New Energy Bus: Four Safety Assurances for Electrification of CRRC TEV
2016-05-05 Source：www.chinabuses.org
Summarize：The safety quartet for the electrification of CRRC TEV will take away all your worries about electric leakage, catching a fire, fault and operational safety!
www.chinabuses.org: When there is water on the road and you worry that there may be a electric leakage?
Do you worry that your battery may catch a fire under the high temperature in summer?
Do you worry that the motor may have a fault in the rush hour?
How to monitor operational safety?
……
The safety quartet for the electrification of CRRC TEV will take away all your worries!
First Safety Assurance: “Electrical” Safety
Why is it reported in the news that new energy vehicles have spontaneous combustion? The spontaneous combustion of new energy vehicles are usually caused by that of the battery. As the OEM, how to ensure battery safety and prevent the spontaneous combustion of new energy vehicles?
Thus, our first safety assurance –“design”, is very important.
CRRC TEV provides quadruple protection design for battery safety. First one is “insulation monitoring”. The insulation monitoring is like the “firewall” in a computer system, by real-time monitoring of the high-voltage electrical system, if it detects an electrical leakage or a safety hazard of an insulation problem, it will send an alarm alert immediately and even can guide the driver to stop the vehicle for inspection, eliminating the danger at its bud; the second is “fuse design”. When the battery has the danger of high temperature or high voltage, it will automatically disconnect to eliminate the heat source; the third is the smoke detector. It is like a “guard”, which constantly monitors the smoke concentration of important parts e.g. engine compartment and high-voltage electrical system, and if there is a safety hazard, it will automatically send an alarm and the vehicle will automatically stop working; finally, to ensure it is perfectly safe, all vehicles are equipped with a completely intelligent fire extinguishing system. Even if the early warning mechanism fails and the driver deals with the situation improperly, the automatic fire extinguishing system will automatically detect the flames or high temperature of 170℃ and the spout that covers the fire hazard location will automatically spray the fire extinguishing agent so as to 100% ensure the safety of vehicles and personnel.
Design engineers are discussing about the insulation monitor
Meanwhile, in terms of motors and electrical control, thoroughly consider the life cycle and durability. The key components of motors, e.g. bearings and resolvers, all use world-class brands. The motor stators use vacuum impregnation process and choose high temperature resistant materials and permanent magnets, which can resist high temperature up to 180℃ (Level H). The application of equivalent electromagnetic simulation and electromagnetic simulation design ensure the motors will not have an excitation-loss phenomenon. Use high-grade rare earth permanent magnets and patented excitation-loss prevention technology, so the magnetic stability is good. Key components of controllers all have reliability as design principle, fully considering the requirement of special environments like high temperature and vibration of vehicles, the protection class all reaching IP67, which means that the vehicle will have no problem even when immersing in water for 3 meters deep.
Second Safety Assurance: “Test” Safety
The test standards higher than those of the industry are the second safety assurance for creating “unrivaled” new energy vehicles. Completely carry out the tests for the machine and parts of motor controllers, including the following test contents: machine output performance characteristics test, temperature rise test at complex operating conditions, damp heat environment test, salt spray environment test, vibration test, protection performance test, electromagnetic compatibility test, integrated environment vehicle operating test, whole vehicle 100,000km operating condition simulation test, etc. For example, for the vehicle braking performance involving safety, we arrange to introduce “Vehicle integrated performance test table” from the United States, so as to make each product all get tested by the international standard and achieve perfect braking performance.
Besides the tests higher than industrial standards, there are stricter road tests, such as strengthened road test, fuel consumption test, road test with standard higher than that of bus road. Before leaving the factory, each vehicle has to go through road test for almost 40 km, which is rare in the industry.
Vehicle Comprehensive Performance Test Platform
Third Safety Assurance: “Manufacturing” Safety
MES System
During the manufacturing process of vehicles, many key points support the vehicle safety performance. For example, a strong vehicle frame not only need first-class profile, but also need more excellent welding techniques. Flexible fixtures, high quality welding equipment like fully automatic combined assembly machine, plus a large number of international welding personnel, make CRRC TEV pass the international welding quality certification – ISO3834 standard, and CRRC TEV become the only one passing this certification in the bus industry. This certification is for the railway and high-speed trains and it is not a compulsory requirement for the bus industry. Digital lean workshop has MES (i.e. manufacturing execution systems for manufacturing companies, a set of production information management system for the workshop execution level of manufacturing companies) as support. “By using RFID (Radio-frequency identification) technology, we realize the “all-purpose card” for the whole process of product tracking, material distribution and process inspection, improving the speed and accuracy of information transmission.” The manager of the operation management department, Chen Longfu gives such an actual example: during the assembly process, there may be wiring mistakes, which is directly related to the electrical safety of the vehicle. By product tracking and monitoring and system error information output, wee can timely correct errors and avoid electrical safety problems. The CRRC TEV “Digital Lean Factory Construction” project with MES as core, won the first prize for management and innovation in Hunan province in 2013 and 2015.
First Flexible Solder Mask Production Line in the Industry
Fourth Safety Assurance: “Cloud” Safety
Try to think, if there is a device that can monitor the all the key parts of vehicles and in case of vehicle having safety hazard, can timely send feedback to the driver and after-sales personnel, then the danger can be reduced to the minimum. CRRC TEV new energy vehicles have this device – “ Yuzhitong (literally translated as Cloud Intelligence Pass)”. “Yunzhitong” is a system platform for remotely monitoring the vehicle operation status with the help of the Internet. If any part of the vehicle body has a problem, the system will immediately trigger an alarm and send the feedback information to the APP terminals of drivers and after-sales personnel, and the after-sales personnel will arrive at site right away. “Yunzhitong” can also realize big data analysis, which plays an important part for the long-term maintenance and care of vehicles.
After you have listened to the four safety assurances, are you more interested in CRRC TEV? Vehicle safety is above all others. While bringing environmentally friendly and green traffic, CRRC TEV will continue to consider vehicle safety as the core standard, making every passenger ride comfortably and safety without any worry.
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