SAE-J2380 Vibration Shaker System Test Standards
SAE J2380 provides a test procedure for characterizing the effects of long-term, road-induced vibration and shock on the performance and service life of electric vehicle batteries.
The purpose of this process is to verify the vibrational durability of the battery. Scanning sine wave vibration or random vibration is commonly used for this test of performance
The performance of the program requires a one - to three-axis table capable of generating accelerations of up to 1.9G on the vibration spectrum detailed in Figure 2, extending from 10 Hz to about 200 Hz. If the unit to be tested can only vibrate in a specific physical direction, a multi-axis table is required. In addition, if longitudinal and transverse axis vibrations (or all three axes) can be performed simultaneously, the time required to perform the test can be greatly reduced
2.2. Fully charge the battery according to the manufacturer's recommended charging method.
2.3.For each vertical, longitudinal, and transverse axis of the battery, select a normal or optional g level from Table 1 and program the excitation table appropriately. This choice will determine the vibration time required for each axis, also consistent with Table 1. (As shown in Figure 2, the vibration spectrum is expressed in G/Hz, so any set of G-levels can be scaled.)
2.4.According to the physical orientation recommended by the manufacturer, install the test unit to withstand the vibration along the appropriate axis direction. Depending on the performance of the vibration shaker system used, the program allows the desired vibration to be carried out simultaneously in one, two or all three axes (see 4.4.5).
2.5. During the vibration test of a given battery, when the battery discharge depth changes from 0%(full charge) to 80%(minimum charge), perform the programmed vibration of the required time. There are two ways to do this:
A. If using A single shaker system - or two-axis shaker system, approximately two-thirds of the vertical shaft test should be performed at full charge, followed by longitudinal and lateral vibration at 40% DOD, and then the remaining vertical shaft vibration at 80% DOD.
B. If a three-axis table is used to perform all vibration regimes simultaneously, the total testing period can be divided intol three intervals of roughly equal length. The first interval should be performed with the battery fully charged, the second interval with the battery at 40% DOD, and the third interval at 80% DOD.
2.6 Between each pair of the three intervals of vibration specified in 4.4.5, the battery should be discharged at a C/3 constant current rate for 40% of the rated capacity of the battery.Following the third vibration interval, the battery should be fully recharged.
2.7 Repeat the reference performance test using SAE J1798. This sequence includes C/3 constant discharge, dynamic capacity test discharge to 100% rated capacity, and peak power discharge.
a. Loss of electrical isolation between the positive battery connection and the grounding of the battery housing and/or test equipment. The degree of isolation should be verified periodically, for example 0.5 MΩ or greater per day (1.0 mA or less at 500V DC) during any vibration test.
b.. If the battery voltage is abnormal, an open or short circuit exists.
c. An unexpected resonance occurs inside the battery, indicating that the mechanical fastening component is faulty.
d. The temperature is abnormal, which may damage the battery or components of the thermal management system.
When any of the conditions listed in paragraphs (a) to (d) are detected, the test shall be suspended until the condition has been assessed and it is determined that it is safe to perform or that the test should be terminated.
A report should be prepared detailing the vibration of the actual application, collecting and interpreting all data, as well as detailed component failure analysis results. In addition, electrical performance data before and after vibration should be summarized to confirm whether the battery design is adequate to withstand the vibration environment
The purpose of this process is to verify the vibrational durability of the battery. Scanning sine wave vibration or random vibration is commonly used for this test of performance
The performance of the program requires a one - to three-axis table capable of generating accelerations of up to 1.9G on the vibration spectrum detailed in Figure 2, extending from 10 Hz to about 200 Hz. If the unit to be tested can only vibrate in a specific physical direction, a multi-axis table is required. In addition, if longitudinal and transverse axis vibrations (or all three axes) can be performed simultaneously, the time required to perform the test can be greatly reduced
Test procedure
2.1. Perform a series of reference performance tests, as defined by SAE J1798, including C/3 constant discharge, 100% rated capacity dynamic capacity test discharge and peak power discharge.2.2. Fully charge the battery according to the manufacturer's recommended charging method.
2.3.For each vertical, longitudinal, and transverse axis of the battery, select a normal or optional g level from Table 1 and program the excitation table appropriately. This choice will determine the vibration time required for each axis, also consistent with Table 1. (As shown in Figure 2, the vibration spectrum is expressed in G/Hz, so any set of G-levels can be scaled.)
2.4.According to the physical orientation recommended by the manufacturer, install the test unit to withstand the vibration along the appropriate axis direction. Depending on the performance of the vibration shaker system used, the program allows the desired vibration to be carried out simultaneously in one, two or all three axes (see 4.4.5).
2.5. During the vibration test of a given battery, when the battery discharge depth changes from 0%(full charge) to 80%(minimum charge), perform the programmed vibration of the required time. There are two ways to do this:
A. If using A single shaker system - or two-axis shaker system, approximately two-thirds of the vertical shaft test should be performed at full charge, followed by longitudinal and lateral vibration at 40% DOD, and then the remaining vertical shaft vibration at 80% DOD.
B. If a three-axis table is used to perform all vibration regimes simultaneously, the total testing period can be divided intol three intervals of roughly equal length. The first interval should be performed with the battery fully charged, the second interval with the battery at 40% DOD, and the third interval at 80% DOD.
2.6 Between each pair of the three intervals of vibration specified in 4.4.5, the battery should be discharged at a C/3 constant current rate for 40% of the rated capacity of the battery.Following the third vibration interval, the battery should be fully recharged.
2.7 Repeat the reference performance test using SAE J1798. This sequence includes C/3 constant discharge, dynamic capacity test discharge to 100% rated capacity, and peak power discharge.
Testing Precautions
During the application of a vibration shaker system, the test apparatus shall be equipped with instruments to determine the presence of any of the following conditions:a. Loss of electrical isolation between the positive battery connection and the grounding of the battery housing and/or test equipment. The degree of isolation should be verified periodically, for example 0.5 MΩ or greater per day (1.0 mA or less at 500V DC) during any vibration test.
b.. If the battery voltage is abnormal, an open or short circuit exists.
c. An unexpected resonance occurs inside the battery, indicating that the mechanical fastening component is faulty.
d. The temperature is abnormal, which may damage the battery or components of the thermal management system.
When any of the conditions listed in paragraphs (a) to (d) are detected, the test shall be suspended until the condition has been assessed and it is determined that it is safe to perform or that the test should be terminated.
Data Acquisition and Reporting
The data obtained during the reference performance tests of 2.1 or 2.7 shall meet the requirements for the normal conduct of these tests. If no abnormal behavior is observed during the test, there is no need to retain data from these measurements (other than summary results).A report should be prepared detailing the vibration of the actual application, collecting and interpreting all data, as well as detailed component failure analysis results. In addition, electrical performance data before and after vibration should be summarized to confirm whether the battery design is adequate to withstand the vibration environment
