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1、Page 1 LV215-1: Revision Date 02-2009 Electrical/Electronic Requirements of HV Connectors Edition 1 Feb. 2009 This SR 215-1 was created by WG 4.3.3 of the German car manufacturers. Page 2 LV215-1: Revision Date 02-2009 Content Page 1 Introduction 5 1.1 Scope of application . 5 1.2 References. 5 1.3
2、Glossary, Definitions, and Abbreviations. 7 1.4 Legal stipulations 9 2 Requirements Development Framework 10 2.1 Quality 10 2.1.1 General. 10 2.1.2 Delivery quality. 10 2.1.3 Reliability 10 2.1.3.1 Full functional fulfilment . 10 2.1.3.2 Warranty and goodwill . 10 2.1.4 Maintenance intervals. 10 2.2
3、 Operating and environmental conditions. 10 2.3 Environmental compatibility and emissions. 11 2.3.1 Environmental compatibility 11 2.4 Operating reliability and product safety. 11 2.4.1 Operational reliability 11 2.4.2 Product safety. 11 2.5 Requirements Protection against electrical hazards. 11 2.5
4、.1 Additional measures for deenergising the HV electric circuit 11 2.5.2 IP degree of protection 11 2.5.3 Protection against direct contact of active components 11 2.5.3.1 General . 11 2.5.4 Protection against direct contact. 12 2.5.4.1 General. 12 2.5.5 Contacting system 12 2.5.6 HV interlock (HVIL
5、). 12 2.5.6.1 General. 12 2.5.6.2 Design 12 2.6 Component identification of HV connectors 12 2.6.1 Functional models and prototypes 13 2.6.2 Production parts . 13 2.7 Design of electrical system/electronics . 13 2.7.1 Electromagnetic compatibility . 13 2.8 Documentation 13 2.9 Corrosion resistance.
6、13 3 Requirement Integration Framework. 14 3.1 Geometric requirements 14 3.2 Thermal requirements. 14 3.3 Mechanical requirements 14 3.3.1 Electrical requirements . 14 3.3.1.1 Current-carrying capacity 14 3.3.1.2 Electric, insulating strength . 15 3.3.1.3 Shield connexion 15 4 Requirements Functiona
7、lity 16 4.1 Overall functionality 16 4.2 Functional features . 6 Page 3 LV215-1: Revision Date 02-2009 4.2.1 Contact cover . 16 4.2.1.1 Pin-socket contact . 16 4.2.1.2 Front contact 16 4.2.2 Contact arrangement 16 4.2.2.1 Insertion forces. 16 4.2.3 Contact locking device . 16 4.2.4 Contact lock 16 4
8、.2.4.1 Lock in the contact cavity 16 4.2.4.2 Disassembly of contact component 16 4.2.4.3 Holding forces 16 4.2.4.4 Holding force of primary locking device. 17 4.2.4.5 Holding force of secondary locking device . 17 4.2.5 Function of secondary locking elements . 17 4.2.5.1 Active secondary locking sys
9、tem 17 4.2.6 Polarisation/keying . 17 4.2.6.1 Keying . 17 4.2.6.2 Polarisation 18 4.2.7 Housing pre-guide . 18 4.2.7.1 Housing guide. 18 4.2.7.2 Angled housing connection. 18 4.2.7.3 Push-on safeguarding. 18 4.2.8 Housing lock/locking device 18 4.2.8.1 Locking. 18 4.2.9 CPA 18 4.2.10 Crimps 18 4.2.1
10、1 Crimping pull-out forces 19 4.3 Assembly forces . 19 4.3.1 Insertion force . 19 4.3.2 Separation force . 19 4.4 IP protection classes (tightness/contact protection) 19 4.4.1 Contact protection . 19 4.4.1.1 Uninserted state 19 4.4.1.2 Inserted state . 19 4.4.1.3 HVIL system 19 4.4.1.4 HVIL system,
11、mechanism . 19 4.4.2 Tightness 20 4.4.2.1 Inserted state. 20 4.4.2.2 Design of sealing elements and sealing surfaces 20 4.4.2.3 Seal at conductor side 21 4.4.3 Operational reliability 21 4.5 Customizability . 21 4.6 EMC requirement . 21 4.6.1 Shielding . 21 4.6.1.1 In the HV connector. 21 4.6.1.2 Fr
12、om HV cable set to HV connector. 21 4.6.2 Shroud 22 4.6.2.1 Geometric design . 22 4.6.3 Shield connexion 22 4.6.3.1 Shield connexion between receptacle housing and cable. 22 4.6.3.2 Shield connexion between receptacle housing and unit connection . 22 4.7 Electrical requirements . 22 Page 4 LV215-1:
13、Revision Date 02-2009 4.7.1 Electric strength 22 4.7.2 Insulating strength . 22 4.8 Housing identification and labelling. 23 4.8.1 Housing chamber . 23 4.8.2 Component identification 23 4.9 Housing colour 23 4.10 Material selection 23 5 Test and protection. 24 5.1 Test and inspection requirements on
14、 the component 24 5.2 Inspections and execution 24 5.2.1 Measurement of insulating resistance of component 24 5.2.2 Identification of HV components . 25 5.2.3 Protection against direct contact of active components 25 5.2.4 Electric strength 26 5.2.5 HV interlock 27 5.2.6 Shield transfer . 27 5.2.7 A
15、ir gaps and creepage distances 27 Preface This standard was put together in its present version by representatives from the car manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG and Volkswagen AG. This standard is deposited as a Word file in the Standardization department of Audi AG. This standa
16、rd does not claim to be complete. Car manufacturers are always free to require additional inspections according to the respective state of the art. Since the individual car manufacturers can make changes, if necessary, inspections may not be performed using this standard. Instead, the supplier must ensure that the currently valid internal standard of the car manufacturer is at his disposal. Deviations from the present standard are represented in italics in the internal standards. If m
