‘ANNEX Xb

CERTIFICATION OF ELECTRIC POWERTRAIN COMPONENTS

1. Introduction

The component test procedures described in this Annex shall produce input data relating to electric machine systems, IEPC, IHPC Type 1, battery systems and capacitor systems for the simulation tool.

2. Definitions and abbreviations

For the purposes of this Annex, the following definitions shall apply:

(1) “battery control unit” or “BCU” means an electronic device that controls, manages, detects or calculates electric and thermal functions of the battery system and that provides communication between the battery system or battery pack or part of a battery pack and other vehicle controllers.

(2) “battery pack” means a REESS (rechargeable electric energy storage system) that includes secondary cells or secondary cell assemblies, which are normally connected with cell electronics, power supply circuits and overcurrent shut-off device, including electrical interconnections and interfaces for external systems (examples of external systems are systems intended for thermal conditioning, high voltage and low voltage auxiliary and communication).

(3) “battery system” means a REESS that consists of secondary cell assemblies or battery pack(s) as well as electrical circuits, electronics, interfaces for external systems (e.g. thermal conditioning system), BCUs and contactors.

(4) “representative battery subsystem” means a subsystem of a battery system that consists of either secondary cell assemblies or battery pack(s) in serial and/or parallel configuration with electrical circuits, thermal conditioning system interfaces, control units and cell electronics.

(5) “cell” means a basic functional unit of a battery, consisting of an assembly of electrodes, electrolyte, container, terminals and usually separators, that is a source of electric energy obtained by direct conversion of chemical energy.

(6) “cell electronics” means an electronic device that collects and possibly monitors thermal or electric data of cells or cell assemblies or capacitors or capacitor assemblies and contains electronics for balancing between cells or capacitors, if necessary.

(7) “secondary cell” means a cell which is designed to be electrically recharged by way of a reversible chemical reaction.

(8) “capacitor” means a device for storage of electrical energy achieved by the effects of electrostatic double-layer capacitance and electrochemical pseudo capacitance in an electrochemical cell.

(9) “capacitor cell” means a basic functional unit of a capacitor, consisting of an assembly of electrodes, electrolyte, container, terminals and usually separators.

(10) “capacitor control unit” or “CCU” means an electronic device that controls, manages, detects or calculates electric and thermal functions of the capacitor system and that provides communication between the capacitor system or capacitor pack or part of a capacitor pack and other vehicle controllers.

(11) “capacitor pack” means a REESS that includes capacitor cells or capacitor assemblies normally connected with capacitor cell electronics, power supply circuits and overcurrent shut-off device, including electrical interconnections, interfaces for external systems and CCU. Examples of external systems are thermal conditioning, high voltage and low voltage auxiliary and communication.

(12) “capacitor system” means a REESS that includes capacitor cells or capacitor assemblies or capacitor pack(s) as well as electrical circuits, electronics, interfaces for external systems (e.g. thermal conditioning system), CCU and contactors.

(13) “representative capacitor subsystem” means a subsystem of a capacitor system that consists of either capacitor assemblies or capacitor pack(s) in serial and/or parallel configuration with electrical circuits, thermal conditioning system interfaces, control units and capacitor cell electronics.

(14) “nC” means the current rate equal to n times the one hour discharge capacity expressed in ampere (i.e. current that takes 1/n hours to fully charge or discharge the tested device based on the rated capacity).

(15) “continuously variable transmission” or “CVT” means an automatic transmission that can change seamlessly through a continuous range of gear ratios.

(16) “differential” means a device that splits a torque into two branches, e.g., for left- and right-hand side wheels, while allowing these branches to rotate at unequal speeds. The torque-splitting function can be biased or deactivated by a differential brake- or differential lock device (if applicable).

(17) “differential gear ratio” means the ratio of differential input speed (towards the primary propulsion energy converter) over differential output speed (towards driven wheels) with both differential output shafts running at the same speed.

(18) “drivetrain” means the connected elements of the powertrain for transmission of the mechanical energy between the propulsion energy converter(s) and the wheels.

(19) “electric machine” (EM) means an energy converter transforming between electrical and mechanical energy.

(20) “electric machine system” means a combination of electric powertrain components as installed in the vehicle comprising of an electric machine, inverter and electronic control unit(s), including connections and interfaces for external systems

(21) “electric machine type” is either (a) an asynchronous machine (ASM), (b) an excited synchronous machine (ESM), (c) a permanent magnet synchronous machine (PSM), or (d) a reluctance machine (RM).

(22) “ASM” means an asynchronous electric machine type in which the electric current in the rotor needed to produce torque is obtained by electromagnetic induction from the magnetic field of the stator winding.

(23) “ESM” means an excited synchronous electric machine type which contains multiphase AC electromagnets on the stator that create a magnetic field which rotates in time with the oscillations of the line current. It requires direct current supplied to the rotor for excitation.

(24) “PSM” means a permanent magnet sychronous electric machine type which contains multiphase AC electromagnets on the stator that create a magnetic field which rotates in time with the oscillations of the line current. Permanent magnets embedded in the steel rotor create a constant magnetic field.

(25) “RM” means a reluctance electric machine type which contains multiphase AC electromagnets on the stator that create a magnetic field which rotates in time with the oscillations of the line current. It induces non-permanent magnetic poles on the ferromagnetic rotor which does not have any windings. It generates torque through magnetic reluctance.

(26) “housing” means an integrated and structural part of the component, enclosing the internal units and providing protection against direct contact from any direction of access.

(27) “energy converter” means a system where the form of energy output is different from the form of energy input.

(28) “propulsion energy converter” means an energy converter of the powertrain which is not a peripheral device whose output energy is used directly or indirectly for the purpose of vehicle propulsion.

(29) “category of propulsion energy converter” means (i) an internal combustion engine, (ii) an electric machine, or (iii) a fuel cell.

(30) “energy storage system” means a system which stores energy and releases it in the same form as the input energy.

(31) “propulsion energy storage system” means an energy storage system of the powertrain which is not a peripheral device and whose output energy is used directly or indirectly for the purpose of vehicle propulsion.

(32) “category of propulsion energy storage system” means (i) a fuel storage system, (ii) a rechargeable electric energy storage system (REESS), or (iii) a rechargeable mechanical energy storage system.

(33) “form of energy” means (i) electrical energy, (ii) mechanical energy, or (iii) chemical energy (including fuels).

(34) “fuel storage system” means a propulsion energy storage system that stores chemical energy as liquid or gaseous fuel.

(35) “gearbox” means a device changing torque and speed with defined fixed ratios for each gear which may include the functionality of shiftable gears as well

(36) “gear number” means an identifier for the different shiftable gears for forward direction in a transmission with specific gear ratios; the shiftable gear with the highest gear ratio gets assigned the number 1; the identifying number is increased by the increment of 1 for each gear in descending order of gear ratios.

(37) “gear ratio” means the forward gear ratio of the speed of the input shaft (towards the primary propulsion energy converter) to the speed of the output shaft (towards driven wheels) without slip.

(38) “high-energy battery system” or “HEBS” means a battery system or representative battery subsystem, for which the numerical ratio between maximum discharge current in A, declared by the component manufacturer at a SOC of 50 % in accordance with point 5.4.2.3.2, and the nominal electric charge output in Ah at a 1C discharge rate at RT is lower than 10.

(39) “high-power battery system” or “HPBS” means a battery system or representative battery subsystem, for which the numerical ratio between maximum discharge current in A, declared by the component manufacturer at a SOC of 50 % in accordance with point 5.4.2.3.2, and the nominal electric charge output in Ah at a 1C discharge rate at RT is equal to or higher than 10.

(40) “integrated electric powertrain component” or “IEPC” means a combined system of an electric machine system together with the functionality of either a single- or multi-speed gearbox or a differential or both, characterised by at least one of the following features: — shared housing of at least two components — shared lubrication circuit of at least two components — shared cooling circuit of at least two components — shared electric connection of at least two components Additionally, an IEPC shall comply with the following criteria: — It shall have only output shaft(s) towards the driven wheels of the vehicle and shall have no input shaft(s) for feeding propulsion torque into the system. — In the case of more than one electric machine system being part of the IEPC, all electric machines shall be connected to a single DC power source for all test runs performed in accordance with this Annex. — In the case of the functionality of a multi-speed gearbox being included, there shall be only discrete gear steps.

(41) “IEPC design type wheel motor” means an IEPC with either one output shaft or two output shafts connected directly to the wheel hub(s) and where two configurations shall be distinguished for the purpose of this Annex: — Configuration “L”: In the case of one output shaft, the same component is installed twice in symmetrical application (i.e. one on the left and one on the right side of the vehicle at the same wheel position in longitudinal direction). — Configuration “T”: In the case of two output shafts, only a single component is installed with one output shaft connected to the left and the other output shaft connected to the right side of the vehicle at the same wheel position in longitudinal direction.

(42) “integrated hybrid electric vehicle powertrain component type 1” or “IHPC Type 1” means a combined system of multiple electric machine systems together with the functionality of a multi-speed gearbox characterised by a shared housing of all components and at least one of the following features: — shared lubrication circuit of at least two components — shared cooling circuit of at least two components — shared electric connection of at least two components Additionally, an IHPC Type 1 shall comply with the following criteria: — It shall have only one input shaft for feeding propulsion torque into the system and only one output shaft towards the driven wheels of the vehicle. — Only discrete gear steps shall be used for all test runs performed in accordance with this Annex. — It shall enable operation of the powertrain as parallel hybrid (at least in one specific mode used for all test runs performed in accordance with this Annex). — It shall be able to be tested in the transmission test in accordance with Annex VI with the electric power supply disconnected in accordance with subpoint (b) of point 4.4.1.2. — All electric machines shall be connected to a single DC power source for all test runs performed in accordance with this Annex. — The gearbox part within the IHPC Type 1 shall not be operated as CVT for all test runs performed in accordance with this Annex. — A hydrodynamic torque converter shall not be part of the IHPC Type 1.

(43) “internal combustion engine” or “ICE” means an energy converter with intermittent or continuous oxidation of combustible fuel transforming between chemical and mechanical energy.

(44) “inverter” means an electric energy converter that changes direct electric current to single-phase or polyphase alternating electric currents

(45) “peripheral device” means any energy consuming, converting, storing or supplying devices, where the energy is not directly or indirectly used for the purpose of vehicle propulsion but which are essential to the operation of the powertrain and are therefore considered to be part of the powertrain.

(46) “powertrain” means the total combination in a vehicle of propulsion energy storage system(s), propulsion energy converter(s) and the drivetrain(s) providing the mechanical energy at the wheels for the purpose of vehicle propulsion, plus peripheral devices.

(47) “rated capacity” means the total number of ampere-hours that can be withdrawn from a fully charged battery determined in accordance with point 5.4.1.3

(48) “rated speed” means the highest rotational speed of the electric machine system where the overall maximum torque occurs

(49) “room temperature” or “RT” means that the ambient air inside the test cell shall have a temperature of (25 ± 10) °C

(50) “state of charge” or “SOC” means the available electrical charge stored in a battery system expressed as a percentage of its rated capacity in accordance with 5.4.1.3 (where 0 % represents empty and 100 % represents full)

(51) “unit under test” or “UUT” means the electric machine system, IEPC or IHPC Type 1 to be actually tested

(52) “battery UUT” means the battery system or representative battery subsystem to be actually tested

(53) “capacitor UUT” means the capacitor system or representative capacitor subsystem to be actually tested.

For the purposes of this Annex, the following abbreviations shall apply:

AC alternating current DC direct current DCIR direct current internal resistance EMS electric machine system OCV open circuit voltage SC standard cycle

3. General requirements

The calibration laboratory facilities shall comply with the requirements of either IATF 16949, ISO 9000 series or ISO/IEC 17025. All laboratory reference measurement equipment, used for calibration and/or verification, shall be traceable to national or international standards.

3.1 Measurement equipment specifications

The measurement equipment shall meet the following accuracy requirements:

Table 1

Requirements of measurement systems

Measurement system Accuracy (1) Rotational speed 0,5 % of the analyser reading or 0,1 % of max. calibration (2) of rotational speed whichever is larger Torque 0,6 % of the analyser reading or 0,3 % of max. calibration (2) or 0,5 Nm of torque whichever is larger Current 0,5 % of the analyser reading or 0,25 % of max. calibration (2) or 0,5 A of current whichever is larger Voltage 0,5 % of the analyser reading or 0,25 % of max. calibration (2) of voltage whichever is larger Temperature 1,5 K

Multi-point calibration shall be allowed which means that a measurement system is allowed to be calibrated up to a nominal value which is less than the capacity of the measurement system.

3.2 Data recording

All measurement data, except temperature, shall be measured with and recorded at a frequency of not less than 100 Hz. For temperature a measurement frequency of not less than 10 Hz is sufficient.

Signal filtering may be applied in agreement with the approval authority. Any aliasing effect shall be avoided.

4. Testing of electric machine systems, IEPCs and IHPCs Type 1

4.1 Test conditions

The UUT shall be installed and the measurands current, voltage, electric inverter power, rotational speed and torque shall be defined in accordance with Figure 1 and point 4.1.1.

Figure 1

Provisions for measurement of electric machine system or IEPC

4.1.1 Equations for power figures

Power figures shall be calculated in accordance with the following equations:

4.1.1.1 Inverter power

The electric power to or from the inverter (or DC/DC converter if applicable) shall be calculated in accordance with the following equation:

PINV_in = VINV_in × IINV_in

where:

PINV_in is the electric inverter power to or from the inverter (or DC/DC converter if applicable) on the DC side of the inverter (or on the side of the DC powersource of the DC/DC converter) [W] VINV_in is the voltage at the inverter (or DC/DC converter if applicable) input on the DC side of the inverter (or on the side of the DC powersource of the DC/DC converter) [V] IINV_in is the current at the inverter (or DC/DC converter if applicable) input on the DC side of the inverter (or on the side of the DC powersource of the DC/DC converter) [A]

In the case of multiple connections of inverter(s) (or DC/DC converter(s) if applicable) to the electric DC powersource as defined in accordance with point 4.1.3, the total sum of all different electric inverter powers shall be measured.

4.1.1.2 Mechanical output power

The mechanical output power of the UUT shall be calculated in accordance with the following equation:

where

PUUT_out is the mechanical output power of the UUT [W] TUUT is the torque of the UUT [Nm] n is the rotational speed of the UUT [min–1]

For an electric machine system the torque and speed shall be measured at the rotational shaft. For an IEPC the torque and speed shall be measured at the output side of the gearbox or, if a differential is also included, at the output side(s) of the differential.

For an IEPC with integrated differential, the output torque measuring device(s) can either be installed on both output sides, or only one of the output sides. For test setups with only one dynamometer on the output side, the free rotating end of the IEPC with integrated differential shall be rotatably locked to the other end on the output side (e.g., by an activated differential lock or by means of any other mechanical differential lock implemented only for the measurement).

In the case of an IEPC design type wheel motor, either one single component or two such components may be measured. Where two such components are measured, the following provisions shall apply, depending on the configuration:

— For configuration “L” torque and speed shall be measured at the output side of the gearbox. In this case the input parameter “NrOfDesignTypeWheelMotorMeasured” shall be set to 1.

— For configuration “T”, the output torque measuring device(s) can either be installed on both output shafts or only on one of the output shafts. (a) Where the output torque measuring devices are installed on both output shafts, the following provisions shall apply: — The torque values of both output shafts shall be summed up virtually in the test bench data processing or the data post-processing. — The speed values of both output shafts shall be averaged virtually in the test bench data processing or post-processing. — In this case the input parameter “NrOfDesignTypeWheelMotorMeasured” shall be set to 2. (b) Where an output torque measuring device is installed only on one of the output shafts, the following provisions shall apply: — Torque and speed are measured at the output side of the gearbox. — In this case the input parameter “NrOfDesignTypeWheelMotorMeasured” shall be set to 1.

4.1.2 Run-in

On request of the applicant a run-in procedure may be applied to the UUT. The following provisions shall apply for a run-in procedure:

— The total run-time for the optional run-in and the measurement of an UUT (except wheel-ends) shall not exceed 120 hours.

— Only factory fill oil shall be used for the run-in procedure. The oil used for the run-in may also be used for the testing performed in accordance with point 4.2.

— The speed and torque profile for the run-in procedure shall be specified by the component manufacturer.

— The run-in procedure shall be documented by the component manufacturer with regard to run-time, speed, torque and oil temperature and reported to the approval authority.

— The requirements for the oil temperature (point 4.1.8.1), measurement accuracy (point 3.1) and test setup (points 4.1.3 to 4.1.7) shall not apply for the run-in procedure.

4.1.3 Power supply to inverter

The power supply to the inverter (or DC/DC converter if applicable) shall be a direct-current constant-voltage power supply, which is capable of supplying/absorbing adequate electric power to/from the inverter (or DC/DC converter if applicable) at the maximum (mechanical or electrical) power of the UUT for the duration of the test runs specified in this Annex.

The DC input voltage to the inverter (or DC/DC converter if applicable) shall be in a range of ±2 % of the requested target value of DC input voltage to the UUT during all periods where actual measurement data is recorded that is used as a basis for determining input data for the simulation tool.

Table 2 in paragraph 4.2 defines which test runs shall be performed at which voltage level(s). There are 2 different voltage levels defined for the measurements to be performed:

— Vmin,Test shall be the target value of the DC input voltage to the UUT corresponding to the minimum voltage for unlimited operating capability.

— Vmax,Test shall be the target value of the DC input voltage to the UUT corresponding to the maximum voltage for unlimited operating capability.

4.1.4 Setup and wiring

All wiring, shielding, brackets, etc. shall be in accordance with conditions specified by the manufacturer(s) of the different components of the UUT.

4.1.5 Cooling system

The temperature of all parts of the electric machine system shall be within the range allowed by the component manufacturer during the whole operating time of all test runs performed in accordance with this Annex. For IEPC and IHPC Type 1 this includes also all other components as gearboxes and axles being part of the IEPC or IHPC Type 1.

4.1.5.1 Cooling power during test runs

4.1.5.1.1 Cooling power for measurement of torque limitations

For all test runs performed in accordance with point 4.2, except for the EPMC in accordance with paragraph 4.2.6, the component manufacturer has to declare the number of used cooling circuits with connection to an external heat exchanger. For each of these circuits with connection to an external heat exchanger the following parameters at the inlet of the respective cooling circuit of the UUT shall be declared:

— the maximum coolant mass flow or maximum inlet pressure as specified by the component manufacturer

— the admitted maximum coolant temperatures as specified by the component manufacturer

— maximum available cooling power on the testbench

These declared values shall be documented in the information document for the respective component.

The following actual values shall remain below the declared maximum values and be recorded for each cooling circuit with connection to an external heat exchanger, together with the test data for all different test runs performed in accordance with point 4.2 except for the EPMC in accordance with point 4.2.6:

— coolant volume flow or mass flow

— coolant temperature at the inlet of the cooling circuit of the UUT

— coolant temperature at the inlet and outlet of the test bed heat exchanger on the side of the UUT

For all test runs performed in accordance with point 4.2, the minimum temperature of the coolant at the inlet of the cooling circuit of the UUT, in the case of liquid cooling shall be 25 °C.

Where fluids other than the regular cooling fluids are used for testing in accordance with this Annex, they must not exceed the temperature limits as defined by the component manufacturer.

In the case of liquid cooling, the maximum available cooling power on the testbench shall be determined based on the coolant massflow, the temperature difference over the test bed heat exchanger on the side of the UUT and the specific heat capacity of the coolant.

No additional fan with the purpose of actively cooling the components of the UUT shall be allowed in the test setup.

4.1.6 Inverter

The inverter shall be operated in the same mode and settings as specified for the actual in-vehicle using conditions by the component manufacturer.

4.1.7 Ambient conditions in test cell

All tests shall be performed at an ambient temperature in the testcell of 25 ± 10 °C. The ambient temperature shall be measured within a distance of 1 m to the UUT.

4.1.8 Lubricating oil for IEPCs or IHPC Type 1

Lubricating oil shall fulfill the provisions defined in points 4.1.8.1 to 4.1.8.4 below. These provisions shall not apply to EM systems.

4.1.8.1 Oil temperatures

The oil temperatures shall be measured at the centre of the oil sump or at any other suitable point in accordance with good engineering practice.

An auxiliary regulating system in accordance with paragraph 4.1.8.4 may be used, if necessary, to maintain the temperatures within the specified limits by the component manufacturer.

In the case of external oil conditioning which is added for testing purposes only, the oil temperature may be measured in the outlet line from the housing of the UUT to the conditioning system within 5 cm downstream of the outlet. In both cases the oil temperature shall not exceed the temperature limit as specified by the component manufacturer. Solid engineering rationale shall be provided to the type approval authority to explain that the external oil conditioning system is not used to improve the efficiency of the UUT. For oil circuits which are neither part of, nor connected to the cooling circuit of any components of the electric machine system, the temperature shall not exceed 70 °C.

4.1.8.2 Oil quality

Only recommended factory fill oils as specified by the component manufacturer of the UUT shall be used for the measurement.

4.1.8.3 Oil viscosity

If different oils are specified for the factory fill, the component manufacturer shall choose an oil for which the kinematic viscosity (KV) at the same temperature is within a range of ±10 % of the kinematic viscosity of the oil with the highest viscosity (within the specified tolerance band for KV100) for performing the measurements of the UUT related to certification.

4.1.8.4 Oil level and conditioning

The oil level or filling volume shall be within the maximum and minimum levels as defined in the component manufacturer’s maintenance specifications.

An external oil conditioning and filtering system is permitted. The housing of the UUT may be modified for the inclusion of the oil conditioning system.

The oil conditioning system shall not be installed in a way which would enable changing oil levels of the UUT in order to raise efficiency or to generate propulsion torques in accordance with good engineering practice.

4.1.9 Sign conventions

4.1.9.1 Torque and power

Measured values of torque and power shall have a positive sign for the UUT driving the dyno and a negative sign for the UUT braking the dyno (i.e. dyno driving the UUT).

4.1.9.2 Current

Measured values of current shall have a positive sign for the UUT drawing electric power from the power supply to the inverter (or DC/DC converter if applicable) and a negative sign for the UUT delivering electric power to the inverter (or DC/DC converter if applicable) and to the power supply.

4.2 Test runs to be performed

Table 2 defines all test runs to be performed for the purpose of certification of one specific electric machine system family or IEPC family defined in accordance with Appendix 13.

The electric power mapping cycle (EPMC) in accordance with point 4.2.6 and the drag curve in accordance with point 4.2.3 shall be omitted for all other members within a family except the parent of the family.

Where, upon request of the component manufacturer, Article 15(5) of this Regulation is applied, the EPMC in accordance with point 4.2.6 and the drag curve in accordance with point 4.2.3 shall be performed additionally for that specific EM or IEPC.

Table 2

Overview of test runs to be performed for electric machine systems or IEPCs

Test run Reference to point Required voltage level(s) to be performed (in accordance with 4.1.3) Required to be run for parent Required to be run for other members within a family Maximum and minimum torque limits 4.2.2 Vmin,Test and Vmax,Test yes yes Drag curve 4.2.3 Either Vmin,Test or Vmax,Test yes no Maximum 30 minutes continuous torque 4.2.4 Vmin,Test and Vmax,Test yes yes Overload characteristics 4.2.5 Vmin,Test and Vmax,Test yes yes EPMC 4.2.6 Vmin,Test and Vmax,Test yes no

4.2.1 General provisions

The measurement shall be performed with all temperatures of the UUT during the test kept within the component manufacturer defined limit values.

All tests need to be performed with de-rating functionality depending on temperature limits of the electric machine system fully active. Where additional parameters of other systems located outside of the electric machine system’s boundaries do influence the de-rating behaviour in in-vehicle applications, these additional parameters shall not be taken into account for all test runs performed in accordance with this Annex.

For an electric machine system all torque and speed values indicated shall refer to the rotational shaft of the electric machine unless stated otherwise.

For an IEPC all torque and speed values indicated shall refer to the output side of the gearbox or, if a differential is also included, to the output side of the differential unless stated otherwise.

4.2.2 Test of maximum and minimum torque limits

The test measures the maximum and minimum torque characteristics of the UUT in order to verify the declared limitations of the system.

For IEPC with multispeed gearbox the test shall be performed only for the gear with the gear ratio closest to 1. Where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios.

4.2.2.1 Declaration of values by the component manufacturer

The component manufacturer shall declare the values for the maximum and minimum torque of the UUT as a function of the rotational speed of the UUT between 0 rpm and the maximum operating speed of the UUT prior to the test. This declaration shall be separately made for each of the two voltage levels Vmin,Test and Vmax,Test.

4.2.2.2 Verification of maximum torque limits

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 ± 10 °C for a minimum of two hours until the start of the test run. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of two hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ± 10 °C.

Just before beginning the test, the UUT shall be run on the bench for three minutes delivering a power equal to 80 % of the maximum power at the speed recommended by the component manufacturer.

The output torque and rotational speed of the UUT shall be measured at at least 10 different rotational speeds to define correctly the maximum torque curve between lowest and the highest speed.

The lowest speed setpoint shall be specified by the component manufacturer at a speed equal or smaller than 2 % of the maximum operating speed of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1. Where the test setup does not allow operating the system at such a low speed setpoint, the lowest speed setpoint shall be specified by the component manufacturer as the lowest speed which can be realised by the specific test setup.

The highest speed setpoint shall be defined by the maximum operating speed of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1.

The remaining 8 or more different rotational speed setpoints shall be located between the lowest and highest speed setpoint and shall be specified by the component manufacturer. The interval between two adjacent speed setpoints shall not be larger than 15 % of the maximum operating speed of the UUT as declared by the component manufacturer.

All operating points shall be held for an operating time of at least 3 seconds. Output torque and rotational speed of the UUT shall be recorded as average value of the last second of the measurement. The whole test shall be completed within 5 minutes.

4.2.2.3 Verification of minimum torque limits

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 ±10 °C for a minimum of two hours until the start of the test run. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of two hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ±10 °C.

Just before beginning the test, the UUT shall be run on the bench for three minutes delivering a power equal to 80 % of the maximum power at the speed recommended by the component manufacturer.

The output torque and rotational speed of the UUT shall be measured at the same rotational speeds as selected in point 4.2.2.2.

All operating points shall be held for an operating time of at least 3 seconds. Output torque and rotational speed of the UUT shall be recorded as average value of the last second of the measurement. The whole test shall be completed within 5 minutes.

4.2.2.4 Interpretation of results

The maximum torque of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1 shall be accepted as final values if they are not higher than + 2 % for overall maximum torque and than +4 % at the other measurement points with a tolerance of ± 2 % for rotational speeds from the values measured in accordance with point 4.2.2.2.

Where the values for maximum torque declared by the component manufacturer exceed the limits defined above, the actual measured values shall be used as final values.

Where the values for maximum torque of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1 are lower than the values measured in accordance with point 4.2.2.2, the values declared by the component manufacturer shall be used as final values.

The minimum torque of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1 shall be accepted as final values if they are not lower than -2 % for overall minimum torque and than – 4% at the other measurement points with a tolerance of ±2 % for rotational speeds from the values measured in accordance with point 4.2.2.3.

Where the values for minimum torque declared by the component manufacturer exceed the limits defined above, the actual measured values shall be used as final values.

Where the values for minimum torque of the UUT as declared by the component manufacturer in accordance with point 4.2.2.1 are higher than the values measured in accordance with point 4.2.2.3, the values declared by the component manufacturer shall be used as final values.

4.2.3 Test of drag curve

The test measures the drag losses in the UUT, i.e. the mechanical and/or electrical power necessary to spin the system at a certain speed by external power sources.

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 ±10 °C for a minimum of two hours. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of two hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ±10 °C.

Just before beginning of the actual test, the UUT may optionally be run on the bench for three minutes delivering a power equal to 80 % of the maximum power at the speed recommended by the component manufacturer.

The actual test shall be performed in accordance with one of the following options:

— Option A: The output shaft of the UUT shall be connected to a load machine (i.e. dynamometer) and the load machine (i.e. dynamometer) shall be driving the UUT at the target rotational speed. Either the electric power supply to the inverter (or DC/DC converter if applicable) or the AC phase cables between the electric machine and inverter may be set inactive or disconnected.

— Option B: The output shaft of the UUT shall not be connected to a load machine (i.e. dynamometer) and the UUT shall be operated at the target rotational speed by electric power supplied to the inverter (or DC/DC converter if applicable).

— Option C: The output shaft of the UUT shall be connected to a load machine (i.e. dynamometer) and the UUT shall be operated at the target rotational speed either by the load machine (i.e. dynamometer) or the electric power supplied to the inverter (or DC/DC converter if applicable) or a combination of both

The test shall be performed at least at the same rotational speeds as selected in point 4.2.2.2, more operating points at other rotational speeds may be added. All operating points shall be held for an operating time of at least 10 seconds, during which the actual rotational speed of the UUT shall be within ± 2 % of the setpoint for rotational speed.

The following values shall be recorded as average value over the last 5 seconds of the measurement, depending on the chosen testing option:

— For option B and C above: electric power to the inverter (or DC/DC converter if applicable)

— For option A and C above: the torque of the load machine (i.e. dynamometer) applied to the output shaft(s) of the UUT

— For all options: the rotational speed of the UUT

Where the UUT is an IEPC with multispeed gearbox, the test shall be performed for the gear with the gear ratio closest to 1. Where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios.

Additionally, the test may be performed also for all other forward gears of the IEPC so that a dedicated dataset for each forward gear of the IEPC is determined.

4.2.4 Test of maximum 30 minutes continuous torque

The test measures the maximum 30 minutes continuous torque which can be achieved by the UUT on average over a duration of 1 800 seconds.

For IEPC with multispeed gearbox the test shall be performed only for the gear with the gear ratio closest to 1. Where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios.

4.2.4.1 Declaration of values by the component manufacturer

The component manufacturer shall declare the values for the maximum 30 minutes continuous torque of the UUT as well as the corresponding rotational speed prior to the test. The rotational speed shall be in a range, in which the mechanical power is greater than 90 % of the overall maximum power determined from the maximum torque limit data recorded in accordance with point 4.2.2 for the respective voltage level. This declaration shall be separately made for each of the two voltage levels Vmin,Test and Vmax,Test.

4.2.4.2 Verification of maximum 30 minutes continuous torque

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 ±10 °C for a minimum of four hours. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of four hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ±10 °C.

The UUT shall be run at the torque and speed setpoint which corresponds to the maximum 30 minutes continuous torque declared by the component manufacturer in accordance with point 4.2.4.1 for a total period of 1 800 seconds.

The output torque and rotational speed of the UUT as well as the electric power to or from the inverter (or DC/DC converter if applicable) shall be measured over this period of 1 800 seconds. The mechanical power value measured over time shall be in a range of ±5 % of the mechanical power value declared by the component manufacturer in accordance with paragraph 4.2.4.1, the rotational speed shall be within ±2 % of the value declared by the component manufacturer in accordance with point 4.2.4.1. The maximum 30 minutes continuous torque is the average of the output torque within the 1 800-second measurement period. The corresponding rotational speed is the average of the rotational speed within the 1 800-second measurement period.

4.2.4.3 Interpretation of results

The values declared by the component manufacturer in accordance with point 4.2.4.1 shall be accepted as final values if they do not differ by more than +4 % for torque with a tolerance of ±2 % for rotational speed from the average values determined in accordance with point 4.2.4.2.

Where the values declared by the component manufacturer exceed the limits defined above, the requirements referred to in points 4.2.4.1 to 4.2.4.3 shall be repeated with different values for the maximum 30 minutes continuous torque and/or the corresponding rotational speed.

Where the value for torque declared by the component manufacturer in accordance with point 4.2.4.1 is lower than the average value for torque determined in accordance with point 4.2.4.2 with a tolerance of ±2 % for rotational speed, the values declared by the component manufacturer shall be used as final values.

Additionally, the average of the actual measured electric power to or from the inverter (or DC/DC converter if applicable) over the 1 800-second measurement period shall be calculated. Also the average 30 minutes continuous power shall be calculated from the final values of maximum 30 minutes continuous torque and the corresponding average rotational speed.

4.2.5 Test of overload characteristics

The test measures the duration of the capability of the UUT to provide the maximum output torque in order to derive the overload characteristics of the system.

For IEPC with multispeed gearbox the test shall be performed only for the gear with the gear ratio closest to 1. Where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios.

4.2.5.1 Declaration of values by the component manufacturer

The component manufacturer shall declare the value for the maximum output torque of the UUT at the specific rotational speed chosen for the test as well as the corresponding rotational speed prior to the test. The corresponding rotational speed shall be the same speed setpoint as used for the measurement performed in accordance with point 4.2.4.2 for the respective voltage level. The declared value for the maximum output torque of the UUT shall be equal or greater than the value of the maximum 30 minutes continuous torque determined in accordance with point 4.2.4.3 for the respective voltage level.

In addition the component manufacturer shall declare a duration t0_maxP for which the maximum output torque of the UUT can be constantly achieved starting from the conditions as set out in point 4.2.5.2. This declaration shall be separately made for each of the two voltage levels Vmin,Test and Vmax,Test.

4.2.5.2 Verification of maximum output torque

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 °C ± 10 °C for a minimum of two hours. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of two hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ±10 °C.

Just before beginning the test, the UUT shall be run on the bench for 30 minutes delivering 50 % of the maximum 30 minutes continuous torque at the respective speed setpoint as determined in accordance with point 4.2.4.3.

Then the UUT shall be run at the torque and speed setpoint which corresponds to the maximum output torque declared by the component manufacturer in accordance with point 4.2.5.1.

The output torque and rotational speed of the UUT as well as the DC input voltage to the inverter (or DC/DC converter if applicable) and the electric power to or from the inverter (or DC/DC converter if applicable) shall be measured over a period of t0_maxP declared by the component manufacturer in accordance with point 4.2.5.1.

4.2.5.3 Interpretation of results

The recorded values for torque and speed over time measured in accordance with point 4.2.5.2 shall be accepted if they do not differ by more than ±2 % for torque and ±2 % for rotational speed from the values declared by the component manufacturer in accordance with point 4.2.5.1 over the whole period of t0_maxP.

Where the values declared by the component manufacturer are outside the tolerances defined in the first paragraph of this point, the procedures laid down in points 4.2.5.1, 4.2.5.2 and in this point shall be repeated with different values for the maximum output torque of the UUT and/or the duration t0_maxP.

The average of the actual measured values over the period of t0_maxP calculated for the different signals of rotational speed, torque and DC input voltage to the inverter (or DC/DC converter if applicable) shall be used as final values for characterisation of the overload point. Additionally, the average of the actual measured electric power to or from the inverter (or DC/DC converter if applicable) over the period of t0_maxP shall be calculated.

4.2.6 EPMC test

The EPMC test measures the electric power to or from the inverter (or DC/DC converter if applicable) for different operating points of the UUT.

4.2.6.1 Preconditioning

The UUT shall be conditioned (i.e. without operating the system) at an ambient temperature of 25 ±10 °C for a minimum of two hours. If this test is performed directly consecutive to any other test run performed in accordance with this Annex the conditioning for a minimum of two hours may be omitted or shortened as long as the UUT stays within the testcell with the ambient temperature in the testcell kept within 25 ±10 °C.

4.2.6.2 Operating points to be measured

For IEPC with multispeed gearbox the setpoints for rotational speed in accordance with point 4.2.6.2.1 and for torque accordance with point 4.2.6.2.2 are determined for each single forward gear.

4.2.6.2.1 Setpoints for rotational speed

The setpoints for either a standalone electric machine system or an IEPC with no shiftable gears shall be defined in accordance with the following provisions:

(a) As setpoints for rotational speed of the UUT the same setpoints used for the measurement performed in accordance with point 4.2.2.2 for the respective voltage level shall be used.

(b) The speed setpoint for the maximum 30 minutes continuous torque verification performed in accordance with point 4.2.4.2 for the respective voltage level shall be used in addition to the setpoints defined in subpoint (a) above.

(c) Further speed setpoints may be defined in addition to the setpoints defined in subpoints (a) and (b) above.

In the case of an IEPC with multispeed gearbox, a separate dataset of setpoints for rotational speed of the UUT shall be defined for each single forward gear based on the following provisions:

(d) The rotational speed setpoints for the gear with the gear ratio closest to 1 (where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios) determined in accordance with subpoints (a) to (c), nk,gear_iCT1, shall be used as basis for the further step in subpoint (e).

(e) These rotational speed setpoints shall be converted to the respective setpoints for all other gears by the following equation: nk,gear = nk,gear_iCT1 × igear_iCT1 / igear where: nk,gear = rotational speed setpoint k for a specific gear (where k = 1, 2, 3, …, maximum number of rotational speed setpoints) (where gear = 1, …, highest gear number) nk,gear_iCT1 = rotational speed setpoint k for the gear with the gear ratio closest to 1 in accordance with subpoint (d) (where k = 1, 2, 3, …, maximum number of rotational speed setpoints) igear = gear ratio of a specific gear [-] (where gear = 1, …, highest gear number) igear_iCT1 = gear ratio of the gear with the gear ratio closest to 1 in accordance with subpoint (d) [-]

4.2.6.2.2 Setpoints for torque

The setpoints for either a standalone electric machine system or an IEPC with no shiftable gears shall be defined in accordance with the following provisions:

(a) At least 10 setpoints for torque of the UUT shall be defined for the measurement, located both on the positive (i.e. driving) and negative (i.e. braking) torque side. The lowest and highest torque setpoint shall be defined based on the minimum and maximum torque limits determined in accordance with point 4.2.2.4 for the respective voltage level, where the lowest torque setpoint shall be the overall minimum torque, Tmin_overall, and the highest torque setpoint shall be the overall maximum torque, Tmax_overall, determined from these values.

(b) The remaining 8 or more different torque setpoints shall be located between the lowest and highest torque setpoint. The interval between two adjacent torque setpoints shall not be larger than 22.5 % of the overall maximum torque of the UUT determined in accordance with point 4.2.2.4 for the respective voltage level.

(c) The limit value for positive torque at a particular rotational speed shall be the maximum torque limit at this particular rotational speed setpoint determined in accordance with point 4.2.2.4 for the respective voltage level, minus 5 % of Tmax_overall. All torque setpoints at a particular rotational speed setpoint that are located higher than the limit value for positive torque at this particular rotational speed shall be replaced by one single target torque setpoint located at the maximum torque limit at this particular rotational speed setpoint.

(d) The limit value for negative torque at a particular rotational speed shall be the minimum torque limit at this particular rotational speed setpoint determined in accordance with point 4.2.2.4 for the respective voltage level, minus 5 % of Tmin_overall. All torque setpoints at a particular rotational speed setpoint that are located lower than the limit value for negative torque at this particular rotational speed shall be replaced by one single target torque setpoint located at the minimum torque limit at this particular rotational speed setpoint.

(e) Minimum and maximum torque limitations for a particular rotational speed setpoint shall be determined based on the data generated in accordance with point 4.2.2.4 for the respective voltage level, by using linear interpolation.

In the case of an IEPC with multispeed gearbox, a separate dataset of setpoints for torque of the UUT shall be defined for each single gear based on the following provisions:

(f) The torque setpoints for the gear with the gear ratio closest to 1 (where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios) determined in accordance with subpoints (a) to (e), Tj,gear_iCT1, shall be used as basis for the further step in subpoints (g) and (h).

(g) These torque setpoints shall be converted to the respective setpoints for all other gears by the following equation: Tj,gear = Tj,gear_iCT1 / igear_iCT1 × igear where: Tj,gear = torque setpoint j for a specific gear (where j = 1, 2, 3, …, maximum number of torque setpoints) (where gear = 1, …, highest gear number) Tj,gear_iCT1 = torque setpoint j for the gear with the gear ratio closest to 1 in accordance with subpoint (f) (where j = 1, 2, 3, …, maximum number of torque setpoints) igear = gear ratio of a specific gear [-] (where gear = 1, …, highest gear number) igear_iCT1 = gear ratio of the gear with the gear ratio closest to 1 in accordance with subpoint (f) [-]

(h) All torque setpoints Tj,gear that have an absolute value higher than 10 kNm shall not be required to be measured during the actual test run performed in accordance with point 4.2.6.4.

4.2.6.3 Signals to be measured

Under the operating points specified in accordance with point 4.2.6.2 the electric power to or from the inverter (or DC/DC converter if applicable) and the output torque and speed of the UUT shall be measured.

4.2.6.4 Test sequence

The test sequence consists of steady state setpoints with defined rotational speed and torque at each setpoint in accordance with point 4.2.6.2.

In case an unforeseen interruption occurs, the test sequence may be continued under the following provisions:

— The UUT stays within the testcell, with the ambient temperature in the testcell kept within 25 ±10 °C;

— Before continuing the test the UUT shall be run on the bench for warm-up according to the recommendations of the component manufacturer.

— After the warm-up the test sequence shall be continued at the next lower rotational speed setpoint to the rotational speed setpoint where the interruption occurred.

— At the next lower rotational speed setpoint the test sequence described by subpoint (a) to (m) further below shall be followed, but only for preconditioning purposes without recording any measurement data.

— Recording of measurement data shall be done, starting from the first operating point at the rotational speed setpoint where the interruption occurred.

In the case of an IEPC, the following provisions shall apply:

— The test sequence shall be performed for each single gear sequentially starting from the gear with the highest gear ratio to be continued with the gears in descending order of gear ratio.

— All setpoints within a dataset for a specific gear determined in accordance with point 4.2.6.2 shall be completed before the measurement is continued in a different gear.

— It is allowed to interrupt the test after completion of measurement for each specific gear.

— The use of different torque meters is allowed.

Just before beginning the test at the first setpoint, the UUT shall be run on the bench for warm-up in accordance with the recommendations of the component manufacturer. The first rotational speed setpoint for the actual measured gear for starting the EPMC test is defined at the lowest rotational speed setpoint.

The remaining setpoints for the actual measured gear shall be applied in the following order:

(a) The first operating point at a particular rotational speed setpoint is defined at the highest torque at this specific speed.

(b) The next operating point shall be set at the same speed and the lowest positive (i.e. driving) torque setpoint.

(c) The next operating point shall be set at the same speed and the second highest positive (i.e. driving) torque setpoint.

(d) The next operating point shall be set at the same speed and the second lowest positive (i.e. driving) torque setpoint.

(e) This order of switching from the remaining highest to the remaining lowest torque setpoint shall be continued until all positive (i.e. driving) torque setpoints at a particular rotational speed setpoint are measured.

(f) Before continuing with step (g) the UUT may be cooled down in accordance with the component manufacturer’s recommendations by running at a particular setpoint defined by the component manufacturer.

(g) Then measurement of the negative (i.e. braking) torque setpoints at the same rotational speed setpoint shall be performed starting at the lowest torque at this specific speed.

(h) The next operating point shall be set at the same speed and the highest negative (i.e. braking) torque setpoint.

(i) The next operating point shall be set at the same speed and the second lowest negative (i.e. braking) torque setpoint.

(j) The next operating point shall be set at the same speed and the second highest negative (i.e. braking) torque setpoint.

(k) This order of switching from the remaining lowest to the remaining highest torque setpoint shall be continued until all negative (i.e. braking) torque setpoints at a particular rotational speed setpoint are measured.

(l) Before continuing with step (m) the UUT may be cooled down in accordance with the component manufacturer’s recommendations by running at a particular setpoint defined by the component manufacturer.

(m) The test shall continue at the next higher rotational speed setpoint by repeating steps (a) to (m) of the defined test sequence above until all rotational speed setpoints for the actual measured gear were completed.

All operating points shall be held for an operating time of at least 5 seconds. During this operating time the rotational speed of the UUT shall be held at the rotational speed setpoint within a tolerance of ±1 % or 20 rpm whatever is larger. Additionally, during this operating time, except for the highest and lowest torque setpoint at each rotational speed setpoint, the torque shall be held at the torque setpoint within a tolerance of ±1 % or ±5 Nm whatever is larger of the value of the torque setpoint.

The electric power to or from the inverter (or DC/DC converter if applicable), the output torque and rotational speed of the UUT shall be recorded as average value over the last two seconds of the operating time.

4.3. Post-processing of measurement data of the UUT

4.3.1 General provisions for post-processing

All post-processing steps defined in points 4.3.2 to 4.3.6 shall be performed for the datasets measured for the two different voltage levels in accordance with point 4.1.3 separately.

4.3.2 Maximum and minimum torque limits

The data for maximum and minimum torque limits determined in accordance with point 4.2.2.4 shall be extended by means of linear extrapolation (using the two closest points) to zero rotational speed and to the maximum operating speed of the UUT as declared by the component manufacturer in the event that the recorded measurement data does not cover these ranges.

4.3.3 Drag curve

The data for the drag curve determined in accordance with point 4.2.3 shall be modified in accordance with the following provisions:

(1) Where the electric power supply to the inverter (or DC/DC converter if applicable) was set inactive or disconnected, the respective values for electric power to the inverter (or DC/DC converter if applicable) shall be set to 0.

(2) Where the output shaft of the UUT was not connected to the load machine (i.e. dynamometer), the respective torque values shall be set to 0.

(3) The data modified in accordance with points (1) and (2) above shall be extended by means of linear extrapolation to the maximum operating speed of the UUT as declared by the component manufacturer where the recorded measurement data does not cover these ranges.

(4) The values of electric power to the inverter (or DC/DC converter if applicable) modified in accordance with points (1) to (3) above shall be seen as virtual mechanical loss power. These values of virtual mechanical loss power shall be converted to virtual drag torque with the respective rotational speed of the output shaft of the UUT.

(5) At each setpoint of rotational speed of the output shaft of the UUT in the data modified in accordance with points (1) to (3) above, the value of virtual drag torque determined in accordance with point (4) above shall be added to the actual torque of the load machine (i.e. dynamometer) to define the total drag torque of the UUT as function of rotational speed.

(6) The values of the total drag torque of the UUT at the lowest rotational speed setpoint, determined from the data modified in accordance with point (5) above, shall be copied to a new entry at 0 rpm rotational speed and added to the data modified in accordance with point (5) above.

4.3.4 EPMC

The data for the EPMC determined in accordance with point 4.2.6.4 shall be extended in accordance with the following provisions for each forward gear measured separately:

(1) The values of all data pairs for output torque and eletric inverter power determined at the lowest rotational speed setpoint shall be copied to a new entry at zero rotational speed.

(2) The values of all data pairs for output torque and eletric inverter power determined at the highest rotational speed setpoint shall be copied to a new entry at the highest rotational speed setpoint times 1.05.

(3) If at a specific rotational speed setpoint (including the newly introduced data in points 1 and 2 above) a torque setpoint determined in accordance with the provisions of point 4.2.6.2.2 in subpoints (a) to (g) was ommited for the actual measurement in accordance with subpoint (h) of point 4.2.6.2.2 a new data point shall be calculated based on the following provisions: (a) Rotational speed: using the value of the omitted setpoint for the rotational speed (b) Torque: using the value of the omitted setpoint for torque (c) Inverter power: calculating a new value by means of linear extrapolation where the slope of the least squares linear regression line determined based on the three actually measured torque points located closest to the torque value from subpoint (b) above for the corresponding rotational speed setpoint shall be applied. (d) For positive torque values, extrapolated values of inverter power resulting in values lower than the measured one at the actually measured torque point located closest to the torque value from subpoint (b) above shall be set to the inverter power actually measured at the torque point located closest to the torque value from subpoint (b) above. (e) For negative torque values, extrapolated values of inverter power resulting in values higher than the measured one at the actually measured torque point located closest to the torque value from subpoint (b) above shall be set to the inverter power actually measured at the torque point located closest to the torque value from subpoint (b) above.

(4) At each rotational speed setpoint (including the newly introduced data in points 1 to 3 above) a new data point shall be calculated based on the data at the highest torque setpoint in accordance with the following rules: (a) Rotational speed: using the same value for the rotational speed (b) Torque: using the value for torque multiplied by a factor of 1,05 (c) Inverter power: calculating a new value in such a way that the efficiency defined as the ratio of mechanical power to inverter power stays constant

(5) At each rotational speed setpoint (including the newly introduced data in points 1 to 3 above) a new data point shall be calculated based on the data at the lowest torque setpoint in accordance with the following rules: (a) Rotational speed: using the same value for the rotational speed (b) Torque: using the value for torque multiplied by a factor of 1.05 (c) Inverter power: calculating a new value in such a way that the efficiency defined as the ratio of inverter power to mechanical power stays constant

4.3.5 Overload characteristics

From the data for the overload characteristics determined in accordance with point 4.2.5.3 an efficiency figure shall be determined by dividing the average mechanical output power over the period of t0_maxP by the average electric power to or from the inverter (or DC/DC converter if applicable) over the period of t0_maxP.

4.3.6 Maximum 30 minutes continuous torque

From the data determined in accordance with point 4.2.4.3 an efficiency figure shall be determined by dividing the average 30 minutes continuous power by the average electric power to or from the inverter (or DC/DC converter if applicable).

From the measurement data for the maximum 30 minutes continuous torque determined in accordance with point 4.2.4.2 the following average values shall be determined from the time-resolved values over the 1 800-second measurement period for each cooling circuit with connection to an external heat exchanger separately:

— cooling power

— coolant temperature at the inlet of the cooling circuit of the UUT

The cooling power shall be determined based on the specific heat capacity of the coolant, the coolant massflow and the temperature difference over the test bed heat exchanger on the side of the UUT.

4.4 Special provisions for testing of IHPCs Type 1

IHPCs Type 1 are virtually split into two separate components for handling in the simulation tool, i.e. an electric machine system and a transmission. Therefore, two separate component data sets shall be determined by following the provisions described in this point.

For component testing of IHPCs Type 1, points 4.1 to 4.2 of this Annex shall apply.

For an IHPC Type 1 the torque and speed shall be measured at the output shaft of the system (i.e. the output side of the gearbox towards the wheels of the vehicle).

The definition of families in accordance with Appendix 13 shall not be allowed for IHPCs Type 1. Therefore, omission of test runs is not allowed and all test runs described in point 4.2 shall be performed for one specific IHPC Type 1. Notwithstanding these provisions, the test of the drag curve in accordance with point 4.2.3 shall be omitted for IHPCs Type 1.

Generating input data for IHPCs Type 1 based on standard values shall not be allowed.

4.4.1 Test runs to be performed for IHPCs Type 1

4.4.1.1 Test runs to determine the total system characteristics

This subpoint describes the details for determining the characteristics of the complete IHPC Type 1 including the losses of the gearbox part within the system.

The following test runs shall be performed in accordance with the provisions defined for IEPC with multispeed gearbox in the respective points. For all of these test runs, the input shaft for feeding propulsion torque into the system shall be either disconnected and rotating freely or shall be fixed without rotating.

Table 2a

Overview of test runs to be performed for IHPC Type 1

Test run Reference to point Maximum and minimum torque limits 4.2.2 Maximum 30 minutes continuous torque 4.2.4 Overload characteristics 4.2.5 EPMC 4.2.6

Due to the applicability of the provisions defined for IEPC with multispeed gearbox to IHPCs Type 1, the EPMC shall be measured for each single forward gear in accordance with point 4.2.6.2.

4.4.1.2 Test runs to determine the losses of the gearbox part within the system

This subpoint describes the details for determining the losses of the gearbox part within the system.

Therefore, the system shall be tested in accordance with the provisions in point 3.3 of Annex VI. Notwithstanding these provisions, the following provisions shall be applied:

— The input shaft for feeding propulsion torque into the system shall be connected to and driven by a dynamometer in accordance with the provisions in point 3.3 of Annex VI.

— The power supply from the electric DC powersource to the inverter(s) (or DC/DC converter(s) if applicable) shall be disconnected. In order to allow this disconnection without any parts of the system being damaged, the system may be modified in a way that dummy magnets or dummy rotors are used in the electric machine(s) part for the measurement.

— The torque range as defined in point 3.3.6.3 of Annex VI shall be extended to cover also negative torque values in such a way that the same torque setpoints from the positive side are measured also with a negative algebraic sign.

4.4.2 Post-processing of measurement data of IHPCs Type 1

For post-processing of measurement data of IHPCs Type 1, all provisions as laid down in point 4.3 shall apply unless stated otherwise.

4.4.2.1 Post-processing of data regarding total system characteristics

All measurement data determined in accordance with point 4.4.1.1 shall be handled in accordance with the provisions as laid down in points 4.3.1 to 4.3.6. The provisions of point 4.3.3 shall be omitted since measurement of the drag curve in accordance with point 4.2.3 is not performed for IHPCs Type 1. Where there are specific provisions defined for IEPC with multispeed gearbox in the respective points, such specific provisions shall be applied.

4.4.2.2 Post-processing of data regarding losses of the gearbox part within the system

All measurement data determined in accordance with point 4.4.1.2 shall be handled in accordance with the provisions as laid down in point 3.4 of Annex VI. Notwithstanding these provisions, the following provisions shall be applied:

— The provisions as laid down in points 3.4.2 to 3.4.5 of Annex VI shall be applied analogously also for negative torque values.

— The provisions as laid down in point 3.4.6 of Annex VI shall not be applied.

4.4.2.3 Post-processing of data to derive the specific data of the virtual electric machine system

In order to determine the component data of the virtual electric machine system the following steps shall be applied. The following post-processing steps shall be omitted for the two efficiency figures determined in accordance with points 4.3.5 and 4.3.6 since these efficiency figures only serve for assessment of conformity of the certified CO2 emissions and fuel consumption related properties.

(a) All speed and torque values of the measurement data handled in accordance with point 4.4.2.1 shall be converted from the output shaft to the input shaft of the IHPC Type 1 in accordance with the following equations. Where the same test run was performed for several gears, the conversion shall be performed for each gear separately. where: nEM,virt = rotational speed of the virtual electric machine system referring to the input shaft of the IHPC Type 1 [1/min] noutput = measured rotational speed at the output shaft of the IHPC Type 1 [1/min] igbx = ratio of rotational speed at the input shaft over the rotational speed at the output shaft of the IHPC Type 1 for a specific gear engaged during the measurement [-] TEM,virt = torque of the virtual electric machine system referring to the input shaft of the IHPC Type 1 [Nm] Toutput = measured torque at the output shaft of the IHPC Type 1 [Nm] Tloss,gbx = torque loss depending on rotational speed and torque at the input shaft of the IHPC Type 1 [Nm]. It shall be calculated by means of two-dimensional linear interpolation from the loss maps of the gearbox determined in accordance with point 4.4.2.2 for the respective gear. gear = specific gear engaged during the measurement [-]

(b) The electric power maps determined for each forward gear in accordance with point 4.4.2.1 and converted to the input shaft in accordance with subpoint (a) of point 4.4.2.3 shall be used as basis for the following calculations. All values of electric inverter power of these electric power maps shall be converted to the respective maps for the virtual electric machine system by deducting the losses of the gearbox part in accordance with the following equation: where: Pel,virt electric inverter power of the virtual electric machine system [W] nEM,virt rotational speed of the virtual electric machine system referring to the input shaft of the IHPC Type 1 determined in accordance with subpoint (a) of point 4.4.2.3 [1/min] TEM,virt torque of the virtual electric machine system referring to the input shaft of the IHPC Type 1 determined in accordance with subpoint (a) of point 4.4.2.3 [Nm] Pel,meas measured electric inverter power [W] Tloss,gbx torque loss depending on rotational speed and torque at the input shaft of the IHPC Type 1 [Nm]. It shall be calculated by means of two-dimensional linear interpolation from the loss maps of the gearbox determined in accordance with point 4.4.2.2 for the respective gear. gear specific gear engaged during the measurement [-]

(c) The drag torque values of the virtual electric machine system shall be specified at the same rotational speed setpoints, nEM,virt, referring to the input shaft of the IHPC Type 1 as used for the definition of the maximum and minimum torque curve of the virtual electric machine system. Each single value of drag torque in Nm indicated at the different rotational speed setpoints shall be set to zero.

(d) The rotational inertia of the virtual electric machine system shall be calculated by converting the inertia value(s) of the actual electric machine(s) determined in accordance with point 8 of Appendix 8 of this Annex to the corresponding value of rotational inertia referring to the input shaft of the IHPC Type 1.

4.4.3 Generation of input data for the simulation tool

Since IHPCs Type 1 are virtually split into two separate components for handling in the simulation tool, separate component input data shall be determined for an electric machine system and a transmission. The certification number indicated in the input data shall be the same for both components, electric machine system and transmission.

4.4.3.1 Input data of the virtual electric machine system

The input data for the virtual electric machine system shall be generated in accordance with the definitions for the electric machine system in Appendix 15 based on the final data resulting from following the provisions in point 4.4.2.3.

4.4.3.2 Input data of the virtual transmission

The input data for the virtual transmission shall be generated in accordance with the definitions for the transmission in Table 1 to Table 3 of Appendix 12 of Annex VI based on the final data resulting from following the provisions in point 4.4.2.2. The value of the parameter “TransmissionType” in Table 1 shall be set to “IHPC Type 1”.

5. Testing of battery systems or representative battery subsystems

The battery UUT thermal conditioning device and the corresponding thermal conditioning loop at the test bench equipment shall be operational to satisfy the battery UUT thermal conditioning performances, according to the vehicle application and shall enable the test bench equipment to perform the requested test procedure within the battery UUT operational limits

5.1 General provisions

Battery UUT components may be distributed in different devices within the vehicle.

The battery UUT shall be controlled by the BCU, the test bench equipment shall follow the operational limits provided by the BCU via bus communication. The battery UUT thermal conditioning device and the corresponding thermal conditioning loop at the test bench equipment shall be operational in accordance with the controls by the BCU, unless otherwise specified in the given test procedure. The BCU shall enable the test bench equipment to perform the requested test procedure within the battery UUT operational limits. If necessary, the BCU program shall be adapted by the component manufacturer for the requested test procedure but within the operational and safety limits of the battery UUT.

5.1.1 Conditions for thermal equilibration

Thermal equilibration is reached if during a period of 1 hour the deviations between cell temperature as specified by the component manufacturer and temperature of all cell temperature measuring points are lower than ±7 K.

5.1.2 Sign conventions

5.1.2.1 Current

Measured values of current shall have a positive sign for discharging and a negative sign for charging.

5.1.3 Reference location for ambient temperature

The ambient temperature shall be measured within a distance of 1 m to the battery UUT at a point indicated by the component manufacturer.

5.1.4 Thermal conditions

Battery testing temperature, i.e. the target operating temperature of the battery UUT, shall be specified by the component manufacturer. The temperature of all cell temperature measuring points shall be within the limits specified by the component manufacturer during all test runs performed.

For battery UUT with liquid conditioning (i.e. heating or cooling), the temperature of the conditioning fluid shall be recorded at the battery UUT inlet and must be maintained within ±2 K of a value specified by the component manufacturer.

For air cooled battery UUT, the temperature of the battery UUT at a point indicated by the component manufacturer shall be kept within +0/-20 K of the maximum value specified by the component manufacturer.

For all test runs performed the available cooling and/or heating power on the testbench shall be limited to a value declared by the component manufacturer. This value shall be recorded together with the test data.

The available cooling and/or heating power on the testbench shall be determined based on the following procedures and recorded together with the actual component test data:

(1) For liquid conditioning from the massflow of the conditioning fluid and the temperature difference over the heat exchanger on the side of the battery UUT.

(2) For electric conditioning from the voltage and current. The component manufacturer may modify the electric connection of this conditioning unit for the certification of the battery UUT to enable a measurement of the battery UUT characteristics without considering the electric power required for conditioning (e.g. if the conditioning is directly implemented and connected within the battery UUT). Notwithstanding these provisions, the required electric cooling and/or heating power externally provided to the battery UUT by a conditioning unit shall be recorded.

(3) For other types of conditioning based on good engineering judgement and discussion with the type approval authority.

5.2 Preparation cycles

The battery UUT shall be conditioned by performing maximum five cycles of full discharging followed by full charging in order to ensure stabilisation of the system’s performance before the actual testing starts.

Consecutive cycles of full discharging followed by full charging shall be performed at the component manufacturer defined operational set temperature until the “preconditioned” status is reached. The criterion for a “preconditioned” battery UUT is that the discharged capacity during two consecutive discharges does not change by a value greater than 3 % of the rated capacity or that five repetitions were performed.

The voltage of the battery UUT shall not fall below the minimum voltage recommended by the component manufacturer at the end of the discharge (the minimum voltage is the lowest voltage under discharge without irreversible damage done to the battery UUT). The termination criteria for the full discharging and the full charging cycles shall be defined by the component manufacturer.

5.2.1 Current levels in preparation cycles for HPBS

Discharging shall be performed at a current of 2C, charging shall be performed in accordance with the recommendations of the component manufacturer.

5.2.2 Current levels in preparation cycles Preconditioning for HEBS

Discharging shall be performed at a current of 1/3C, charging shall be performed in accordance with the recommendations of the component manufacturer.

5.3 Standard cycle

The purpose of a standard cycle (SC) is to ensure the same initial condition for each dedicated test of a battery UUT, as well as the charged energy for COP purposes in accordance with Appendix 12. It shall be performed at the component manufacturer defined operational set temperature.

5.3.1 Standard cycle for HPBS

The SC for HPBS shall consist of the following events in consecutive order: a standard discharge, a rest period, a standard charge and a second rest period.

The standard discharge procedure shall be performed at a current of 1C down to the minimum SOC in accordance with the specifications of the component manufacturer.

The rest period shall start directly after the end of discharge and shall last for 30 minutes.

The standard charge procedure shall be performed in accordance with the specifications of the component manufacturer regarding criteria for end of charge as well as applicable time limits for the overall charging procedure.

The second rest period shall start directly after the end of charge and shall last for 30 minutes.

5.3.2 Standard cycle for HEBS

The SC for HEBS shall consist of the following events in consecutive order: a standard discharge, a rest period, a standard charge and a second rest period.

The standard discharge procedure shall be performed at a current of 1/3C down to the minimum SOC in accordance with the specifications of the component manufacturer.

The rest period shall start directly after the end of discharge and shall last for 30 minutes.

The standard charge procedure shall be performed in accordance with the specifications of the component manufacturer regarding criteria for end of charge as well as applicable time limits for the overall charging procedure.

The second rest period shall start directly after the end of charge and shall last for 30 minutes.

5.4 Test runs to be performed

Before any test runs in accordance with this point are performed the battery UUT shall be subjected to the provisions in accordance with point 5.2.

5.4.1 Test procedure for rated capacity

This test measures the rated capacity of the battery UUT in Ah at constant current discharge rates.

5.4.1.1 Signals to be measured

The following signals shall be recorded during preconditioning, standard cycles performed and the actual test run:

— Charge/Discharge current at the terminals of the battery UUT

— Voltage across the terminals of the battery UUT

— Temperatures of all measuring points of the battery UUT

— Ambient temperature in the testbench

— Heating or cooling power for battery UUT

5.4.1.2 Test run

After the battery UUT was fully charged in accordance with the specifications of the component manufacturer and thermal equilibration in accordance with point 5.1.1 was reached, a standard cycle in accordance with point 5.3 shall be performed.

The actual test run shall start within a period of 3 hours after the end of the standard cycle, otherwise the standard cycle shall be repeated.

The actual test run shall be performed at RT and consist of a constant current discharge at the following discharge rates:

— For HPBS to the component manufacturer’s rated 1 C capacity in Ah

— For HEBS to the component manufacturer’s rated 1/3C capacity in Ah

All discharge tests shall be terminated at the minimum conditions in accordance with the specifications of the component manufacturer.

5.4.1.3 Interpretation of results

The capacity in Ah obtained from the integrated battery current over time during the actual test run in accordance with point 5.4.1.2 shall be used as value for the rated capacity.

5.4.1.4 Data to be reported

The following data shall be reported:

— Rated capacity determined in accordance with point 5.4.1.3

— Average values over the actual test run of all signals recorded in accordance with point 5.4.1.1

For the purpose of conformity of production testing, also the following values shall be calculated:

— The total charged energy, Echa, from 20 to 80 % SOC during the standard cycle performed prior to the actual test run.

— The total discharged energy, Edis, from 80 to 20 % SOC during the actual test run.

All SOC values used shall be calculated based on the actual measured rated capacity determined in accordance with point 5.4.1.3.

The round trip efficiency ηBAT shall be calculated by dividing the total discharged energy, Edis, by the total charged energy, Echa and reported in the information document in accordance with Appendix 5.

5.4.2 Test procedure for open circuit voltage, internal resistance and current limits

This test determines the ohmic resistance for discharge and charge conditions as well as the OCV of the battery UUT as a function of SOC. In addition, the maximum current for discharging and charging as declared by the component manufacturer shall be verified.

5.4.2.1 General provisions for testing

All SOC values used shall be calculated based on the actual measured rated capacity determined in accordance with point 5.4.1.3.

Only where the battery UUT reaches the discharge voltage limit during discharge, shall the current be reduced such that the battery UUT terminal voltage is maintained at the discharge voltage limit throughout the whole discharge pulse.

Only where the battery UUT reaches during charging the charge voltage limit, shall the current be reduced such that the battery UUT terminal voltage is maintained at the charge voltage limit throughout the whole regenerative charge pulse.

If the test equipment cannot provide the current value with the requested accuracy of ±1 % of the target value within 100 ms after a change in the current profile, the respective recorded data shall be discarded and no related values for open circuit voltage and internal resistance shall be calculated from this data.

If the operational limits provided by the BCU via bus communication demand the current to be reduced in order to stay within the operational limits of the battery UUT the test bench equipment shall reduce the respective target current in accordance with the demands of the BCU.

5.4.2.2 Signals to be measured

The following signals shall be recorded during preconditioning and the actual test run:

— Discharge current at the terminals of the battery UUT

— Voltage across the terminals of the battery UUT

— Temperatures of all measuring points of the battery UUT

— Ambient temperature in the testbench

— Heating or cooling power for battery UUT

5.4.2.3 Test run

5.4.2.3.1 Preconditioning

After the battery UUT was fully charged in accordance with the specifications of the component manufacturer and thermal equilibration in accordance with point 5.1.1 was reached, a standard cycle in accordance with point 5.3 shall be performed.

Within a period of 1 to 3 hours after the end of the standard cycle, the actual test run shall be started. Otherwise, the procedure in the preceding paragraph shall be repeated.

5.4.2.3.2 Test procedure

For HPBS, the test shall be performed at five different SOC levels: 80, 65, 50, 35 and 20 %.

For HEBS, the test shall be performed at five different SOC levels: 90, 70, 50, 35 and 20 %.

At the last step at 20 % SOC the component manufacturer may reduce the maximum discharge current of the battery UUT in order for the SOC to stay above the minimum SOC, in accordance with the specifications of the component manufacturer and avoid a deep discharge.

Before the beginning of the actual test runs at each SOC level, the battery UUT shall be preconditioned in accordance with point 5.4.2.3.1.

In order to reach the required SOC levels for testing from the initial condition of the battery UUT, it shall be discharged at a constant current rate of 1C for HPBS and of 1/3C for HEBS followed by a rest period of 30 minutes before the next measurement starts.

The component manufacturer shall prior to the test declare the maximum charge and discharge current at each different SOC level that can be applied throughout the length of the respective time increment of the current pulse defined in accordance with Table 3 for HPBS and Table 4 for HEBS.

The actual test run shall be performed at RT and shall consist of the current profile in accordance with Table 3 for HPBS and in accordance with Table 4 for HEBS.

Table 3

Current profile for HPBS

Time increment [s] Time cumulative [s] Target current 0 0 0 20 20 Idischg_max/33 40 60 0 20 80 Ichg_max/33 40 120 0 20 140 Idischg_max/32 40 180 0 20 200 Ichg_max/32 40 240 0 20 260 Idischg_max/3 40 300 0 20 320 Ichg_max/3 40 360 0 20 380 Idischg_max 40 420 0 20 440 Ichg_max 40 480 0





Table 4

Current profile for HEBS

Time increment [s] Time cumulative [s] Target current 0 0 0 120 120 Idischg_max/33 40 160 0 120 280 Ichg_max/33 40 320 0 120 440 Idischg_max/32 40 480 0 120 600 Ichg_max/32 40 640 0 120 760 Idischg_max/3 40 800 0 120 920 Ichg_max/3 40 960 0 120 1080 Idischg_max 40 1120 0 120 1240 Ichg_max 40 1280 0

Where

Idischg_max is the absolute value of the maximum discharge current specified by the component manufacturer at the specific SOC level that can be applied throughout the length of the respective time increment of the current pulse Ichg_max is the absolute value of the maximum charge current specified by the component manufacturer at the specific SOC level that can be applied throughout the length of the respective time increment of the current pulse

The voltage at time zero of the test run before the first change in target current occurs, i.e. V0, shall be measured as average value over 100 ms.

For HPBS the following voltages and currents shall be measured:

(1) For each different discharging and charging current pulse level specified in Table 3, the voltage under zero current as average value over the last second before the change in target current occurs, i.e. Vdstart for discharging and Vcstart for charging, shall be measured.

(2) For each different discharging current pulse level specified in Table 3, the voltage at 2, 10 and 20 seconds after the change in target current occurs (Vd2, Vd10, Vd20) and the corresponding current (Id2, Id10, and Id20) shall be measured as average value over 100ms.

(3) For each different charging current pulse level specified in Table 3, the voltage at 2, 10 and 20 seconds after the change in target current occurs (Vc2, Vc10, Vc20) and the corresponding current (Ic2, Ic10, and Ic20) shall be measured as average value over 100 ms.

Table 5 gives an overview of voltage and current values to be measured over time after the change in target current occurs for HPBS.

Table 5

Voltage measurement points for each different level of a current pulse (discharging and charging) for HPBS

Time after the change in target current occurs [s] Discharging (D) or charging (C) Voltage Current 2 D Vd2 Id2 10 D Vd10 Id10 20 D Vd20 Id20 2 C Vc2 Ic2 10 C Vc10 Ic10 20 C Vc20 Ic20

For HEBS the following voltages and currents shall be measured:

(1) For each different discharging and charging current pulse level specified in table 4 the voltage under zero current as average value over the last second before the change in target current occurs, i.e. Vdstart for discharging and Vcstart for charging, shall be measured.

(2) For each different discharging current pulse level specified in table 4, the voltage at 2, 10 20 and 120 seconds after the change in target current occurs (Vd2, Vd10, Vd20 and Vd120) and the corresponding current (Id2, Id10, Id20 and Id120) shall be measured as average value over 100ms.

(3) For each different charging current pulse level specified in table 4, the voltage at 2, 10, 20 and 120 seconds after the change in target current occurs (Vc2, Vc10, Vc20 and Vc120) and the corresponding current (Ic2, Ic10, Ic20 and Ic120) shall be measured as average value over 100 ms.

Table 6 gives an overview of voltage and current values to be measured over the time after the change in target current occurs for HEBS.

Table 6

Voltage measurement points for each different level of a current pulse (discharging and charging) for HEBS

Time after the change in target current occurs [s] Discharging (D) or charging (C) Voltage Current 2 D Vd2 Id2 10 D Vd10 Id10 20 D Vd20 Id20 120 D Vd120 Id120 2 C Vc2 Ic2 10 C Vc10 Ic10 20 C Vc20 Ic20 120 C Vc120 Ic120

5.4.2.4 Interpretation of results

The following calculations shall be performed separately for each level of SOC measured in accordance with point 5.4.2.3.

5.4.2.4.1 Calculations for HPBS

(1) For each different discharging current pulse level specified in Table 3, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations: — RId2 = (Vdstart – Vd2) / Id2 — RId10 = (Vdstart – Vd10) / Id10 — RId20 = (Vdstart – Vd20) / Id20

(2) The internal resistances for discharging RId2_avg, RId10_avg, RId20_avg shall be calculated as average over all different current pulse levels specified in Table 3 from the individual values calculated under point 1.

(3) For each different charging current pulse level specified in Table 3, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations: — RIc2 = (Vcstart – Vc2) / Ic2 — RIc10 = (Vcstart – Vc10) / Ic10 — RIc20 = (Vcstart – Vc20) / Ic20

(4) The internal resistances for charging RIc2_avg, RIc10_avg, RIc20_avg shall be calculated as average over all different current pulse levels specified in Table 3 from the individual values calculated under point 3.

(5) The overall internal resistances RI2, RI10 and RI20 shall be calculated as average over the respective values for discharging and charging calculated under points 2 and 4.

(6) The open circuit voltage shall be the value of V0 measured in accordance with point 5.4.2.3 for the respective SOC level.

(7) The limits for maximum discharging current shall be calculated as average value over 20 seconds at the target current Idischg_max for each level of SOC measured in accordance with point 5.4.2.3.

(8) The limits for maximum charging current shall be calculated as average value over 20 seconds at the target current Ichg_max for each level of SOC measured in accordance with point 5.4.2.3. Absolute values of the results shall be reported as final values.

5.4.2.4.2 Calculations for HEBS

(1) For each different discharging current pulse level specified in Table 4, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations: — RId2 = (Vdstart – Vd2) / Id2 — RId10 = (Vdstart – Vd10) / Id10 — RId20 = (Vdstart – Vd20) / Id20 — RId120 = (Vdstart – Vd120) / Id120

(2) The internal resistances for discharging RId2_avg, RId10_avg, RId20_avg and RId120_avg shall be calculated as average over all different current pulse levels specified in Table 4 from the individual values calculated under point 1.

(3) For each different charging current pulse level specified in Table 4, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations: — RIc2 = (Vcstart – Vc2) / Ic2 — RIc10 = (Vcstart – Vc10) / Ic10 — RIc20 = (Vcstart – Vc20) / Ic20 — RIc120 = (Vcstart – Vc120) / Ic120

(4) The internal resistances for charging RIc2_avg, RIc10_avg, RIc20_avg and RIc120_avg shall be calculated as average over all different current pulse levels specified in Table 4 from the individual values calculated under point 3.

(5) The overall internal resistances RI2, RI10, RI20 and RI120 shall be calculated as average over the respective values for discharging and charging calculated under points 2 and 4.

(6) The open circuit voltage shall be the value of V0 measured in accordance with point 5.4.2.3 for the respective SOC level.

(7) The limits for maximum discharging current shall be calculated as average value over 120 seconds at the target current Idischg_max for each level of SOC measured in accordance with point 5.4.2.3.

(8) The limits for maximum charging current shall be calculated as average value over 120 seconds at the target current Ichg_max for each level of SOC measured in accordance with point 5.4.2.3. Absolute values of the results shall be reported as final values.

5.5. Post-processing of measurement data of the battery UUT

The values of OCV dependent on SOC shall be defined based on the values determined for the different SOC levels in accordance with point 6 of point 5.4.2.4.1 for HPBS and 5.4.2.4.2 for HEBS.

The different values of internal resistances dependent on SOC shall be defined based on the values determined for the different SOC levels in accordance with point 5.4.2.4.1(5) for HPBS and 5.4.2.4.2 for HEBS.

The limits for maximum discharging current and maximum charging current shall be defined based on the values as declared by the component manufacturer prior to the test. If a specific value for the maximum discharging current or maximum charging current determined in accordance with point 5.4.2.4.1(7) and (8) for HPBS and 5.4.2.4.2 for HEBS deviates by more than ±2 % from the value declared by the component manufacturer prior to the test, the respective value determined in accordance with points 5.4.2.4.1(7) and (8) for HPBS and 5.4.2.4.2 for HEBS shall be reported.

6. Testing of capacitor systems or representative capacitor subsystems

6.1 General provisions

Capacitor system components of the capacitor UUT may also be distributed in different devices within the vehicle.

The characteristics for a capacitor are hardly dependent on its state of charge or current, respectively. Therefore, only a single test run is prescribed for the calculation of the model input parameters.

6.1.1 Sign convention for current

Measured values of current shall have a positive sign for discharging and a negative sign for charging.

6.1.2 Reference location for ambient temperature

The ambient temperature shall be measured within a distance of 1 m to the capacitor UUT at a point indicated by the component manufacturer of the capacitor UUT.

6.1.3 Thermal conditions

Capacitor testing temperature, i.e. the target operating temperature of the capacitor UUT, shall be specified by the component manufacturer. The temperature of all capacitor cell temperature measuring points shall be within the limits specified by the component manufacturer during all test runs performed.

For capacitor UUT with liquid conditioning (i.e. heating or cooling), the temperature of the conditioning fluid shall be recorded at the capacitor UUT inlet and must be maintained within ±2 K of a value specified by the component manufacturer.

For air cooled capacitor UUT, the temperature at a point indicated by the component manufacturer shall be kept within +0/–20 K of the maximum value specified by the component manufacturer.

For all test runs performed the available cooling and/or heating power on the testbench shall be limited to a value declared by the component manufacturer. This value shall be recorded together with the test data.

The available cooling and/or heating power on the testbench shall be determined based on the following procedures and recorded together with the actual component test data:

(1) For liquid conditioning from the massflow of the conditioning fluid and the temperature difference over the heat exchanger on the side of the capacitor UUT.

(2) For electric conditioning from the voltage and current. The component manufacturer may modify the electric connection of this conditioning unit for the certification of the capacitor UUT to enable a measurement of the capacitor UUT characteristics without considering the electric power required for conditioning (e.g. if the conditioning is directly implemented and connected within the capacitor UUT). Notwithstanding these provisions, the required electric cooling and/or heating power externally provided to the capacitor UUT by a conditioning unit shall be recorded.

(3) For other ty