary of the conditions required versus content can be found in Appendix N. 4.3.1 Condition 1 Sequence Test Shutter Closed Ice Mode Min SOC (with Shutters Only). Run GMW14555 condition 1 (Global Sequence Procedure) at the ambient and SOC c

28、ondition as follows: Ice Mode Shutter Ambient (if unknown use 10 C Shutters Closed), 60% humidity, 0 W/m2, and no air conditioning (A/C). Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Min SOC. Test Complete. 4.3.2 Condition 2 Sequence Test Shutter Closed Ice Mode F

29、ull SOC (Plug-in with Shutters Only). Run GMW14555 condition 1 (Global Sequence Procedure) at the following ambient and SOC conditions: Ice Mode Shutter Ambient (if unknown use 10 C Shutters Closed), 60% humidity, 0 W/m2, and no A/C. Vehicle Load settings per GMW14555. The SOC conditioning for this

30、test shall be: Full SOC for plug-in vehicles (completing each section as much as possible in charge depleting mode). For some vehicles (such as limited range Electric Vehicles, Plug-in Hybrid Vehicles, and Extended Range Electric Vehicles), it is necessary to run the Global Sequence Test parts indiv

31、idually (as allowed per GMW14555), without the pre-conditioning portion, and with a charging cycle between each part. The individual parts for these vehicles shall be run starting from Full SOC and then ending at Min SOC (for example the Rural Highway portion should be run back to back until the cha

32、rge depletes from Full SOC to Min SOC). To minimize test time for these vehicles the recharge cycles should be run using the recharge test conditions in this document. Test Complete. 4.3.3 Condition 3 Sequence Test 20 C Min SOC. Run GMW14555 condition 1 (Global Sequence Procedure) at the following a

33、mbient and SOC conditions: Low Ambient: 20 C, 40% humidity, 600 W/m2, and no A/C. Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Min SOC. Test Complete. 4.3.4 Condition 4 Sequence Test 20 C Full SOC (Plug-in Only). Run GMW14555 condition 1 (Global Sequence Procedure

34、) at the following ambient and SOC conditions: Low Ambient: 20 C, 40% humidity, 600 W/m2, and no A/C. Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Full SOC for plug-in vehicles (completing each section as much as possible in charge depleting mode). Additional Test

35、ing Required in Min SOC for plug-in vehicles such as Extended Range Electric Vehicles and Plug-in Hybrid Electric Vehicles. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM

36、WORLDWIDE ENGINEERING STANDARDS GMW15738 Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 4 of 34 For some vehicles (such as limited range Electric Vehicles, Plug-in Hybrid Vehicles, and Extended Range Electric Vehicles), it is necessary to run the Global Sequence Test pa

37、rts individually (as allowed per GMW14555), without the pre-conditioning portion, and with a charging cycle between each part. The individual parts for these vehicles shall be run starting from Full SOC and then ending at Min SOC (for example the Rural Highway portion should be run back to back unti

38、l the charge depletes from Full SOC to Min SOC). To minimize test time for these vehicles the recharge cycles should be run using the recharge test conditions in this document. Test Complete. 4.3.5 Condition 5 Sequence Test 30 C Min SOC. Run GMW14555 condition 1 (Global Sequence Procedure) at the fo

39、llowing ambient and SOC conditions: Mid-ambient: 30 C, 40% humidity, 600 W/m2, and auto 22 C (automatic systems) or A/C full cold, mid- (6 V) blower (manual systems), customer selectable outside air (OSA). Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Min SOC. Test

40、 Complete. 4.3.6 Condition 6 Sequence Test 30 C Full SOC (Plug-in Only). Run GMW14555 condition 1 (Global Sequence Procedure) at the following ambient and SOC conditions: Mid-ambient: 30 C, 40% humidity, 600 W/m2, and auto 22 C (automatic systems) or A/C full cold, mid-(6 V) blower (manual systems),

41、 customer selectable OSA. Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Full SOC for plug-in vehicles (completing each section as much as possible in charge depleting mode). For some vehicles (such as limited range Electric Vehicles, Plug-in Hybrid Vehicles, and Ex

42、tended Range Electric Vehicles), it is necessary to run the Global Sequence Test parts individually (as allowed per GMW14555), without the pre-conditioning portion, and with a charging cycle between each part. The individual parts for these vehicles shall be run starting from Full SOC and then endin

43、g at Min SOC (for example the Rural Highway portion should be run back to back until the charge depletes from Full SOC to Min SOC). To minimize test time for these vehicles, the recharge cycles should be run using the recharge test conditions in this document. Test Complete. 4.3.7 Condition 7 Sequen

44、ce Test 38 C Min SOC. Run GMW14555 condition 1 (Global Sequence Procedure) at the following ambient and SOC conditions: High Ambient: 38 C, 40% humidity, 1000 W/m2, A/C full cold, high (14 V) blower, customer selectable OSA (duplication of standard GMW14555 included here for SOC Clarification). Vehi

45、cle Load settings per GMW14555. The SOC conditioning for this test shall be: Min SOC. Test Complete. 4.3.8 Condition 8 Sequence Test 38 C Full SOC (Plug-in Only). Run GMW14555 condition 1 (Global Sequence Procedure) at the following ambient and SOC conditions: High Ambient: 38 C, 40% humidity, 1000

46、W/m2, A/C full cold, high (14 V) blower, customer selectable OSA (duplication of standard GMW14555 included here for SOC Clarification). Vehicle Load settings per GMW14555. The SOC conditioning for this test shall be: Full SOC for plug-in vehicles (completing each section as much as possible in char

47、ge depleting mode). For some vehicles (such as limited range Electric Vehicles, Plug-in Hybrid Vehicles, and Extended Range Electric Vehicles), it is necessary to run the Global Sequence Test parts individually (as allowed per GMW14555), without the pre-conditioning portion, and with a charging cycl

48、e between each part. The individual parts for these vehicles shall be run starting from Full SOC and then ending at Min SOC (for example the Rural Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without l

49、icense from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15738 Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 5 of 34 Highway portion should be run back to back until the charge depletes from Full SOC to Min SOC). To minimize test time for these vehicles, the recharge cycles should be run using the recharge test conditions in this document. Test Complete. 4.3.9 C