Study On Test Technology For Electric Vehicle In Full Frontal Crash Test

Along with the development of pure electric automobile, hybrid electric automobile and fuel cell automobile in our country, the technology of such new energy environmental protection automobile is growing up rapidly. As a populace's consumable, safety request of automobiles is a realistic question which domestic and foreign automobile manufacturers must face. An important characteristic of electric automobile is the high voltage power return route loaded in the vehicle which goes far beyond the safe voltage. Therefore compared with the traditional automobile, the crashworthiness request of the electric automobile becomes higher.Except the national standard (GB11551-2003)"Passengers Protection In Vehicle Frontage Collision", the electric automobile frontage impact test, in view of electric automobile unique feature and characteristic, also should conform to the corresponding laws and standards. The main laws and the standards of domestic and foreign electric automobiles are American FMVSS 305, Chinese GB/T 18384.1-2001 and GB/T 19751-2005 as well as European ECE R100 and so on. But European ECE R100 mainly requests the electrical vehicles in structure and the function aspect without the detail stipulation and the request regarding the impact test aspect, therefore Chinese and US's standards are mainly analyzed in this thesis. The standard requests of electric automobile impact test in electrolyte divulging and power accumulator cell position holding is consistent. Although in dielectric resistance aspect national standard (GB/T 18384.1-2001) was established early and not requested, from the collision security angle, to survey and the assesment dielectric resistance is necessary after the impact test. Regarding request of the short circuit prevents and the electric current shutting-off device aspect, although the American standard has not requested, it is an extremely effective protection way to prevent passengers from receiving electric shock in the collision accident. However, the request of the short circuit prevent is quite simple and there is no concrete appraisal target. If it is possible to survey the battery voltage including monomer battery voltage change in the impact test change before and after, it will be more concrete and detail as an appraisal target and also be easy to implement and to operate in the experiment.The electric automobile impact test is different with the ordinary automobile impact test. In the electric automobile impact test, there will involve each kind of power battery types and arrangement position of the power battery in vehicles, which will directly affect the risk of power battery. If the cell box was destroyed by outside hitting, the power battery would be possibly detonated on fire and threat safety of persons and equipments. But in the above standard, there is no detail stipulation of experiment procedure and the testing method. In order to protect staffs and the equipments, establishing detailed experimental procedure and the test method in the electric automobile impact test is extremely essential.In view of electric automobile unique feature and characteristic, in order to conform to the frontage impact test safety performance, it should consider the following several aspects at least regarding the electric automobile structural design:The power cell box arranges as far as possible at the collision vehicles in non-distortion endergonic region, especially the lithium ion battery which is easy detonated or on fire, and should avoid the power battery having the extrusion distortion in the collision;The power cell box fixed way should as far as possible be connected with the automobile body carline and the steady firmware. Monomer battery should be fixed on the independent stable overall frame type structure;The high voltage matchable line should be arranged on non-distortion structure automobile body as far as possible, and strengthening insulation protection of high voltage line is nessesery.Surveying electric resistance and monomer battery voltage in the impact test before and after, which the standard does not request, is a necessary target that understanding the change of power battery in cell box in the experiment.Based on the traditional automobile frontage impact test, revolved the related electric automobile collision standard of security and aimed at questions and electric automobile unique feature and electricity security, that the main research was made in this thesis includes:1) American FMVSS 305 "the electrically operated vehicles: Electrolyte divulging and electric installation collision safety requirements", American SAE J1766: 1998 "Electrically operated and hybrid electrically operated vehicles battery system collision integrity experiment procedure" and the standard specification which has carried on the comparative analysis with China's related standard were studied and has analyzed, some domestic standard existent question and the way to solve it was proposed.2) Detailed analysis to the electric automobile structure and the key component power battery was carried on, and the preliminary study the electric automobile structural arrangement form was conducted as well;3) Based on the traditional automobile frontage impact test procedure and test method research and combined with the electric automobile unique feature and the power battery characteristic, the electric automobile frontage impact test procedure and test method were proposed and established.4) The electric automobile real vehicle impact test has confirmed the electric automobile frontage impact test procedure and the test method validity, and for experiments persons and equipments' safety it has provided the guarantee.5) The electric automobile with reasonable structural design can completely conform to the correlation collision standard of security and provide the passengers security in the collision accident.The test result indicated that: 1) Using this topic disposition of the collision test system and coordinated the electricity security test system and the safe protection procedure, it can definitely complete the existing electric automobile, hybrid electric automobile collision test accord with national standards.2) Before and after the electric automobile impact test, increasing survey of monomer battery voltage and the dielectric resistance and so on two appraisal targets, combining qualitative determination target and the quota target ,are advantageous for the experimental operation and the implementation.3) Through the analysis of electric automobile and the prototype vehicle frontage collision test results, the electric automobile crashworthiness conforms to the national standards completely and can protect the passengers in the vehicles.