ISO 6469 Electric Passenger Vehicle Electrical Safety Testing Equipment

Complied Standards & Clauses

ISO 6469-1:2019 Electrically propelled road vehicles — Safety specifications — Part 1: Rechargeable energy storage system (RESS)

IEC 62196:2020 Plugs, socket-outlets, vehicle connectors and vehicle inlets-Conductive charging of electric vehicles

GB 7258-2017 Safety technical conditions for motor vehicle operation

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Equipment Overview

Special Safety Test System for new Energy Vehicles is suitable for vehicle safety testing and high-voltage electrical safety testing of new energy vehicles and passenger vehicles. It conforms to the national standard test content. It has been successfully applied to many domestic new energy vehicle manufacturers. The product quality and technical services have won customer’s approval and unanimously praised.

Technical Parameters

1. Capacitive coupling test
2. Potential equalization test
3. Insulation resistance of power load
4. Insulation resistance of charging socket
5. AC withstand voltage test
6. Vehicle insulation resistance test
7. DC withstand voltage test
8. Insulation detection function verification
9. Leakage current test

Main Functions

1. Multifunctional: Including potential equalization test, insulation resistance of charging socket, vehicle insulation resistance, insulation detection function verification, capacity coupling test, insulation resistance of power load, AC withstand voltage, DC withstand voltage and leakage current test etc.

2. Screen display: 21.5-inch true color LCD screen is used, and the interface of the test process is visible, which is convenient for observation and judgment.

3. Open platform: It equipped with test program editing function, test project editing function, test report editing and printing function, user permission setting function etc.

4. Scan code function: It can record the vehicle VIN number, VSN number and main accessories number, and automatically associate the barcode to print the test report after test is completed.

5. Intelligent judgment: With Open/Short open and short circuit check function, it is not allowed to find short problems in the loop after high voltage output, to avoid the equipment and user damage caused by wrong output.

6. Permission management: multi-level permission setting, which is convenient for management.

7. Data management: Manage various data, protect the integrity and security of the data, and have functions such as query and export to meet the data management needs of the production line.

8. Safety protection: Over-current protection, over-voltage protection, under-voltage protection, leakage current protection and emergency protection, etc.

9. Massive data: Support massive data storage and analysis; MES system docking, etc.

10. Flexible startup: Support multiple startup methods such as scan code startup, button startup, remote startup, etc.

Main Features

Detailed Introduction

Vehicle insulation resistance test

1 Principle introduction

1.1 Power on the vehicle to ensure that all power and electronic switches on the vehicle are in an active state.

1.2 Measure the voltage between the two terminals of REESS and the electric platform, as shown in the figure below, the higher one is U1, and the lower one is U1'.

1.3 Add a known resistance R0 (1MΩ). Connect in parallel between the U1 side terminal of REESS and the electric platform as shown in the figure below.Measure the voltage between the two terminals of REESS and the electric platform, and the measured values are U2 and U2'.

2 Parameter requirements:

2.1 Under the maximum working voltage, the minimum insulation resistance of the DC circuit should be greater than 100Ω/V, and the AC circuit should be greater than 500Ω/V

2.2 The lower limit of insulation resistance is recommended to be 0.375MΩ.

Insulation detection function verification

1. The current insulation resistance value of the entire vehicle is measured as Ri.
2. Put the vehicle into "driving mode" according to the normal operation process of the vehicle under test.
3. Reduce the resistance of the adjustable resistor to the target value Rx, which is calculated according to the following formula.
4. Confirm whether the vehicle has sound and light alarm.

Calculation formula
When the minimum insulation requirement is 100Ω/V, the resistance value is:

When the minimum insulation requirement is 500Ω/V, the resistance value is:

UREESS is the current total voltage of the battery pack.

Potential equalization test

1 Principle Introduction

1.1 Take a specified current from a power source with no load not exceeding 12V, apply it to the ground wire of the vehicle charging port, the exposed conductive shell of the parts and the frame, and measure the voltage drop to finally calculate the grounding resistance value.

1.2 Test the conduction resistance between the ground wire of each charging interface of the car, the exposed conductive shell of the parts and the frame of the vehicle with a distance of no more than 2.5m.

Charging Gun Interface Insulation Resistance Test

1 Principle Introduction

The positive and negative terminals of the charging socket are short-circuited through the inside of the meter, and the tester inputs a high DC voltage to the vehicle through the charging gun. The high voltage exists between the positive and negative terminals and the frame, and finally the insulation resistance of the charging socket is calculated value.

Sinuo Testing Equipment Co., Limited established in 2019, but Sinuo has rich experience in manufacturing test euipment, test system and offering overall laboratory construction of electronic and electrical products. Sinuo's main products include electrical vehicle test equipment, battery testing equipment,  electromagnetic compatibility (EMC) test system, environmental testing equipment, fire retardant test equipment, dust-proof waterproof testing equipment and electrical appliances testing equipment. Our products covering electrical vehicle, electric power, communication, electrical appliances and electronic devices industries.

Sinuo has a professional technical research and development team, which is proficient in various international standards such AS IEC, ISO, EN, VDE, BS, AS, ASTM, GB and industry standards such AS MBN LV124, VW-80000. We master physical mechanics, heat, electricity, fluid and other theoretical knowledge in the application of equipment. And continue to focus on industry standard equipment performance optimization, operation simplification and equipment stability and reliability improvement.

Sinuo has two factories in Guangzhou and Dongguan, and cooperates with many research institutions and schools. Our R&D and production capacity are in the forefront. We have authorized agents in South Korea, the United States, South Africa, Egypt, Pakistan, the Philippines and other places, we serve customers BV, CSA, Intertek, SGS, TUV and other internationally renowned testing and certification institutions, local government quality inspection departments and production factories.