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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 entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr
2、om, 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 2002 Society of Automotive Engineers, Inc. All rights reserved. No part of
3、this publication may 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: 724-776-4
4、970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS:http:/www.sae.org SURFACE VEHICLE RECOMMENDED PRACTICE J2578 ISSUED DEC2002 Issued2002-12 Recommended Practice for General Fuel Cell Vehicle Safety ForewordVehicles manufactured with liquid hydrocarbon as fuels have a long his
5、tory of creating appropriate safety countermeasures. With the onset of new hydrogen fuel cell systems, new mechanical and electrical system safety design parameters will need to be provided to vehicle developers. These SAE reports are an initial attempt to formalize a list of important safety items
6、for fuel cell vehicle and subsystem developers. The purpose of this document is to identify the unique requirements and criteria for the integration of fuel cell systems into vehicles. This document relates to the overall design, construction, operation and maintenance of fuel cell vehicles includin
7、g the integration of the Fuel Systems (and other fuel cell systems containing potentially hazardous fluids as defined in this document) into the vehicle. TABLE OF CONTENTS 1.Scope. 3 1.1Purpose 3 1.2Field of Application . 3 2.References. 4 2.1Applicable Publications 4 2.1.1SAE Publications 4 2.1.2AN
8、SI Standards 4 2.1.3Federal Motor Vehicle Safety Standards 4 2.1.4IEC Publications .5 2.1.5ISO Publications.5 2.1.6UL Publications 5 2.1.7Other Publications 5 2.2Related Publications. 5 2.2.1SAE Publications 5 2.2.2ANSI Standards 6 2.2.3CISPR Publications 6 2.2.4EU Directives 7 2.2.5IEC Publications
9、 .7 2.2.6ISO Publications.7 2.2.7Other Publications 8 3.Definitions.8 SAE J2578 Issued DEC2002 -2- 4.Technical Systems Safety Guidelines 10 4.1General Vehicle Safety .10 4.1.1Design for Safety 10 4.1.1.1Failure Modes and Effects Analysis (FMEA) as Best Practice .10 4.1.1.2Isolation and Separation of
10、 Hazards.10 4.1.1.3Critical Control Function .10 4.1.1.4Fail-Safe Design.11 4.1.2Electromagnetic Capability (EMC) and Electrical Transients11 4.1.3Fuel Cell Vehicle Crashworthiness.11 4.1.3.1Fuel System Integrity 11 4.1.3.2Electrical Integrity .11 4.1.4Vehicle Immersion 12 4.1.5Towability Design Cri
11、teria .12 4.2Fuel System Safety.12 4.2.1Installation.12 4.2.2Fail-Safe Shutoff .12 4.2.3Management of Potentially Hazardous Conditions Within Vehicle Compartments.12 4.2.3.1Barriers .12 4.2.3.2Potentially Flammable Atmospheres 13 4.2.3.3Potential Ignition Sources .13 4.2.3.4Potential Hydrogen Evolut
12、ion from Traction Batteries 13 4.2.4Normal Discharge Systems14 4.2.5Discharges from Pressure Relief Devices 14 4.2.6Fueling 14 4.2.7Defueling.14 4.2.8Fuel System Monitoring 14 4.3Fuel Cell System Safety .14 4.3.1Fuel Cell System Design 14 4.3.2Fuel Cell Stack Design .14 4.3.3High Voltage Isolation.1
13、5 4.3.3.1Design Validation15 4.3.3.2Operation15 4.3.4High Voltage Dielectric Withstand Capability15 4.3.5Fuel Cell System and Stack Monitoring15 4.4Electrical System Safety.15 4.4.1High Voltage Wire.15 4.4.2High Voltage Connectors 15 4.4.3High Voltage Isolation.15 4.4.3.1Design Validation15 4.4.3.2O
14、peration16 4.4.4High Voltage Dielectric Withstand Capability16 4.4.5Access to Live Parts .16 4.4.6Labeling16 4.4.7Fusing/Overcurrent Protection16 4.4.8Bonding and Grounding16 4.4.8.1Vehicle Bonding16 4.4.8.2Vehicle Interior Bonding17 4.4.8.3Electrical Components Bonding17 4.4.8.4Grounding to Fill St
15、ation During Refueling .17 4.4.9Electrical System Fault Monitoring .17 4.4.10Hybrid Fuel Cell Vehicles18 4.4.10.1Use of Electric Supply Equipment 18 4.4.10.2Back-feed to Fuel Cell 18 4.4.10.3Traction Battery Pack .18 SAE J2578 Issued DEC2002 -3- 4.4.11Automatic Disconnects.18 4.4.12Manual Disconnect
16、s .18 4.4.13High Voltage Buss Discharge.18 4.5Mechanical Safety 18 4.5.1Main Switch 18 4.5.2Shift Mechanisms .18 4.6Fail-Safe Procedures 19 4.6.1Main Switch Deactivated 19 4.6.2Response to Crash .19 4.6.3Vehicle Start-Up19 4.6.4Vehicle Not Moving.19 4.6.5Vehicle Moving .19 4.7Safety Labeling .19 5.O
17、peration20 5.1Owners Guide or Manual.20 5.2Fuel Releases During Normal Operation20 5.2.1Normal Gaseous Discharges Outside Vehicle20 5.2.2Normal Gaseous Discharges to Passenger Compartment.21 5.2.3Normal Gaseous Discharges to Other Compartments .21 5.2.4Parking in Non-mechanically Ventilated Enclosur
18、es.21 5.2.5Operation in Ventilated Structures21 5.3Byproducts21 6.Emergency Response 21 7.Maintenance.22 7.1Service Manual.22 7.2Defueling Procedures .22 7.3Facility Safety .22 Appendix ACalculations for Fuel System Integrity Coefficients23 Appendix BGuidance for Conducting High Voltage Tests26 Appe
19、ndix CGuidance for Conducting Discharge Tests.28 1.ScopeThis SAE Recommended Practice identifies and defines the preferred technical guidelines relating to the safe integration of fuel cell system, fuel storage, and electrical systems into the overall Fuel Cell Vehicle. 1.1PurposeThe purpose of this
20、 document is to provide introductory mechanical and electrical system safety guidelines that should be considered when designing fuel cell vehicles for use on public roads. 1.2Field of ApplicationThis document covers fuel cell vehicles designed for use on public roads. SAE J2578 Issued DEC2002 -4- 2
21、.ReferencesThe following publications form a part of this information report to the extent specified. Unless otherwise indicated, the latest version of publications should apply. 2.1Applicable PublicationsThe following publications form a part of this specification to the extent specified herein. Un
22、less otherwise specified, the latest issue of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. Applicable FMVSS standards and regulations should supersede any SAE recommended practices as described in this document. SAE J1142To
23、wability Design Criteria and Equipment UsePassenger Cars, Vans, and Light-Duty Trucks SAE J1645Fuel SystemElectrostatic Charge SAE J1718Measurement of Hydrogen Gas Emission from Battery-Powered Passenger Cars and Light Trucks during Battery Charging SAE J1739Potential Failure Mode and Effects Analys
24、is in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA), and Potential Failure Mode and Effects Analysis for Machinery (Machinery FMEA) SAE J1742Connections for High Voltage On-Board Road Vehicle Electrical Wiring HarnessesTest M
25、ethods and General Performance Requirements SAE J1766Recommended Practice for Electric and Hybrid Electric Vehicle Battery Systems Crash Integrity Testing SAE J1772SAE Electric Vehicle Conductive Charge Coupler SAE J1773SAE Electric Vehicle Inductively Coupling Charging SAE J2344Guidelines for Elect
26、ric Vehicle Safety SAE J2574Fuel Cell Vehicle Terminology 2.1.2ANSI STANDARDThe following publication is provided for information purposes only and is not directly applicable to this document. The publication is available from ANSI, 25 West 43rd Street, New York, NY 10036-8002. ANSI Z535.4Product Sa
27、fety Sign and Label 2.1.3FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS)The publications are available from the U.S. Government Printing Office, 710 N. Capitol St. NW, Washington, DC 20401. The following Federal Motor Vehicle Safety Standards are specifically applicable to this document for use in th
28、e U.S. See the Code of Federal Regulations (49 CFR 571) for other applicable FMVSS. In other countries, other regulations may apply. FMVSS 301Fuel system integrity FMVSS 303Fuel system integrity of compressed natural gas vehicles FMVSS 305Electric powered vehicles: electrolyte spillage and electrica
29、l shock protection SAE J2578 Issued DEC2002 -5- 2.1.4IEC PUBLICATIONSThe following publications are provided for guidance. The publications are available from International Electrotechnical Commission, 3, rue de Verambe, P.O. Box 131, 1211 Geneva 20 Switzerland. IEC 60079 (Parts 0 through 20)Electri
30、cal Apparatus for Explosive Gas Atmospheres IEC 60417 (Parts 1 and 2)Graphical Symbols for Use on Equipment IEC 61508-11998 10 kHz to 200 MHzCrawford TEM Cell and 10 kHz to 5 GHzWideband TEM Cell SAE J1113-25Electromagnetic Compatibility Measurement Procedure for Vehicle Components Immunity to Radia
31、ted Electromagnetic Fields, 10 KHz to 1000 MHzTri-Plate Line Method SAE J1113-26Electromagnetic Compatibility Measurement Procedure for Vehicle Components Immunity to AC Power Line Electric Fields SAE J1113-41Limits and Methods of Measurement of Radio Disturbance Characteristics of Components and Mo
32、dules for the Protection of Receivers Used on Board Vehicles SAE J1113-42Electromagnetic CompatibilityComponent Test ProcedurePart 42 - Conducted Transient Emissions SAE J1115Guidelines for Developing and Revision SAE Nomenclature and Definitions SAE J1654High Voltage Primary Cable SAE J1673High Vol
33、tage Automotive Wiring Assembly Design SAE J1715Electric Vehicle Terminology SAE J1752-1Electromagnetic Compatibility Measurement Procedures for Integrated Circuits Integrated Circuit EMC Measurement ProceduresGeneral and Definitions SAE J1752-2Electromagnetic Compatibility Measurement Procedures fo
34、r Integrated Circuits Integrated Circuit Radiated Emissions Diagnostic Procedure 1 MHz to 1000 MHz, Magnetic Field Loop Probe SAE J1812Function Performance Status Classification for EMC Immunity Testing 2.2.2ANSI STANDARDSThe following publications are provided for information purposes only and are
35、not directly applicable to this document. The publications are available from ANSI, 25 West 43rd Street, New York, NY 10036-8002. ANSI/IEEE C62.41Surge Voltages in Low-Voltage AC Power Circuits ANSI/IEEE C62.45Equipment Connected to Low-Voltage AC Power Circuits, Guide on Surge Testing for ANSI Z21.
36、83Standard for Stationary Fuel Cell Power Plants 2.2.3CISPR PUBLICATIONSThe following publications are provided for information purposes only and are not directly applicable to this document. The publications are available from IEC. See 2.2.5. CISPR 12Vehicles, motorboats and spark-ignited engine-dr
37、iven devicesRadio disturbance characteristicsLimits and methods of measurement CISPR 22Information technology equipmentRadio disturbance characteristicsLimits and methods of measurement CISPR 25Limits and methods of measurement of radio disturbance characteristics for the protection of receivers use
38、d on board vehicles SAE J2578 Issued DEC2002 -7- 2.2.4EU DIRECTIVESThe following Directive is available for download from the European Union at http:/ www.europa.eu.int/eur-lex/en/index.html Commission Directive 95/54/ECAutomotive Directive (amends 72/245/EEC) 2.2.5IEC PUBLICATIONSThe following publ
39、ications are provided for guidance. The publications are available from International Electrotechnical Commission, 3, rue de Verambe, P.O. Box 131, 1211 Geneva 20 Switzerland. IEC 61508-2, 2000Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems - Part 2: Require
40、ments for Electrical/Electronic/Programmable Electronic Safety-Related Systems IEC 61508-4, 1998 connections for conducting fuels, oxidants, and exhausts; electrical connections for the power delivered by the stacks; and means for monitoring and/or control. Additionally, fuel cell modules may incorp
41、orate means for conducting additional fluids (e.g., cooling media, inert gas), means for detecting normal and/or abnormal operating conditions, enclosures or pressure vessels, and ventilation systems. SAE J2578 Issued DEC2002 -9- 3.12 Hazardous AreaAn area or space in which an explosive gas atmosphe
42、re or other hazardous condition is or may be expected to be present in such quantities as to require special precautions for the construction, installation and use apparatus. 3.13 Hazardous ConditionA condition that is potentially dangerous. Among these are hazardous fluids (3.14) and hazardous elec
43、trical voltages (3.15). 3.14 Hazardous FluidsGases or liquids that pose potential dangers. Hazards present with fluids in fuel systems are as follows: a.FlammabilitySufficient quantities of fuel/air mixtures at or above the lower flammability limit (LFL) are by definition dangerous. Fuel/air mixture
44、s below 25% LFL are considered non-hazardous. b.ToxicityPoint sources greater than the IDLH (Immediately Dangerous to Life and Health) and occupiable areas greater than OSHA TWA (Time Weighted Average) should be considered hazardous. c.High PressureHigh-pressure fluids in fuel supply subsystems, fue
45、l processors, fuel cells, and/or thermal management subsystems that can transfer kinetic energy causing personal injury. d.Extreme TemperatureVery high or low temperature fluids or materials that are capable of causing personal injury such as burns or frostbite. 3.15 Hazardous VoltageIntermediate or
46、 high voltage which can cause current through a human body. Hazardous voltage levels are defined in the Outline of Investigation for Personnel Protection Systems for Electric Vehicle (EV) Supply Circuits; General Requirements, UL 2231-1 July 1996 and in UL 2202. 3.16 Hazardous Voltage Interlock Loop
47、 (HVIL)The HVIL is a system intended to protect people from exposure to hazardous voltage or other hazardous conditions. It typically detects unwanted access or faults by passing a small (non-hazardous) signal through a loop connecting a set of normally-closed conductors, connectors, sensors, and sw
48、itches to check for electrical continuity. 3.17 High VoltageVoltage levels greater than 30 VAC or 60 VDC can harm humans through electric shock. 3.18 Ignition SourcesThermal or electric energy sources capable of igniting flammable gas mixtures. See 4.2.3.2 for discussion of avoiding thermal, electri
49、cal, and static discharges, respectively. 3.19 Immediately Dangerous to Life or Health (IDLH) An IDLH exposure condition is defined as one that poses a threat of exposure to airborne contaminants when that exposure is likely to cause death or immediate or delayed permanent adverse health effects or prevent escape from such an environment. 3.20 Intermediate VoltageVoltage levels greater than 15 VAC or 30 VDC and less than high voltage levels. 3.21 Normal DischargesDischarges expected during normal operation