Electrically propelled road vehicles — Test specification for electric propulsion components — Part 5: Operating load testing of the motor system

This document specifies operating load tests and test criteria for the motor system designed as a voltage class B electric propulsion system for electrically propelled road vehicles.

Véhicules à propulsion electrique — Spécification d'essai pour les composants de propulsion électrique — Partie 5: Essai de charge de fonctionnement d'un système de moteur

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Published
Publication Date
16-May-2021
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6060 - International Standard published
Start Date
17-May-2021
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17-May-2021
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INTERNATIONAL ISO
STANDARD 21782-5
First edition
2021-05
Electrically propelled road vehicles —
Test specification for electric
propulsion components —
Part 5:
Operating load testing of the motor
system
Véhicules à propulsion electrique — Spécification d'essai pour les
composants de propulsion électrique —
Partie 5: Essai de charge de fonctionnement d'un système de moteur
Reference number
ISO 21782-5:2021(E)
ISO 2021
---------------------- Page: 1 ----------------------
ISO 21782-5:2021(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2021

All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may

be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting

on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address

below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii © ISO 2021 – All rights reserved
---------------------- Page: 2 ----------------------
ISO 21782-5:2021(E)
Contents Page

Foreword ........................................................................................................................................................................................................................................iv

1 Scope ................................................................................................................................................................................................................................. 1

2 Normative references ...................................................................................................................................................................................... 1

3 Terms and definitions ..................................................................................................................................................................................... 1

4 Symbols and abbreviated terms ........................................................................................................................................................... 1

5 Tests and requirements ................................................................................................................................................................................ 1

5.1 Endurance test ........................................................................................................................................................................................ 1

5.1.1 General...................................................................................................................................................................................... 1

5.1.2 Test diagram ........................................................................................................................................................................ 2

5.1.3 Test conditions................................................................................................................................................................... 2

5.1.4 Test procedure ................................................................................................................................................................... 3

5.1.5 Test requirements ........................................................................................................................................................... 5

5.2 Surge voltage measurement test ............................................................................................................................................. 6

5.2.1 General...................................................................................................................................................................................... 6

5.2.2 Test diagram ........................................................................................................................................................................ 6

5.2.3 Test conditions................................................................................................................................................................... 7

5.2.4 Test procedure ................................................................................................................................................................... 8

5.2.5 Test requirements ........................................................................................................................................................... 8

5.3 Over speed test ....................................................................................................................................................................................... 8

5.3.1 General...................................................................................................................................................................................... 8

5.3.2 Test diagram ........................................................................................................................................................................ 8

5.3.3 Test conditions................................................................................................................................................................... 9

5.3.4 Test procedure ................................................................................................................................................................... 9

5.3.5 Test requirements ........................................................................................................................................................... 9

6 Test report ................................................................................................................................................................................................................... 9

Annex A (informative) Methods for determining the rank for over speed test .....................................................10

Annex B (informative) Test report .......................................................................................................................................................................12

© ISO 2021 – All rights reserved iii
---------------------- Page: 3 ----------------------
ISO 21782-5:2021(E)
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards

bodies (ISO member bodies). The work of preparing International Standards is normally carried out

through ISO technical committees. Each member body interested in a subject for which a technical

committee has been established has the right to be represented on that committee. International

organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.

ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of

electrotechnical standardization.

The procedures used to develop this document and those intended for its further maintenance are

described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the

different types of ISO documents should be noted. This document was drafted in accordance with the

editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of

any patent rights identified during the development of the document will be in the Introduction and/or

on the ISO list of patent declarations received (see www .iso .org/ patents).

Any trade name used in this document is information given for the convenience of users and does not

constitute an endorsement.

For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and

expressions related to conformity assessment, as well as information about ISO's adherence to the

World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso .org/

iso/ foreword .html.

This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 37,

Electrically propelled vehicles.
A list of all parts in the ISO 21782 series can be found on the ISO website.

Any feedback or questions on this document should be directed to the user’s national standards body. A

complete listing of these bodies can be found at www .iso .org/ members .html.
iv © ISO 2021 – All rights reserved
---------------------- Page: 4 ----------------------
INTERNATIONAL STANDARD ISO 21782-5:2021(E)
Electrically propelled road vehicles — Test specification
for electric propulsion components —
Part 5:
Operating load testing of the motor system
1 Scope

This document specifies operating load tests and test criteria for the motor system designed as a

voltage class B electric propulsion system for electrically propelled road vehicles.

2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

ISO 21782-1:2019, Electrically propelled road vehicles — Test specification for electric propulsion

components — Part 1: General test conditions and definitions

ISO 21498-1, Electrically propelled road vehicles — Specification of voltage sub-classes for voltage class B

3 Terms and definitions

For the purposes of this document, the terms and definitions given in ISO 21782-1 apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
4 Symbols and abbreviated terms

For the purposes of this document, symbols and abbreviated terms given in ISO 21782-1 apply.

5 Tests and requirements
5.1 Endurance test
5.1.1 General

The purpose of this test is to evaluate and rank the strength for the components – motor shaft key,

rotor fixture, shaft tightening part, stator fixtures, power semiconductor chip, and DC bus capacitor –

which are affected by mechanical or electrical fatigue. The test is set considering repeated operations

at the upper specification limits of the motor system, which operate under the conditions of the paired

inverter and motor combination. Unless otherwise specified, the test method can be decided by the

supplier and customer.
© ISO 2021 – All rights reserved 1
---------------------- Page: 5 ----------------------
ISO 21782-5:2021(E)
5.1.2 Test diagram
The test diagram is shown in Figure 1.
Key
1 DUT
2 motor
3 inverter
4 DC power supply
5 load
6 torque / speed detector
7 power meter
8 torque / speed meter
9 thermo meter
10 inverter output current (in A)
11 motor torque (in Nm)
12 motor speed (in min )
13 measurement points temperatures (in °C)
Figure 1 — Diagram for the endurance test of the motor system
5.1.3 Test conditions
Test conditions are shown in Table 1.
Table 1 — Conditions for endurance test of the motor system
Items Value Remark

Inverter input voltage Rated voltage as defined in ISO 21782- — DC voltage tolerance, see ISO

1:2019, 3.22 21782-1:2019, 5.3
Ambient conditions Room temperature (RT) and humidity as
defined in ISO 21782-1:2019, 5.4

Coolant tem- Liquid Maximum temperature for unlimited operat- — Ethylene glycol and propylene

perature ing capability glycol as example of coolant
Air Maximum temperature for unlimited operat-
ing capability
Coolant flow Liquid Minimum flow rate for unlimited operating
rate capability
Air Minimum flow rate for unlimited operating
capability
2 © ISO 2021 – All rights reserved
---------------------- Page: 6 ----------------------
ISO 21782-5:2021(E)
5.1.4 Test procedure

The test pattern consisting of maximum torque mode and maximum speed mode is shown in Figure 2.

Time parameter t , t and t in Figure 2 shall be as shown in Table 2. The tests shall be conducted by

1 2 3

alternating the maximum torque mode and maximum speed mode as shown in Figure 3 and Table 3.

The tests shall be conducted by repeating the number of cycles according to the corresponding rank

listed in Table 4. The temperature of each part of the motor system shall be controlled so that they are

substantially equal to the saturation temperature.

NOTE To protect torque meter, test can be performed without it, after setting up the maximum torque. In

that case, torque meter can be replaced by power meter to measure motor input currents.

a) maximum torque mode b) maximum speed mode
Key
t time (in s)
n speed (in min )
n rated speed (in min )
n maximum speed (in min )
M torque (in Nm)
M maximum torque of the motor system for duration of t =2 (in Nm)
t=2 0
M calculated torque of the motor system at operating point “c” (in Nm)
s 1 cycle
t , t , t time parameter
1 2 3
Figure 2 — Endurance test pattern for the motor system
Table 2 — Description of time parameter in Figure 2
Time
Requirements and recommendations
parameters
t This shall be reduced to the technically possible minimum.
t This should be shorter than 1 s.
© ISO 2021 – All rights reserved 3
---------------------- Page: 7 ----------------------
ISO 21782-5:2021(E)
Table 2 (continued)
Time
Requirements and recommendations
parameters
t Thi
...

INTERNATIONAL ISO
STANDARD 21782-5
First edition
Electrically propelled road vehicles —
Test specification for electric
propulsion components —
Part 5:
Operating load testing of the motor
system
Véhicules à propulsion electrique — Spécification d'essai pour les
composants de propulsion électrique —
Partie 5: Essai de charge de fonctionnement d'un système de moteur
PROOF/ÉPREUVE
Reference number
ISO 21782-5:2021(E)
ISO 2021
---------------------- Page: 1 ----------------------
ISO 21782-5:2021(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2021

All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may

be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting

on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address

below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: +41 22 749 01 11
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii PROOF/ÉPREUVE © ISO 2021 – All rights reserved
---------------------- Page: 2 ----------------------
ISO 21782-5:2021(E)
Contents Page

Foreword ........................................................................................................................................................................................................................................iv

1 Scope ................................................................................................................................................................................................................................. 1

2 Normative references ...................................................................................................................................................................................... 1

3 Terms and definitions ..................................................................................................................................................................................... 1

4 Symbols and abbreviated terms ........................................................................................................................................................... 1

5 Tests and requirements ................................................................................................................................................................................ 1

5.1 Endurance test ........................................................................................................................................................................................ 1

5.1.1 General...................................................................................................................................................................................... 1

5.1.2 Test diagram ........................................................................................................................................................................ 2

5.1.3 Test conditions................................................................................................................................................................... 2

5.1.4 Test procedure ................................................................................................................................................................... 3

5.1.5 Test requirements ........................................................................................................................................................... 5

5.2 Surge voltage measurement test ............................................................................................................................................. 6

5.2.1 General...................................................................................................................................................................................... 6

5.2.2 Test diagram ........................................................................................................................................................................ 6

5.2.3 Test conditions................................................................................................................................................................... 7

5.2.4 Test procedure ................................................................................................................................................................... 8

5.2.5 Test requirements ........................................................................................................................................................... 8

5.3 Over speed test ....................................................................................................................................................................................... 8

5.3.1 General...................................................................................................................................................................................... 8

5.3.2 Test diagram ........................................................................................................................................................................ 8

5.3.3 Test conditions................................................................................................................................................................... 9

5.3.4 Test procedure ................................................................................................................................................................... 9

5.3.5 Test requirements ........................................................................................................................................................... 9

6 Test report ................................................................................................................................................................................................................... 9

Annex A (informative) Methods for determining the rank for over speed test .....................................................10

Annex B (informative) Test report .......................................................................................................................................................................12

© ISO 2021 – All rights reserved PROOF/ÉPREUVE iii
---------------------- Page: 3 ----------------------
ISO 21782-5:2021(E)
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards

bodies (ISO member bodies). The work of preparing International Standards is normally carried out

through ISO technical committees. Each member body interested in a subject for which a technical

committee has been established has the right to be represented on that committee. International

organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.

ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of

electrotechnical standardization.

The procedures used to develop this document and those intended for its further maintenance are

described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the

different types of ISO documents should be noted. This document was drafted in accordance with the

editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of

any patent rights identified during the development of the document will be in the Introduction and/or

on the ISO list of patent declarations received (see www .iso .org/ patents).

Any trade name used in this document is information given for the convenience of users and does not

constitute an endorsement.

For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and

expressions related to conformity assessment, as well as information about ISO's adherence to the

World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso .org/

iso/ foreword .html.

This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 37,

Electrically propelled vehicles.
A list of all parts in the ISO 21782 series can be found on the ISO website.

Any feedback or questions on this document should be directed to the user’s national standards body. A

complete listing of these bodies can be found at www .iso .org/ members .html.
iv PROOF/ÉPREUVE © ISO 2021 – All rights reserved
---------------------- Page: 4 ----------------------
INTERNATIONAL STANDARD ISO 21782-5:2021(E)
Electrically propelled road vehicles — Test specification
for electric propulsion components —
Part 5:
Operating load testing of the motor system
1 Scope

This document specifies operating load tests and test criteria for the motor system designed as a

voltage class B electric propulsion system for electrically propelled road vehicles.

2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

ISO 21782-1:2019, Electrically propelled road vehicles — Test specification for electric propulsion

components — Part 1: General test conditions and definitions

ISO 21498-1, Electrically propelled road vehicles — Specification of voltage sub-classes for voltage class B

3 Terms and definitions

For the purposes of this document, the terms and definitions given in ISO 21782-1 apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
4 Symbols and abbreviated terms

For the purposes of this document, symbols and abbreviated terms given in ISO 21782-1 apply.

5 Tests and requirements
5.1 Endurance test
5.1.1 General

The purpose of this test is to evaluate and rank the strength for the components – motor shaft key,

rotor fixture, shaft tightening part, stator fixtures, power semiconductor chip, and DC bus capacitor –

which are affected by mechanical or electrical fatigue. The test is set considering repeated operations

at the upper specification limits of the motor system, which operate under the conditions of the paired

inverter and motor combination. Unless otherwise specified, the test method can be decided by the

supplier and customer.
© ISO 2021 – All rights reserved PROOF/ÉPREUVE 1
---------------------- Page: 5 ----------------------
ISO 21782-5:2021(E)
5.1.2 Test diagram
The test diagram is shown in Figure 1.
Key
1 DUT
2 motor
3 inverter
4 DC power supply
5 load
6 torque / speed detector
7 power meter
8 torque / speed meter
9 thermo meter
10 inverter output current (in A)
11 motor torque (in Nm)
12 motor speed (in min )
13 measurement points temperatures (in °C)
Figure 1 — Diagram for the endurance test of the motor system
5.1.3 Test conditions
Test conditions are shown in Table 1.
Table 1 — Conditions for endurance test of the motor system
Items Value Remark

Inverter input voltage Rated voltage as defined in ISO 21782- — DC voltage tolerance, see ISO

1:2019, 3.22 21782-1:2019, 5.3
Ambient conditions Room temperature (RT) and humidity as
defined in ISO 21782-1:2019, 5.4

Coolant tem- Liquid Maximum temperature for unlimited operat- — Ethylene glycol and propylene

perature ing capability glycol as example of coolant
Air Maximum temperature for unlimited operat-
ing capability
Coolant flow Liquid Minimum flow rate for unlimited operating
rate capability
Air Minimum flow rate for unlimited operating
capability
2 PROOF/ÉPREUVE © ISO 2021 – All rights reserved
---------------------- Page: 6 ----------------------
ISO 21782-5:2021(E)
5.1.4 Test procedure

The test pattern consisting of maximum torque mode and maximum speed mode is shown in Figure 2.

Time parameter t , t and t in Figure 2 shall be as shown in Table 2. The tests shall be conducted by

1 2 3

alternating the maximum torque mode and maximum speed mode as shown in Figure 3 and Table 3.

The tests shall be conducted by repeating the number of cycles according to the corresponding rank

listed in Table 4. The temperature of each part of the motor system shall be controlled so that they are

substantially equal to the saturation temperature.

NOTE To protect torque meter, test can be performed without it, after setting up the maximum torque. In

that case, torque meter can be replaced by power meter to measure motor input currents.

a) maximum torque mode b) maximum speed mode
Key
t time (in s)
n speed (in min )
n rated speed (in min )
n maximum speed (in min )
M torque (in Nm)
M maximum torque of the motor system for duration of t =2 (in Nm)
t=2 0
M calculated torque of the motor system at operating point “c” (in Nm)
s 1 cycle
t , t , t time parameter
1 2 3
Figure 2 — Endurance test pattern for the motor system
Table 2 — Description of time parameter in Figure 2
Time
Requirements and recommendations
parameters
t This shall be reduced to the technically possible minimum.
t This should be shorter than 1 s.
© ISO 2021 – All rights reserved PROOF/ÉPREUVE 3
---------------------- Page: 7 ----------------------
ISO 21782-5:2021(E)
Table 2 (continued)
Time
Requirements and recommendations
parameters
t This shall be controlle
...

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