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CMVR Type Approval of Vehicles Retrofitted with Hybrid Electric

1. 3 52 Draft AIS 123 F1 February 2013 Introduction The Government of India felt the need for a permanent agency to expedite the publication of Standards and development of test facilities in parallel when the work of preparation of Standards is going on as the development of improved safety critical parts can be undertaken only after the publication of the Standard and commissioning of test facilities To this end the Ministry of Surface Transport MoST has constituted a permanent Automotive Industry Standard Committee AISC vide order no RT 11028 11 97 MVL dated September 15 1997 The Standards prepared by AISC will be approved by the permanent CMVR Technical Standing Committee CTSC after approval The Automotive Research Association of India ARAI Pune being the secretariat of the AIS Committee has published this Standard For better dissemination of this information ARAI may publish this document on their website This Standard prescribes the CMVR Type Approval requirements for In use vehicles retrofitted with Hybrid Electric System Considerable assistance has been taken from the following ECE regulations 1 ECER 100 Uniform provisions concerning the approval of REESS electric vehicles with regard to specific requirements for the construction and functional safety 2 ECE R 101 Uniform provisions concerning the approval of passenger cars powered by an internal combustion engine only or powered by a hybrid electri
2. resistance type output The input stage of the signal sharing device shall have the following characteristics Differential input This will provide high common mode rejection It will not interfere with the electronics of the existing vehicle as it will not measure the signal with respect of signal ground High Input impedance The input stage impedance should be such a way that it will not load the earlier stage After loading the sensor signal by additional circuit drop in the sensor voltage should not be more than 0 25 of sensor voltage before loading the circuit The device should not allow reverse flow of current The input stage should not pick up any noise The input stage shall not introduce noise if it is kept open The additional circuit shall not have any adverse effect on the existing sensor circuit Example of Voltage Resistance type sensors Throttle Position Sensor Pressure sensor Temperature sensor O2 sensor Air Flow sensor Similar approach is in use for sharing the sensor in a CNG LPG close loop systems For e g O2 Sensor Voltage type Throttle Position sensor potentiometric type Crankshaft position sensor pulse type In case of CNG LPG systems the fuel injectors of the existing system are cut off using an electronic circuit called Emulator It also emulates i e gives false impression to the ECU as if the engine is running on fuel The Motor controller amp onboard charger shall b
3. HEV S D 1 In the case of M and N category vehicles emissions of carbon dioxide CO and fuel consumption shall be determined separately for the Part One urban driving and the Part Two extra urban driving of the specified driving cycle D 2 Test Results D 2 1 The test results fuel consumption C 1 100 km and CO emission M g km of the test are corrected in function of the energy balance AEpa of the vehicle s REESS The corrected values Co 1 100 km and Mo g km should correspond to a zero energy balance AEpat 0 and are calculated using a correction coefficient determined by the HES manufacturer supplier as defined below In case of other storage systems than an electric REESS AEbat is representing AEstorage the energy balance of the electric REESS device D 2 2 The electricity balance Q Ah measured using the procedure specified in Appendix 2 of Annex E is used as a measure of the difference in the vehicle REESS s energy content at the end of the cycle compared to the beginning of the cycle In the case of M and N category vehicles the electricity balance is to be determined separately for the Part One cycle and the Part Two cycle D 2 3 Under the conditions below it is allowed to take the uncorrected measured values C and M as the test results a in case the HES manufacturer supplier can prove that there is no relation between the energy balance and fuel consumption b incase that AEpar always corresponds to
4. Signature Name Name Designation Designation Date Date Sheet no a nee 39 52 Draft AIS 123 F1 February 2013 4 Gear Box 4 1 Model 4 2 Type 4 3 No of Gears 4 4 Gear ratio 1 ond 3rd qth 5th 6 Reverse 4 5 Front Axle 4 6 Rear Axle 4 7 Ratio 5 Steering 5 1 Steering Wheel Diameter 5 2 Ratio 6 Frame 6 1 Long member size mm 6 2 No of cross members 7 Suspension 7 1 Front T2 Rear 8 Brake 8 1 Service Brake 8 2 Front 8 3 Rear 8 4 Parking Brake 8 5 Wheels and Tyres Test Agency Manufacturer Document No indicating revision status Signature Signature Name Name Designation Designation Date Date Sheet no of 40 52 Draft AIS 123 F1 February 2013 9 Electrical System 9 1 System voltage 9 2 REESS 9 3 Alternator Max Output 10 Dimensions 10 1 Wheel Base mm 10 2 Overall Width mm 10 3 Overall Length mm 10 4 Front Track mm 10 5 Rear Track mm 10 6 Min Ground Clearance mm 10 7 Cargo Box Dimensions 10 8 Load Body Platform Area 11 Weights 11 1 Gross Vehicle Weight GVW 11 2 Unladen Weight ULW with 90 fuel Spare wheel amp tools etc 11 3 Front Axle weight FAW 11 4 Rear Axle weight RAW 11 5 Maximum Gradeability in 1st Gear 12 Other details 12 1 Fuel capacity 12 2 Seating capacity Test Agency Manufacturer Document No indicatin
5. Typical layout shall indicate details of circuit brakers MCBs used location of charger etc and key HES components 14 Catalytic Converter OE fitted a Name of manufacturer b Model name Identification No c Type 15 Current limiting Device Fuse a Name of manufacturer b Identification No c Voltage current rating d Type 16 Main Contactor REESS Cut off Switch a Name of manufacturer b Identification No c Voltage current rating d Type Test Agency Manufacturer Document No indicating revision status Signature Signature Name Name Designation Designation Date Date Sheet no Ofe 38 52 Draft AIS 123 F1 February 2013 ANNEXURE F See 18 0 TECHNICAL SPECIFICATION OF IN USE VEHICLE RETROFITTED WITH HYBRID ELECTRIC SYSTEM 1 General Description of Vehicle 1 1 Vehicle Make Model 1 2 Vehicle Type 1 3 Year and Month of Manufacture 1 4 Engine No 1 5 Chassis No 1 6 Type of hybrid vehicle Externally chargeable Not externally chargeable 1 7 Mode selection switch provided Yes No 1 8 If yes the modes available 2 Engine 2 1 Type 2 2 Bore x Stroke mm 2 3 No of Cylinders 2 4 Displacement 25 Compression Ratio 2 6 Max Engine Output 2 1 Max Torque 2 8 Weight of Engine Complete 3 Clutch 3 1 Type 3 2 Outside Diameter Test Agency Manufacturer Document No indicating revision status Signature
6. charging OVC NOVO Operating without with without with mode switch Y also known as externally chargeable 2 also known as not externally chargeable A 2 0 Vehicles Retrofitted with Hybrid Electric System Externally chargeable without an operating mode switch Two tests shall be performed under the following conditions a Condition A test shall be carried out with a fully charged electrical energy power storage device b Condition B test shall be carried out with an electrical energy power storage device in minimum state of charge maximum discharge of capacity c The profile of the state of charge SOC of the electrical energy power storage device during different stages of the Type I test is given in Appendix 1 of this Annexure A 2 1 Condition A A 2 1 1 Discharge of REESS The procedure shall start with the discharge of the electrical energy power storage device as described in paragraph 2 1 1 1 below 2 1 1 1 Discharge of the electrical energy power storage device The electrical energy power storage device of the vehicle is discharged while driving on the test track on a chassis dynamometer etc a Ata steady speed of 50 km h until the fuel consuming engine starts up b Or if a vehicle cannot reach a steady speed of 50 km h without starting up the fuel consuming engine or for other reasons 12 52 Draft AIS 123 F1 February 2013 the speed shall be reduced
7. A discharge according to paragraph A 2 2 2 of Annex A soak according to paragraph A 2 2 3 of Annex A test according to paragraph A 2 2 4 of Annex A charging according to paragraph A 2 2 5 1 discharging according to paragraph A 2 2 5 2 charging according to paragraph A 2 2 5 3 22 52 Draft AIS 123 F1 February 2013 ANNEXURE A APPENDIX 2 METHOD FOR MEASURING THE ELECTRICITY BALANCE OF TI REESS OF OVC AND NOVC HEVS 1 Introduction 1 1 The purpose of this appendix is to define the method and required instrumentation for measuring the electricity balance of Off Vehicle Charging Hybrid Electric Vehicles OVC HEV and Not Off Vehicle Charging Hybrid Electric Vehicles NOVC HEVs Measurement of the electricity balance is necessary a To determine when the minimum state of charge of the REESS has been reached during the test procedure defined in paragraphs A 2 0 and A 3 0 of Annexure A and b To correct the measured fuel consumption and CO2 emissions for the change in REESS energy content occurring during the test using the method defined in paragraphs A 5 0 and A 6 0 Of annexure A 1 2 The method described in this annex shall be used by the HES manufacturer supplier for the measurements that are performed to determine the correction factors K fuel and KCO2 as defined in paragraphs A 4 0 and A 5 0 of this Annexure A The Testing Agency shall check whether these measurements have been performed in accordance with the pr
8. cycle the accelerator pedal shall remain fully depressed until the reference curve has been reached again C 4 2 2 3 To respect human needs up to three interruptions are permitted between test sequences of no more than 15 minutes in total C 4 2 2 4 At the end the measure De of the covered distance in km is the electric range of the hybrid electric vehicle It shall be rounded to the nearest whole number as per IS 2 Where the vehicle operates both in electric and hybrid modes during the test the periods of electric only operation will be determined by measuring current to the injectors or ignition C 4 2 3 To determine the OVC range of a hybrid electric vehicle C 4 2 3 1 To measure the OVC range the end of the test criteria is reached when the REESS has reached its minimum state of charge according to the criteria defined in Annex B paragraph A 2 1 4 4 2 Driving is continued until the final idling period in the extra urban cycle C 4 2 3 2 To respect human needs up to three interruptions are permitted between test sequences of no more than fifteen minutes in total C 4 2 3 3 At the end the total distance driven in km rounded to the nearest whole number as per IS 2 is the OVC range of the hybrid electric vehicle 30 52 Draft AIS 123 F1 February 2013 ANNEXURE D See A 4 4 and A 5 4 SPECIAL REQUIREMENTS FOR MEASUREMENT AND CORRECTION OF THE TEST RESULTS FOR CO AND FUEL CONSUMPTION FOR NOT EXTERNALLY CHARGEABLE NOVC
9. dimension is measured from the outer edge Kindly refer the drawing given below E E E E reece r acer ec seceeseeGes a neSeceleee stesso meses ace cig AE E E A EEA A AEE A E A tases cescas see acees Draft AIS 123 F1 February 2013 4 17 Safety Instructions Minimum one copy of safety instructions shall be displayed in passenger s compartment 5 Responsibility of the HES Installer 5 1 Criteria to Authorize Hybrid Electric System HES Installer Only the Installer authorized by HES manufacturer HES supplier shall fit the HES on vehicles For this purpose the HES manufacturer HES supplier shall issue a certificate of authorization to the installer concerned duly authorizing them to fit the HES on behalf of HES manufacturer HES supplier Only that fitment Centre s shop s which are the franchise dealership of the HES manufacturer HES supplier shall be allowed to carry out the HES fitments 5 2 HES installer shall be equipped with the following tools and equipment Two post lift ramp Electric hand drill machine and H S S drill bits Set of D ring and box spanners Set of screw driver both flat and star Set of Allen keys H S S hand saw Crimping tool for electrical cable termination if required Set letter and number punch Measurement tape Torque Wrench Inspection light Vernier caliper Multimeter Silicon seal sealant Alignment tool Belt tension measuring equipment Puller Fire fi
10. limiting the torque and protecting against overloads and faults REESS REESS means a single mechanical assembly comprising of REESS modules and retaining frames or trays A vehicle may have one or several REESS Charger Means for charging REESS from external power supply Charging Socket Charging Socket means all the parts used to connect the vehicle to an external electric power supply alternative or direct current supply 42 52 Draft AIS 123 F1 February 2013 e Wiring Harness Power and Control Wiring harness is an assembly of cable or wires which transmit electric signals or electrical power e SOC Indicator REESS state of Charge Indicator e Hybrid ECU Electronic Control Unit to manage the Hybrid Electric system s operation e BMS REESS Management System is an electronic Control Unit to manage the REESS operation and ensure safety 4 Responsibility of HES manufacturer HES supplier The retrofitment of the HES shall be type approved by any one of the testing agencies specified in Rule 126 of the Central Motor Vehicle Rules The responsibility of the type approval and ensuring that the HES manufactured comply with the provisions thereof shall be that of the HES manufacturer HES supplier as the case may be 4 1 The HES manufacturer HES supplier should have third party ISO 9000 certification The ISO 9000 certificate shall be submitted to the test agency at the time of type approval 4 2 After
11. out as per AIS 041 Environmental validation tests for Traction Motor Manufacturer supplier of Hybrid Electric System should provide the test reports of the following tests Conducted on Traction Motor a Thermal Shock test Test shall be carried out as per IS 3141 2007 b Media resistance test Test shall be carried out as per IS 3141 2007 c Impact test Test shall be carried out as per IS 9000 Part 7 Sec1 2006 d Dust Test f Test shall be carried out as per IS 3141 2007 e Water immerse test Test shall be carried out as per IS 8925 1978 EMI TEST Test shall be carried out on component level as per AIS 004 Part1 1999 REESS charger shall be excluded from the test as it utilized when vehicle is in off condition EMC TEST Test shall be carried out on component level as per AIS 004 Part3 2009 as and when it becomes applicable VERTICAL ORIENTATION OF DIPPED BEAM HEAD LAMP HES Manufacturer HES Supplier shall carry out Head Lamp Leveling adjustment on retrofitted vehicle at the time of submition of the vehicle for type approval For such adjustment refer procedure given in AIS 008 Declaration to this effect shall be provided by HES Manufacturer HES Supplier to the Type Approval test agency REQUIREMENTS FOR CONSTRUCTIONAL amp FUNCTIONAL SAFETY Requirements for Constructional amp Functional safety shall be as per requirements laid down in Clause no 11 0 of AIS 102 Part 1 2009 8 52 16 0 16 1 17
12. s equipped with a pure electric mode the procedure shall start with the discharge of the electrical energy power storage device of the vehicle while driving with the switch in pure electric position on the test track on a chassis dynamometer etc at a steady speed of 70 per cent 5 per cent of the maximum thirty minutes speed of the vehicle determined according to clause 6 0 of AIS 041 Stopping the discharge occurs when any of the following conditions happens earliest e when the vehicle is not able to run at 65 per cent of the maximum thirty minutes speed or e when an indication to stop the vehicle is given to the driver by the standard onboard instrumentation or e after covering the distance of 100 km A 3 3 2 In case of HEV s not equipped with pure electric mode the discharge procedure shall be as per A 2 1 1 A 3 4 Final test results shall be obtained using procedure given in A 2 3 A 4 0 Vehicles Retrofitted with Hybrid Electric System Not Externally chargeable without an operating mode switch A 4 1 These vehicles shall be tested according to MORTH CMVR TAP 115 116 A 4 2 In the case of M and N category vehicles for preconditioning at least two consecutive complete driving cycles one Part One and one Part Two are carried out without soak A 4 3 The vehicle shall be driven according to driving cycles prescribed taking into account requirements given in paragraph A 2 1 4 2 in case of special gear shift
13. shall be exempted A 6 3 If necessary the special procedure provided for in paragraph A 6 4 shall be used A 6 4 It shall be possible to inspect the vehicle for roadworthiness test in order to determine its performance in relation to the data collected in accordance with the procedure prescribed in MORTH CMVR TAP 115 116 If this inspection requires a special procedure this shall be detailed in the service manual or equivalent media This special procedure shall not require the use of special equipment other than that provided with the vehicle 21 52 Draft AIS 123 F1 February 2013 ANNEXURE A See A 2 0 c Appendix 1 ELECTRICAL ENERGY POWER STORAGE DEVICE STATE OF CHARGE SOC PROFILE FOR OVC HEV S The SOC profiles for OVC HEV s tested under conditions A and B are Condition A minimum 1 2 3 4 5 6 100 initial state of charge of the electrical energy power storage device discharge according to paragraph A 2 1 1 or A 3 3 of Annex A vehicle conditioning according to paragraph A 2 1 2 of Annex A charge during soak according to paragraph A 2 1 3 2 of Annex A test according to paragraph A 2 1 4 of Annex A charging A 2 1 4 4 Condition B 100 f soc mmimum Po 1 2 3 4 5 6 7 8 ww www wne esbeccoqes et eee ee coepecepecess 1 2 3 4 5 6 7 8 initial state of charge vehicle conditioning according to paragraph A 2 2 1 of Annex
14. shall follow the guidelines mentioned below for sharing the signal from existing sensors in a vehicle This approach will ensure that the signals are not loaded and do not impact the functioning of the existing systems in the vehicle 4 9 5 1 Guidelines for sharing sensors with pulse frequency output Or digital output 4 9 5 1 1 The input stage impedance should be such a way that it will not load the earlier stage After loading the sensor signal by additional circuit drop in the sensor voltage should not be more than 0 5 of sensor voltage before loading the circuit 4 9 5 1 2 Logic zero voltage should not lift up due to sharing circuit 4 9 5 1 3 The device should not allow reverse flow of current 4 9 5 1 4 The input stage should not pick up any noise 4 9 5 1 5 The input stage shall not introduce noise if it is kept open 4 9 5 1 6 The additional circuit shall not have any adverse effect on the existing sensor circuit Examples of pulse frequency output type sensors Vehicle Speed sensor VSS Pressure sensor Engine Speed sensor Examples of Digital output type sensors Brake Switch Clutch switch Air Condition ON OFF switch Pressure switch Temperature switch 45 52 4 9 5 2 4 9 5 2 1 4 9 5 2 2 4 9 5 2 3 4 9 5 2 4 4 9 5 2 5 4 9 5 2 6 4 9 5 3 4 9 5 4 4 9 5 5 Draft AIS 123 F1 February 2013 Guidelines for sharing sensors with voltage potentiometric
15. until the vehicle can run at a lower steady speed where the fuel consuming engine just does not start up for a defined time distance to be specified between testing agency and HES HES manufacturer supplier HES supplier c Or with HES HES manufacturer supplier s HES supplier s recommendation The fuel consuming engine shall be stopped within 10 seconds of it being automatically started A 2 1 2 Conditioning of Vehicle A 2 1 2 1 Vehicle with Compression Ignition Engine For conditioning compression ignition engined vehicles the Part Two cycle of the applicable driving cycle shall be used in combination with the applicable gear shifting prescriptions as defined in paragraph A 2 1 4 2 of this annexure Three consecutive cycles shall be driven A 2 1 2 2 Vehicle with Positive Ignition Engine Vehicles fitted with positive ignition engines shall be preconditioned with one Part One and two Part Two cycles of the applicable driving cycle in combination with the applicable gear shifting prescriptions as defined in paragraph A 2 1 4 2 of this annexure A 2 1 3 Soak A 2 1 3 1 After this preconditioning and before testing the vehicle shall be kept in a room in which the temperature remains relatively constant between 293 and 303 K 20 C and 30 C This conditioning shall be carried out for at least six hours and continue until the engine oil temperature and coolant if any are within 2 K of the temperature of the room and the elect
16. 0 17 1 ee 17 3 Draft AIS 123 F1 February 2013 REQUIREMENTS FOR RECHARGEABLE ENERGY STORAGE SYSTEM REESS Requirements for REESS shall be applicable as per AIS048 For HES component level testing will be done The test reports provided by HES manufacturer HES Supplier shall also be considered as compliance to this requirement WIRING HARNESS CABLES CONNECTORS Manufacturer supplier of Hybrid Electric System should comply with the following standards and Guidelines for Control Power harness and all connectors used in harness OR Manufacturer supplier of Hybrid Electric System should provide the test reports of the following tests Conducted on Control Power harness and all connectors used in harness as given in 17 2 and 17 3 The cables used in the harness shall comply with following tests as mentioned in ISO6722_ 2006 a Electrical characteristics Withstand Voltage Test shall be carried out as per clause 6 2 Of ISO 6722 2006 b Low temperature Characteristics Test shall be carried out as per clause 8 of ISO 6722 2006 c Heat ageing Thermal Overload Test shall be carried out as per clause 10 3 Of ISO 6722 2006 d Resistance to chemicals Fluid compatibility Test shall be carried out as per clause 11 2 2 amp 11 2 3 of ISO 6722 2006 e Resistance to flame propagation f Test shall be carried out as per clause of ISO 6722 2006 General guidelines for performance and reliability of single
17. 071 Part 1 GRADEABILITY TEST Test shall be carried out as per AIS 003 1999 with increased Weight of HES as declared by HES manufacturer HES Supplier MASS EMISSION TEST PROCEDURE Emission Test procedure for vehicles retrofitted with hybrid electric system is as per annexure A The HES retrofitted vehicle shall meet base vehicle model year exhaust emission norm The Emission test procedure shall be as per MoRTH CMVR TAP 115 116 with changes as given in Annexure A BRAKE PERFORMANCE Brake performance test for Vehicles retrofitted with Hybrid Electric System HES shall be carried out with increased Weight of HES as declared by HES manufacturer HES Supplier The brake performance shall be evaluated as per IS 11852 2001 Part 3 to Part 9 and Annexure B MEASURMENT OF PASS BY NOISE LEVEL Test shall be carried out as per IS 3028 1998 Test shall be conducted on vehicle retrofitted with HES in following two different modes 1 Without powering Hybrid Electric System and result shall be recorded 2 With powering Hybrid Electric System and result shall be recorded 7 52 10 2 11 0 11 2 12 0 12 1 13 0 14 0 12 1 15 0 Draft AIS 123 F1 February 2013 Test result verification method Values of results with powering HES shall not be more by 2 dB than the values of results without powering HES TRACTION MOTOR TEST Following test shall be carried out on traction motor Motor Power Test Test shall be carried
18. 1 4 6 2 4 6 3 4 6 4 4 6 5 4 6 6 The Owner s manual shall be prepared by the HES manufacturer HES supplier and shall clearly highlight the changes that would supersede the OEM vehicle Owner s manual Hybrid system manual shall clearly highlight the changes that would supersede the original manual The HES manufacturer HES supplier shall ensure and instruct the HES installers that the HES owner s manual is provided with every HES installed vehicles The Owner s manual shall cover the following minimum information Approved HES layout diagram Description of the HES including description of major components and their theory of operation REESS charging procedure Warranty information of HES It should include the warranty information of HES and its implications on the warranty provided by OEM Base vehicle manufacturer This notification must be signed by the purchaser prior to sale of the HES Listing of necessary service intervals and a Check list for checks will be provided in owner s manual Owner s manual shall cover FAQs amp trouble shooting of HES The HES manufacturer HES supplier shall submit the complete owner s manual to the test agency along with the application of the type approval In case the owner s manual is not available at the time of submitting the prototype vehicle they shall be submitted by the HES manufacturer HES supplier as and when they are ready but not later than b
19. 36 52 Draft AIS 123 F1 February 2013 IEC protection class Conduits provided Yes No Cable size DC side sqmm Cable size AC side sqmm Electrical circuit diagram and Layout op oq ph Control Harness Name of manufacturer Model name Identification No Type FLRY Operating Temperature Insulation material used IEC protection class Conduits provided Yes No Cable size in sqmm Electrical circuit diagram and Layout ropa ho ao op 10 REESS State of Charge SOC and Fault indicator HMI a Name of manufacturer b Model name Identification No c Type d Details of indication when state of charge of the REESS reaches a level when the manufacturer recommends re charging i Indication format ii Relationship of state of charge indicator and the indication 11 Hybrid Controller Unit a Name of manufacturer b Model name Identification No c Type 12 REESS Management System Popularly known as Battery Management System BMS a Name of manufacturer b Model name Identification No c Type Test Agency Manufacturer Document No indicating revision status Signature Signature Name Name Designation Designation Date Date Sheet no Of 37 52 Draft AIS 123 F1 February 2013 13 Brief Description of System Including Dimensional Layout for Hybrid Electric System components Installation in the vehicle
20. B 1 0 Definitions B 1 1 Electric Regenerative Braking System A braking system which during deceleration provides for the conversion of vehicle kinetic energy into electrical energy B 1 2 Electric Regenerative Brake Control A device which modulates the action of the electric regenerative braking system B 1 3 Electric Regenerative Braking System of Category A An electric regenerative braking system which is not part of the service braking system B 1 4 Electric Regenerative Braking System of Category B An electric regenerative braking system which is part of the service braking system B 2 0 Vehicles fitted with Electric Regenerative Braking System of Category A B 2 1 The electric regenerative braking shall be only activated by accelerator control and or the gear neutral position In addition for vehicles of categories M2 the electric regenerative braking control can be a separate switch or lever B 2 2 In the case of vehicles fitted with Category A type of regenerative barking system any separate electric regenerative braking control which is provided shall not be used during the Type P and Type F tests B 3 0 Vehicles fitted with Electric Regenerative Braking System of Category B B 3 1 It shall not be possible to disconnect partially or totally one part of the service braking system other than by an automatic device B 3 2 The service braking system control shall also actuate the action of the electric regenerative brak
21. C 4 1 1 2 2 The procedure for discharge of the electrical energy power storage device of the vehicle is as per paragraph A 2 1 1 C 4 1 1 3 For externally chargeable hybrid electric vehicle OVC HEV with an operating mode switch C 4 1 1 3 1 If there is not a pure electric position the HES manufacturer supplier shall provide the means for performing the measurement with the vehicle running in pure electric operating state The procedure for discharge of the electrical energy power storage device of the vehicle is as per paragraph A 2 1 1 C 4 1 1 3 2 If there is a pure electric position the procedure for discharge of the electrical energy power storage device of the vehicle is as per paragraph A 3 3 1 C 4 1 2 Application of a Normal Overnight Charge The electrical energy power storage device shall be charged according to the normal overnight charge procedure given below C 4 1 2 1 Normal Overnight Charge Procedure The charging is carried out a with the on board charger if fitted or b with an external charger recommended by the HES manufacturer supplier using the charging pattern prescribed for normal charging c in an ambient temperature comprised between 20 C and 30 C HES manufacturer supplier This procedure excludes all types of special charges that could be automatically or manually initiated like for instance the equalisation charges or the servicing charges The HES manufacturer supplier shall declare t
22. Draft AIS 123 F1 February 2013 FINALISED DRAFT AUTOMOTIVE INDUSTRY STANDARD CMVR Type Approval of Vehicles Retrofitted with Hybrid Electric System ARAI Date of hosting on website 15 February 2013 Last date for comments 15 March 2013 1 52 Draft AIS 123 F1 February 2013 CHECK LIST FOR PREPARING AUTOMOTIVE INDUSTRY STANDARD Draft AIS 123 CMVR Type Approval of Vehicles Retrofitted with Hybrid Electric System SR PARTICULARS REMARKS NO l Indicate details of the base reference standard AIS 102 Part 1 eg ECE EEC Directive GTR etc 2 Add an explanatory note indicating differences Nil between the above standard and the draft if any 3 Specify details of technical specifications to be Included in the standard Annex E submitted at the time of type approval relevant to the and Annex F requirements of this standard covered 4 Are the details of Worst Case Criteria covered Not applicable 5 Are the performance requirements covered Yes 6 Is there a need to specify dimensional requirements No 7 If yes are they covered NA 8 Is there a need to specify COP requirements Will be considered in future If yes are they covered 9 Is there a need to specify type approval and routine No test separately as in the case of some of the Indian Standards If yes are they covered NA 10 If the standard is for a part component or sub system i AIS 037 or ISI mar
23. S manufacturer supplier shall be verified by Test Agency at the time of type approval REESS compartments containing REESS modules which may produce hazardous gases shall be safely ventilated Details of ventilation provided by HES manufacturer supplier shall be verified by the Test Agency at the time of type approval REESS and the electric power train shall be protected by properly rated fuse or circuit breakers The components on the vehicle shall be as per the specifications declared by the HES manufacturer supplier as per information provided in AIS 007 Annexure E and F The same shall be verified by the Test Agency at the time of type approval Mounting of REESS The mounting REESS in HES fitted vehicle operated vehicle shall be such that REESS is not displaced from its place and there is no spillage of electrolyte when vehicle is driven on gradient or any other type of road This condition shall be deemed to be satisfied if no spillage of electrolyte is observed while conducting various tests for type approval 47 52 4 13 5 4 13 6 Draft AIS 123 F1 February 2013 Creepage Distance Measurement For REESS This clause deals with additional leakage current hazard between the connection terminals of REESS including any conductive fittings attached to them and any conductive parts due to the risk of electrolyte spillage in normal operating conditions It does not apply to REESS for which electrolyte leakage will not occur under n
24. S supplier as well as documentation required by law The HES installer shall assess the fitness of the vehicle for HES fitment explain the same to vehicle owner and seek written consent from vehicle owner Responsibility of HES Vehicle Owner Vehicle owner shall get his HES serviced at HES manufacturer HES supplier authorized franchise shop only as per given service intervals specified in Owner s manual Vehicle owner shall use spare parts recommended by HES manufacturer HES supplier For any kind of HES related repair Vehicle owner has to contact HES manufacturer HES supplier authorized franchise shop In case of any concern issues with the HES installed vehicle the vehicle owner shall first contact HES manufacturer HES supplier for assistance Vehicle owner shall follow safety instructions provided by HES manufacturer HES supplier HES Installer Vehicle owner shall not allow any tampering unauthorized modification in configuration settings or components of HES fitted in the vehicle Vehicle owner shall not allow any unauthorized use of components of HES fitted in the vehicle 6 8 The vehicle owner shall apply to the concerned registering authority within 14 days 6 9 of undertaking the alteration as required under Section 52 of Motor Vehicle Act 1988 for endorsement of particular alteration in registration certificate mentioning place and date of installation and installation certificate number HES
25. a REESS charging c incase that AE always corresponds to a REESS decharging and AEpat iS within 1 per cent of the energy content of the consumed fuel consumed fuel meaning the total fuel consumption over one cycle Energy content of the consumed fuel can be calculated from the following equation Total Fuel Energy NHV fuel Mfuel Where NHV fae Net heating value of consumable fuel in J kg Mface Total mass of fuel consumed over one test cycle The change in REESS energy content AEpat can be calculated from the measured electricity balance Q as follows AE par ASOC ETEban 0 0036 AAH Via 0 0036 Q V bat MJ 31 52 Draft AIS 123 F1 February 2013 with Ertebat MJ the total energy storage capacity of the REESS and Vpatt V the nominal voltage D 3 Fuel Consumption Correction Coefficient Kruc Defined by the HES manufacturer supplier D 3 1 The fuel consumption correction coefficient Knei shall be determined from a set of n measurements performed by the HES manufacturer supplier This set should contain at least one measurement with Q lt 0 and at least one with Q gt 0 D 3 2 If the latter condition can not be realised on the driving cycle Part One or Part Two of modified Indian Driving Cycle in the case of M and N category or IDC in the case of L category as applicable used in this test then it is up to the testing agency to judge the statistical significance of the extrapolation necessary to
26. anges are in parameters not related to the provisions of this standard no further action need be taken If the changes are in parameters related to the provisions of this standard the testing agency shall then consider whether a the model with the changed specifications still complies with provisions of this standard or b any further verification testing is required to establish compliance For considering whether any further verification testing is required or not guidelines given in Annexure H shall be used for the electrical requirements For other cases the guide lines given in the individual standard shall be applicable In case of 20 2 b verification for only those parameters which are affected by the modifications needs to be carried out 10 52 20 4 20 5 21 22 22 1 23 23 1 23 2 Draft AIS 123 F1 February 2013 In case of fulfillment of criterion of para 20 2 a or after results of further verification as per para of 20 2 b are successful the approval of compliance shall be extended for the changes carried out Tests such as Evaporative emission crankcase emission idling emission full load smoke for diesel engine vehicles etc need not be carried out if the related technical specification is same as those of a model already type approved VALIDITY OF ANNEXURES It is expected that in due course of time the details given in Annexures A amp C would be incorporated in CMVR AIS 102 Pa
27. aph C 4 1 2 and C 4 1 3 The energy measurement equipment placed between the mains socket and the vehicle charger measures the charge energy e2 Wh delivered from the mains A 2 2 5 2 The electrical energy power storage device of the vehicle shall be discharged in accordance with paragraph A 2 1 1 A 2 2 5 3 Within the 30 minutes after discharge the electrical energy power storage device shall be charged according to paragraph C 4 1 2 and C 4 1 3 The energy measurement equipment placed between the mains socket and the vehicle charger measures the charge energy e3 Wh delivered from the mains A 2 2 5 4 The electric energy consumption e4 Wh for condition B is e4 e2 e3 15 52 A 2 3 0 A 2 3 1 Draft AIS 123 F1 February 2013 Final Test Results In the case of testing according to paragraph A 2 1 4 4 1 The final results of pollutants for deciding on compliance and for CO shall be Mi De x Mli Dav x M21 De Dav where Mi mass emission of the pollutant i in grams per kilometer Mli average mass emission of the pollutant i in grams per kilometre with a fully charged electrical energy power storage device determined as per paragraph A 2 1 4 M2i average mass emission of the pollutant i in grams per kilometre with an electrical energy power storage device in minimum state of charge maximum discharge of capacity determined as per paragraph A 2 2 4 De vehicle electric range according to the proce
28. ation Mo M Kcoz Q g km where C CO emission measured during test g km Q electricity balance measured during test Ah In the case of M and N category CO gt emission at zero energy balance shall be determined separately for the CO2 emission values measured over the Part One cycle and the Part Two cycle respectively 34 52 Draft AIS 123 F1 February 2013 ANNEXURE E See 18 0 TECHNICAL SPECIFICATION OF HYBRID ELECTRIC SYSTEM pd Details of Hybrid System Manufacturer Supplier Installer Name of the HES Manufacturer HES Supplier Address Telephone No amp Fax No Contact person adage 2 System Identification a Identification No b Variants if any 3 Electric Motor Name of manufacturer Model name Identification No Type e g Asynchronous AC Induction Synchronous Permanent Magnet AC BLDC SRM etc No of Phases Maximum Power kw xxxx rpm Maximum torque Nm xxxx rpm Maximum Thirty Minutes Power kW Maximum Thirty Minutes speed km h Cooling System Liquid Air Naturally air cooled International Protection IP Code oof Sr pga hho a A Motor Controller Unit Name of manufacturer Model name Identification No Type Control Principle e g vectorial open loop closed other Cooling System Liquid Air Naturally air cooled International Protection IP Code monoges Test Agency Manufa
29. c power train with regard to the measurement of the emission of carbon dioxide and fuel consumption and or the measurement of electric energy consumption and electric range and of categories M1 and N1 vehicles powered by an electric power train only with regard to the measurement of electric energy consumption and electric range 4 52 1 0 2 0 Draft AIS 123 F1 February 2013 CMVR Type Approval of Vehicles Retrofitted with Hybrid Electric System SCOPE This standard lays down the requirements specific to vehicles retrofitted with hybrid electric system HES of M1 M2 and N1 category of vehicles which i Comply to BS II or subsequent emission norms il Operate on either Petrol or Diesel fuel only ili Have GVW not exceeding 3500 kg iv Have not been retrofitted earlier or are not operating on any other alternate fuel REFERENCES a AIS 038 Electric Power Train Vehicles Requirements for Construction and Functional Safety b AIS 039 Electric Power Train Vehicles Measurement of Electrical Energy Consumption c AIS 041 Electric Power Train Vehicles Measurement of Net Power and the Maximum 30 Minute Power and Speed d AIS 049 Electric Power Train Vehicles CMVR Type Approval for REESS Operated Vehicles e AIS 053 Automotive Vehicles Types Terminology f S82 Rules for Rounding off Numerical Values g IS 11852 Automotive Vehicles Brakes and Braking Systems 2001 h IS 11825 1986 Vehicle Weightme
30. correction coefficient Kco2 shall be determined as follows from a set of n measurements performed by the HES manufacturer supplier This set should contain at least one measurement with Q lt 0 and at least one with Qj gt 0 If the latter condition can not be realised on the driving cycle Part One or Part Two in the case of M and N category or IDC as applicable used in this test then it is up to the testing agency to judge the statistical significance of the extrapolation necessary to determine the CO2 emission value at AEpat 0 D 5 2 The CO gt emission correction coefficient Kco2 is defined as Keo n LQ Mj 2Q M n Q ZQ g km Ah where Mi CQOs emission measured during i th HES manufacturer supplier s test g km Qi electricity balance during i th HES manufacturer supplier s test Ah n number of data The CQO emission correction coefficient shall be rounded to four significant figures e g 0 xxxx or xx xx The statistical significance of the COp emission correction coefficient is to be judged by the testing agency D 5 3 In the case of M and N category separate CO emission correction coefficients shall be determined for the CO emission values measured over the Part One cycle and the Part Two cycle respectively D 5 4 CO gt emission at zero energy balance Mo 33 52 D 5 5 D 5 6 Draft AIS 123 F1 February 2013 The COz emission Mo at AEpar 0 is determined by the following equ
31. cturer Document No indicating revision status Signature Signature Name Name Designation Designation Date Date Sheet no of 35 52 nn N Sao mood Ss f amp moaoge N gt 79 nr anoop oao oop Draft AIS 123 F1 February 2013 REESS Name of manufacturer Identification No Type e g Lead Acid Li Ion etc Voltage Capacity kWh End of discharge voltage value No of batteries used Weight of REESS Charger Applicable only for Externally Chargeable HEV s Name of the manufacturer Model name Identification No Type Rating Charger on board external Specifications of mains i mains single phase three phase ii Nominal Voltage V amp frequency Hz with tolerances Recommended duration of a complete charge In case of on board charger i Continuous rating of charger socket A ii Maximum initial in rush current A Charging interlocking Socket Name of the manufacturer Model name Identification No Type Rating Power Harness Name of manufacturer Model name Identification No Type FLRY Operating Temperature Insulation material used Test Agency Manufacturer Document No Signature Signature indicating revision status Name Name Designation Designation Date Date Sheet no of
32. determine the fuel consumption value at AEpatt 0 The fuel consumption correction coefficient Kme is defined as K rnei 2 LQ C IQ EC n Q Q 1 100 km Ah where Ci fuel consumption measured during i th HES manufacturer supplier s test 1 100 km Qi electricity balance measured during i th HES manufacturer supplier s test Ah n number of data The fuel consumption correction coefficient shall be rounded to four significant figures e g 0 xxxx or xx xx The statistical significance of the fuel consumption correction coefficient is to be judged by the testing agency D 3 3 In the case of M and N category separate fuel consumption correction coefficients shall be determined for the fuel consumption values measured over the Part One cycle and the Part Two cycle respectively D 4 Fuel consumption at zero energy balance Co D 4 1 The fuel consumption Co at AEpat 0 is determined by the following equation Co C Kre Q 1 100 km where Cs fuel consumption measured during test 1 100 km Q electricity balance measured during test Ah 32 52 Draft AIS 123 F1 February 2013 D 4 2 In the case of M and N category fuel consumption at zero energy balance shall be determined separately for the fuel consumption values measured over the Part One cycle and the Part Two cycle respectively D 5 0 CO gt emission correction coefficient Kco2 defined by the HES manufacturer supplier D 5 1 The CO emission
33. dure described in Annex D where HES manufacturer supplier must provide the means for performing the measurement with the vehicle running in pure electric operating state Dav 25 km average distance between two REESS recharges A 2 3 2 In the case of testing according to paragraph A 2 1 4 4 2 The final results of pollutants for deciding on compliance and for CO2 shall be Mi Dove M1i Dav M21 Dove Dav Where Mi mass emission of the pollutant i in grams per kilometer Mli average mass emission of the pollutant i in grams per kilometre with a fully charged electrical energy power storage device determined as per paragraph A 2 1 4 M2i average mass emission of the pollutant i in grams per kilometre with an electrical energy power storage device in minimum state of charge maximum discharge of capacity determined as per paragraph A 2 2 4 Dove OVC range according to the procedure described in Annex D Dav 25 km average distance between two REESS recharges 16 52 A 2 3 3 A 2 3 4 A 2 3 4 1 A 2 3 4 2 Draft AIS 123 F1 February 2013 Fuel Consumption Reported fuel consumption shall be calculated by carbon balance method as per procedure prescribed in MORTH CMVR TAP 115 116 except that the values of HC CO and CO for calculation of fuel consumption shall be based on figures arrived at as per paragraph A 2 3 1 OR A 2 3 2 Electric Energy Consumption The values of electric energy consumption sha
34. e isolated from the vehicle Battery during Ignition off condition In case HES is connected to the grounded chassis it shall be equipped with Earth Leakage Dark current protection at any time when vehicle is connected to the external mains supply 46 52 Draft AIS 123 F1 February 2013 4 10 Traction Motor HES manufacturer HES supplier shall ensure that the motor used is in compliance with automotive requirements AIS 123 section 11 0 Motor Controller The motor controller shall be designed to provide protection for Short circuit over temperature Input and Output Overloading Controller should be so placed that the heat generated is adequately dissipated Charging Socket and its Location Vehicle starting system shall be disabled if the charging cable is plugged in to the vehicle In case of running engine if the charging cable is plugged in to the vehicle the engine shall be shut down To the extent possible charging socket shall be located close to On board charger if available The location of charging socket should be away from the fuel tank Preferably it should be on the opposite side of the fuel tank inlet The socket body should be adequately earthed to prevent sparking and subsequent hazard of fire 4 13 REESS 4 13 1 4 13 2 4 13 3 4 13 4 Installation of REESS in the vehicle shall not allow any potential dangerous accumulation of gases Details of the ventilation provided by HE
35. edure The test procedures defined in either paragraph A 2 1 4 4 1 or A 2 1 4 4 2 may be used A 2 1 4 4 1 Sampling shall begin BS before or at the initiation of the vehicle start up procedure and end on conclusion of the final idling period in the respective driving cycle end of sampling ES A 2 1 4 4 2 Sampling shall begin BS before or at the initiation of the vehicle start up procedure and continue over a number of repeat test cycles It shall end on conclusion of the final idling period in the first extra urban Part Two cycle during which the REESS reached the minimum state of charge according to the criterion defined below end of sampling ES The electricity balance Q Ah is measured over each combined cycle using the procedure specified in Appendix 2 to This annexure and used to determine when the REESS minimum state of charge has been reached The REESS minimum state of charge is considered to have been reached in combined cycle N if the electricity balance measured during combined cycle N 1 is not more than 3 per cent discharge expressed as a percentage of the nominal capacity of the REESS in Ah in its maximum state of charge as declared by the HES manufacturer supplier At the HES manufacturer supplier request additional test cycles may be run and their results included in the calculations in paragraphs below provided that the electricity balance for each additional test cycle shows less discharge of the REESS t
36. eginning of commercial production 4 7 Service manual for HES The HES manufacturer HES supplier shall make service manual available comprising of company s all service amp warranty policies 4 8 The HES manufacturer HES supplier shall impart training to installer on installation maintenance and operation of HES and issue the training certificate to installer after completion of training 4 9 Wiring harness cables amp connectors Guidelines for Installation amp Routing the Control amp Power Harness through vehicle 4 9 1 requirements of ISO 6722 2006 as per the clause 14 of AIS 123 Electric Cables used in Power and control wiring harness shall comply with the 44 52 4 9 2 4 9 3 4 9 4 4 9 5 Draft AIS 123 F1 February 2013 The electrical circuit shall be provided with current limiting and or short circuit protection device The layout of the wiring harnesses shall be such that they are secured tightly and shall be properly insulated or contained in a loom Non flammable corrugated tube along its length to avoid any metal contact of body damage by any means e g sharp metallic edges or sagging The HES manufacturer HES supplier has to select cables used for harness such a way that there shall not be any EMI causing malfunction of harness and other electrical systems of the vehicle Guidelines for sharing the signal from existing sensors in a vehicle The HES manufacturer HES supplier
37. g revision status Signature Signature Name Name Designation Designation Date Date Sheet no Of 41 52 Draft AIS 123 F1 February 2013 ANNEXURE G CODE OF PRACTICE FOR RETROFITMENT OF HYBRID ELECTRIC SYSTEM ON ICE VEHICLES 1 General This code of practice may be called as Code of Practice for Use of Hybrid Electric System retrofitted in Internal Combustion Engine Vehicles This code of practice is applicable for M1 M2 and N1 category vehicles 2 Scope This code of practice shall apply to the design installation operation inspection and testing and maintenance of Hybrid Electric System Henceforth referred as HES In general the Standard is directed towards vehicle installations 3 Definitions of key components For the purpose of this Standard the following definitions shall apply Hybrid Electric System HES Means Aggregate of components added by HES manufacturer HES supplier to the base vehicle for Hybrid Electric operation without modification change fuel type of base vehicle power train and base vehicle configuration Drive System Means of connecting the Electric Powertrain i e Motor to the engine or wheels Electric Motor An electromechanical device that converts electrical energy into mechanical energy Motor Controller Means for starting and stopping the motor selecting forward or reverse rotation selecting and regulating the speed regulating or
38. ghting equipment Dry chemical powder DCP type fire extinguisher minimum two numbers of 5 kg each with ISI mark CO2 type fire extinguisher minimum 1 number of 5 kg with ISI mark Fire buckets 2 buckets 5 3 Installer shall have trained technicians having qualification as specified by HES manufacturer HES supplier HES manufacturer HES supplier shall impart extensive training to the technicians on HES installation and certify the same 5 4 Installer to display in the premises authorization certificate issued by HES manufacturer HES supplier 5 5 The record of conversion of vehicles carried out by the HES installer shall be maintained and made available to the authorities such as MoRTH or agencies authorized by MoRTH as and when demanded 50 52 5 6 5 7 5 8 5 9 6 1 6 2 6 3 6 4 6 5 6 6 6 7 Draft AIS 123 F1 February 2013 HES Installer should do fitness and performance checks of the HES retrofitted vehicle at least once in a year and maintain the records of the parameters audited and observations as per the norms established by HES manufacturer HES supplier HES installer shall only use spare parts recommended by HES manufacturer HES supplier The HES installer shall install HES as per the guidelines and instructions provided by the HES manufacturer HES supplier The installer shall also provide all documentation to the vehicle owner as instructed by HES manufacturer HE
39. han over the previous cycle In between each of the cycles a hot soak period of up to ten minutes is allowed The powertrain shall be switched off during this period 14 52 Draft AIS 123 F1 February 2013 A 2 1 4 4 3 The test results on the combined cycle Mass emission for Condition A shall be recorded m1 gms km In the case of testing according to paragraph A 2 1 4 4 1 ml is simply the results of the single combined cycle run In the case of testing according to paragraph A 2 1 4 4 2 ml is the sums of the results of the N combined cycles run N ml f mi l A 2 1 4 4 4 Within the 30 minutes after the conclusion of the cycle of the electrical energy power storage device shall be charged according to paragraph C 4 1 2 and C 4 1 3 The energy measurement equipment placed between the mains socket and the vehicle charger measures the charge energy el Wh delivered from the mains The electric energy consumption for condition A is el Wh A 2 2 Condition B A 2 2 1 Conditioning of vehicle shall be as per paragraph A 2 1 2 A 2 2 2 Discharge of REESS shall be as per paragraph A 2 1 1 A 2 2 3 After this discharge of the REESS and before testing the vehicle shall be soaked as per paragraph A 2 1 3 A 2 2 4 Mass emission test shall be as per A 2 1 4 A 2 2 5 Measurement of Energy A 2 2 5 1 Within the 30 minutes after the conclusion of the cycle theelectrical energy power storage device shall be charged according to paragr
40. hat during the test a special charge procedure has not occurred C 4 1 3 End of Charge Criteria The end of charge criteria corresponds to a charging time of 12 hours except if a clear indication is given to the driver by the standard instrumentation that the electrical energy power storage device is not yet fully charged In this case 3 x claimed REESS capacity Wh Mains power supply W The maximum time is 29 52 Draft AIS 123 F1 February 2013 C 4 2 Application of the Cycle and Measurement of the Range C 4 2 1 The applicable test sequence as per the driving cycle used for mass emission testing is applied on a chassis dynamometer until the end of the test criteria is reached Gear shifting pattern shall be as prescribed in paragraph A 2 1 4 2 C 4 2 2 To determine the electric range of a hybrid electric vehicle C 4 2 2 1The end of the test criteria is reached earliest C 4 2 2 1 1 When the vehicle is not able to meet the target curve up to 30 km h C 4 2 2 1 2 or when an indication from the standard on board instrumentation is given to the driver to stop the vehicle C 4 2 2 1 3 or when the fuel consuming engine starts up Then the vehicle shall be slowed down to 5 km h by releasing the accelerator pedal without touching the brake pedal and then stopped by braking C 4 2 2 2 At a speed over speeds specified in paragraph C 4 2 2 1 when the vehicle does not reach the required acceleration or speed of the test
41. ing strategy A 4 4 Special requirements for measurement and correction of the test results for CO and fuel consumption are given in Annexure D A 5 0 Vehicles Retrofitted with Hybrid Electric System Not Externally chargeable with an operating mode switch A 5 1 These vehicles shall be tested in Hybrid mode according to MORTH CMVR TAP 115 116 If several hybrid modes are available the test shall be carried out in the mode that is automatically set after turn on of the ignition key normal mode On the basis of information provided by the HES manufacturer supplier the testing agency will make sure that the limit values are met in all hybrid modes 20 52 Draft AIS 123 F1 February 2013 A 5 2 Preconditioning of vehicle shall be as per A 4 2 A 5 3 The vehicle shall be driven according to driving cycles prescribed taking into account requirements given in paragraph A 2 1 4 2 in case of special gear shifting strategy A 5 4 Special requirements for measurement and correction of the test results for CO and fuel consumption are given in Annexure D A 6 0 Type II Test Methods Idling Emissions for SI Engines A 6 1 The vehicles shall be tested according to MoRTH CMVR TAP 115 116 with the fuel consuming engine running A 6 2 If applicable the HES manufacturer supplier shall provide a service mode that makes execution of this test possible However for HEV s using constant speed engine for charging of batteries above test
42. ing system simultaneously B 3 3 The service braking system shall not be adversely affected by the disengagement of the motor s or gear ratio used except during the short duration of operation of gear shifting 25 52 Draft AIS 123 F1 February 2013 B 4 0 If so desired by the HES manufacturer supplier the performance requirements may be verified without the use of the electric regenerative system by appropriately disconnecting the system If so this shall be recorded in the test report B 5 0 General For vehicles powered completely or partially by an electric motor or motor s permanently connected to the wheels all tests must be carried out with these motor s connected 26 52 C 1 0 C 2 0 C 3 0 C 3 1 C 3 1 1 C 3 1 2 C 3 1 3 C 3 1 4 Draft AIS 123 F1 February 2013 ANNEXURE C See A 3 METHOD OF MEASURING THE ELECTRIC RANGE OF VEHICLES POWERED BY RETROFITTED HYBRID ELECTRIC POWER TRAIN AND THE OVC RANGE OF VEHICLES POWERED BY RETROFITTED HYBRID ELECTRIC POWERTRAIN See A 2 3 1 A 2 3 3 and A 3 2 1 The test method described hereafter permits to measure the electric range and OVC range expressed in km of externally chargeable retrofitted HEV s OVC HEV as defined in paragraph A 1 A Parameters Units and Accuracy of Measurements Parameters units and accuracy of measurements shall be as given in Table C 1 Table C1 Parameters Units and Accuracy of Measurements Speed kmh ipercen
43. installer shall provide all relevant required by the vehicle owner to do so On receipt of intimation from the HES manufacturer HES supplier the vehicle owner shall make the vehicle available for annual fitness and performance check 51 52 Draft AIS 123 F1 February 2013 ANNEXURE H See 20 0 CRITERIA FOR EXTENSION APPROVAL 1 HES manufacturer and test agency shall mutually agree for test to be carried out in case of following variants a Change in Make Type rating of Motor b Change in Make Type rating of Motor Drive ECU c Change in Make Type rating of REESS d Change in cable harness Test Agency Manufacturer Document No indicating revision status Signature Signature Name Name Designation Designation Date Date Sheet no Ofiser 52 52
44. king scheme be Yes for HES kit implemented for this part ii Are there any requirements to be covered for Yes this part when fitted on the vehicle If yes has a separate standard been prepared Present standard includes vehicle installation performance tests as well 11 If the standard is intended for replacing or revising an NA already notified standard are transitory provisions for re certification of already certified parts vehicles by comparing the previous test result certain additional test etc required If yes are they included 2 52 Draft AIS 123 F1 February 2013 12 Include details of any other international or foreign No international standard reference national standards which could be considered as available alternate standard 13 Are the details of accuracy and least counts of test No equipment meters required to be specified If yes have they been included 14 What are the test equipments for establishing Regular test equipment for approval compliance of OE hybrid electric vehicles 15 If possible identify such facilities available in India ARAI Pune ICAT Manesar VRDE Ahmednagar 16 Are there any points on which special comments No or information is to be invited from members If yes are they identified 17 Does the scope of standard clearly identify vehicle Yes categories 18 Has the clarity of definitions been examined Yes
45. ll be E1 Deestt Wh km for condition A and E4 e4 Dtest2 Wh km for condition B with Desi and Des are the actual driven distances in the tests performed under conditions A A 2 1 4 and B A 2 2 4 respectively and e and e4 determined in paragraphs A 2 1 4 4 and A 2 2 5 4 respectively The weighted values of electric energy consumption shall be calculated as below A 2 3 4 2 1 In the case of testing according to paragraph A 2 1 4 4 1 E De E1 Day Es De Dav Where E electric consumption Wh km Ei electric consumption Wh km with a fully charged electrical energy power storage device calculated as per A 2 3 4 1 E electric consumption Wh km with an electrical energy power storage device in minimum state of charge maximum discharge of capacity A 2 3 4 1 De vehicle electric range according to the procedure described in Annex D where HES manufacturer supplier must provide the means for performing the measurement with the vehicle running in pure electric operating state 17 52 A 3 0 Draft AIS 123 F1 February 2013 25 km assumed average distance between two REESS recharges A 2 3 4 2 2 In the case of testing according to paragraph A 2 1 4 4 2 E Dove E1 Dav E4 Dove Dav Where E _ electric consumption Wh km El electric consumption Wh km with a fully charged electrical energy power storage device calculated as per A 2 3 4 1 E4 _ electric consumptio
46. m HES Means Aggregate of components added by manufacturer supplier to the base vehicle for Hybrid Electric operation without modification change fuel type of base vehicle power train and base vehicle configuration OVC range The total distance covered during complete combined cycles run until the energy imparted by external charging of the REESS or other electric REESS device is depleted as measured according to the procedure described in Appendix 2 of Annexure A Where necessary the definitions given in Annexure E of AIS 049 shall apply VEHICLE WEIGHTMENT Vehicle Weightment shall be done as per IS 11825 1986 with retrofitted HES Permissible increase in vehicle unladen weight due to HES shall be as follows Vehicle ULW kg Permissible increase Remarks Category in ULW M1 M2 lt 1100 21 M1 M2 gt 1100 17 N1 Equal to weight of Payload shall be reduced to the extent HES of HES weight 6 52 5 0 6 0 7 0 7 1 8 0 8 1 9 0 9 1 10 0 10 1 Draft AIS 123 F1 February 2013 COAST DOWN TEST Coast down test shall be done at the choice of HES manufacture supplier to find out vehicle coefficient for exhaust emission test Otherwise power table method shall be used VISUAL INDICATION HES manufacturer supplier shall provide minimum following indications REESS SOC Motor temperature HES Fault These indications shall be as per the guidelines of AIS
47. n Wh km with an electrical energy power storage device in minimum state of charge maximum discharge of capacity A 2 3 4 1 Dove OVC range according to the procedure described in Annex D Dav 25 km assumed average distance between two REESS recharges Vehicles Retrofitted with Hybrid Electric System Externally chargeable with operating mode switch Two tests shall be performed under the following conditions Condition A Test shall be carried out with a fully charged electrical energy power storage device Condition B Test shall be carried out with an electrical energy power storage device in minimum state of charge maximum discharge of capacity 18 52 A 3 1 Draft AIS 123 F1 February 2013 The operating mode switch shall be positioned according the table below REESS Hybrid modes State of charge Pure electric Pure fuel Pure electric Hybrid mode n u consumin j Pure ne Hybrid mode m M consuming Hybrid Hybrid Hybrid Switch in position Switch in position Switch in position Switch in position Condition A Condition B Fully charged Min state of charge Hybrid Hybrid Hybrid Most electric hybrid mode x Hybrid Fuel consuming Fuel consuming Most fuel f 3 consuming mode T 2 A 3 2 A 3 2 1 For instance sport economic urban extra urban position Most electric hybrid mode The hybrid mode which can be proven to have
48. nditions C 3 2 1 For testing performed outdoors the ambient temperature shall be between 5 C and 32 C C 3 2 2 The indoors testing shall be performed at a temperature between 20 C and 30 C C 3 2 3 The test may be carried out at temperatures different from those specified above at the request of HES manufacturer supplier C 4 0 Operation Modes The test method includes the following steps a Initial charge of the REESS b Application of the cycle and measurement of the electric range Between the steps if the vehicle shall move it is pushed to the following test area without regenerative recharging C 4 1 Initial Charge of the REESS Charging the REESS consists of the following procedures Note Initial charge of the REESS applies to the first charge of the REESS at the reception of the vehicle In case of several combined tests or measurements carried out consecutively the first charge carried out shall be an initial charge of the REESS and the following may be done in accordance with the normal overnight charge procedure C 4 1 1 Discharge of the REESS C 4 1 1 2 For externally chargeable hybrid electric vehicle OVC HEV without an operating mode switch C 4 1 1 2 1 The HES manufacturer supplier shall provide the means for performing the measurement with the vehicle running in pure electric operating state OR as recommended by HES manufacturer supplier 28 52 Draft AIS 123 F1 February 2013
49. nt i IS 3028 1998 Automotive Vehicles Noise Emitted by moving Vehicles Method of measurement j AIS 003 1999 Automotive Vehicles Starting Gradeability Method of Measurement and Requirements k AIS 004 Part 1 1999 Electromagnetic Radiation from Automotive Vehicle Permissible Levels amp Methods of Tests 5 52 Draft AIS 123 F1 February 2013 1 AIS 004 Part 3 2009 Automotive Vehicles Requirements for Electromagnetic Compatibility m AIS 008 Rev 1 Vertical Orientation of dipped beam Head Lamp n ISO 6722 2006 i Road vehicles 60V and 600V single core cables Dimensions test method and requirements o JASO D 616 2011 Automotive parts Test method and general performance requirements for wiring harness connectors p ECE R101 R2 amd2 Uniform provisions concerning the approval OF passenger 3 0 3 1 3 2 3 3 4 0 4 1 cars powered by an internal combustion engine only or powered by a hybrid electric power train with regard to the measurement of the emission of carbon dioxide and fuel consumption and or the measurement of electric energy consumption and electric range and of categories M and N vehicles powered by an electric power train only with regard to the measurement of electric energy consumption and electric range q TAP 115 116 Emission testing procedures DEFINITION For the purpose of this draft the following definitions shall apply Hybrid Electric Syste
50. obtaining type approval certification HES manufacturer HES supplier shall authorize installer to undertake HES retrofitment The HES manufacturer HES supplier shall submit the information to Regional Transport Authorities as asked 4 3 The HES manufacturer HES supplier shall maintain the record of the vehicle identification numbers VIN and registration numbers of those vehicles on which the HES has been installed As part of this record the HES manufacturer HES supplier shall identify the installation date and the HES type approval certification number and shall identify the vehicle owners at the time of installation including the owner s current addresses and phone numbers 4 4 Name address and phone number of all the installer facilities which are authorised by the HES manufacturer HES supplier to install the approved HES or sell the spare parts of HES shall be published on HES manufacturer supplier website 4 5 Hybrid Electric System layout The layout indicating the locations of key elements of the Hybrid Electric system shall be prepared by the HES manufacturer HES supplier and shall be submitted to the testing agency at the time of Homologation This will include the placement of each important element such as motor controller wiring harness routing batteries charging socket and other components which forms the integral part of the HES 43 52 Draft AIS 123 F1 February 2013 4 6 Owner s manual for HES 4 6
51. ocedure described in this annexure A and Annexure D 1 3 The method described in this annex shall be used by the Testing Agency for the measurement of the electricity balance Q as defined in paragraphs A 2 1 4 4 2 A 4 0 and A 5 0 of this Annexure A and Annexure D 2 Measurement equipment and instrumentation 2 1 During the tests as described in paragraphs A 2 0 A 3 0 A 4 0 and A 5 0 of this annexure A the REESS current shall be measured using a current transducer of the clamp on type or the closed type The current transducer i e the current sensor without connecting to data acquisition equipment shall have a minimum accuracy of 0 5 per cent of the measured value in A or 0 1 per cent of the maximum value of the scale Vehicle HES manufacturer supplier diagnostic testers are not to be used for the purpose of this test 2 1 1 The current transducer shall be fitted on one of the wires directly connected to the REESS In order to easily measure REESS current using external measuring equipment vehicle HES manufacturer suppliers should preferably integrate appropriate safe and accessible connection points in the vehicle If that is not 23 52 Draft AIS 123 F1 February 2013 feasible the vehicle HES manufacturer supplier is obliged to support the Testing Agency by providing the means to connect a current transducer to the wires connected to the REESS in the above described manner 2 1 2 The output of the current transducer
52. ormal operating conditions e g sealed REESS Minimum creepage distance shall be as follows a In the case of a creepage distance between two REESS connection terminals d gt 0 25U 5 Where d is the creepage distance measured on the tested REESS in mm U is the nominal voltage between the two REESS connection terminals in V b In the case of creepage distance between live parts and the electrical chassis d gt 0 125U 5 Where d is the creepage distance measured between the live part and the electrical chassis in mm U is the nominal voltage between the two REESS connection terminals in V REESS disconnect Vehicles should be equipped with an automatic disconnect for REESS to isolate the propulsion circuits in case of any fault in HES The HES manufacturer HES Supplier shall describe the automatic disconnect provided in the Owner s manual A manual service disconnect should also be present This disconnect should be operable with the following capabilities 4 13 6 1 Manual action to break the connection 4 13 6 2 The disconnection does not create exposed conductors capable of 4 13 7 becoming energized while exposed Test Agency shall verify the weight distribution due to HES installation for any adverse impact on vehicle structure using best engineering practices 4 14 REESS Charger The Charger and the BMS shall provide protection for overcharge over discharge Cell pack voltage variation Temperature varia
53. pole and multi pole connectors for wiring harness Counter mating connector shall be used to pig tail any existing connector The mating connector shall meet the following requirements JASO D 616 2011 Standard can be referred 9 52 18 19 19 1 20 0 20 1 20 2 20 3 Draft AIS 123 F1 February 2013 a Water ingress protection when water is splashed during driving or the vehicle is washed Sufficient tensile strength of crimped connections Connector housing lock strength and terminal retention Connection resistance shall be lt 10 mOhms Leakage current shall not exceed 1 mA for non water proof connector and 50uA for onan o water proof connector f Insulation resistance shall be gt 100MOhms TECHNICAL SPECIFICATION Technical Specification for Hybrid Electric System and vehicles retrofitted with Hybrid Electric System shall be as per Annexure E amp F resp CODE OF PRACTICE HES manufacture supplier Authorized retrofitter shall comply code of practice as per Annexure G Documentary evidence shall be provided at the time of Type Approval along with technical specification Annual check up of Type Approved vehicle shall be verified as per CODE OF PRACTICE ANNEXURE G CHANGE IN THE TECHNICAL SPEDIFICATIONS ALREADY TYPE APPROVED Every modification pertaining to the information declared in accordance with paragraph 15 shall be intimated by the HES manufacturer supplier to the testing agency If the ch
54. rical energy power storage device is fully charged as a result of the charging prescribed in paragraph A 2 1 3 2 below A 2 1 3 2 During soak the electrical energy power storage device shall be charged a with the on board charger if fitted or b with an external charger recommended by the HES manufacturer supplier using the normal overnight charging procedure see C 4 1 2 1 This procedure excludes all types of special charges that could be automatically or manually initiated like for instance the equalization charges or the servicing charges The HES manufacturer supplier shall declare that during the test a special charge procedure has not occurred c For details of end of charge see C 4 1 3 13 52 Draft AIS 123 F1 February 2013 A 2 1 4 Mass Emission Test A 2 1 4 1_ Mass emission test shall be carried out as prescribed for corresponding IC engined vehicle A 2 1 4 2 However in case of special gear shifting strategy according to the HES manufacturer supplier s instructions as incorporated in the drivers handbook of production vehicles and indicated by a technical gear shift instrument for drivers information shall be followed For these vehicles the gear shifting points prescribed in MORTH CMVR TAP 115 116 are not applied A 2 1 4 4 Measurement of Energy The vehicle shall be started up by the means provided for normal use to the driver The first cycle starts on the initiation of the vehicle start up proc
55. rt1 and other related documents referred in this draft Once such an incorporation takes place the details given in these annexures would be automatically defunct TRANSITORY PROVISIONS Testing agency may issue a provisional certificate of compliance to CMVR for vehicles retrofitted with HES based on compliance to this standard before this standard is adopted by CMVR TSC and or notified in CMVR Such provisional certificates shall indicate the following This certificate is issued based on compliance to draft notification which is not yet notified in CMVR This certificate is valid for a period of 6 months from date of notification of this standard and needs to be revalidated thereafter VALIDITY OF TYPE APPROVAL CERTIFICATE Testing agency shall issue Type Approval certificate only by model basis Validity of such TA certificate shall be 3 years and needs to be revalidated thereafter During revalidation HES installed vehicle will be subjected to only mass emission test and physical verification of the vehicle as per the Layout submitted by HES manufacturer HES supplier during initial type approval 11 52 Draft AIS 123 F1 February 2013 ANNEXURE A See 6 1 Test Procedure for Measurement of Mass Emissions Fuel Consumption and Hybrid Range of Vehicles Retrofitted with Hybrid Electric System A 1 0 Categories of vehicles retrofitted with HES are mentioned below Vehicle Off Vehicle Charging Not Off Vehicle Charging
56. shall be sampled with a minimum sample frequency of 5 Hz The measured current shall be integrated over time yielding the measured value of Q expressed in Ampere hours Ah 2 1 3 The temperature at the location of the sensor shall be measured and sampled with the same sample frequency as the current so that this value can be used for possible compensation of the drift of current transducers and if applicable the voltage transducer used to convert the output of the current transducer 2 2 A list of the instrumentation HES manufacturer supplier model no serial no used by the HES manufacturer supplier for determining a When the minimum state of charge of the REESS has been reached during the test procedure defined in paragraphs A 2 0 and A 3 0 of annexure A and b The correction factors Kfuel and KCO2 as defined in paragraphs A 4 0 and A 5 0 of annexure A and the last calibration dates of the instruments where applicable should be provided to the Technical Service 3 Measurement procedure 3 1 Measurement of the REESS current shall start at the same time as the test starts and shall end immediately after the vehicle has driven the complete driving cycle 3 2 Separate values of Q shall be logged over the Part One urban driving and Part Two extra urban driving of the MIDC driving cycle 24 52 Draft AIS 123 F1 February 2013 ANNEXURE B See 9 0 ADDITIONAL REQUIREMENTS FOR REGENERATIVE BRAKING SYSTEM
57. t 0 2 km h Mass kg 0S5percent 1kg Electricity Ah 0 5 per cent 0 3 per cent balance Test Conditions Condition of the Vehicle The vehicle tyres shall be inflated to the pressure specified by the vehicle HES manufacturer supplier when the tyres are at the ambient temperature The viscosity of the oils for the mechanical moving parts shall conform to the specifications of the vehicle HES manufacturer supplier The lighting and light signalling and auxiliary devices shall be off except those required for testing and usual daytime operation of the vehicle All REESS systems available for other than traction purposes electric hydraulic pneumatic etc shall be charged up to their maximum level specified by the HES manufacturer supplier 27 52 Draft AIS 123 F1 February 2013 C 3 1 5 If the batteries are operated above the ambient temperature the operator shall follow the procedure recommended by the vehicle HES manufacturer supplier in order to keep the temperature of the REESS in the normal operating range The HES manufacturer supplier s agent shall be in a position to attest that the thermal management system of the REESS is neither disabled nor reduced C 3 1 6 The vehicle must have run at least 300 km during the seven days before the test with those batteries that are installed in the test vehicle This condition can be waived on request of the vehicle HES manufacturer supplier C 3 2 Climatic Co
58. the highest electricity consumption of all selectable hybrid modes when tested in accordance with Condition A of Annex B to be established based on information test reports provided by the HES manufacturer supplier and in agreement with the testing agency Most fuel consuming mode The hybrid mode which can be proven to have the highest fuel consumption of all selectable hybrid modes when tested in accordance with Condition B of Annex B to be established based on information test reports provided by the HES manufacturer supplier and in agreement with the testing agency Two tests shall be performed one under Condition A and the other under Condition B as defined in A 2 0 The test procedures for Condition A and Condition B shall be same as those given in A 2 1 and A 2 2 respectively except that the switching modes shall be as given in A 3 1 A 3 2 1 and A 3 3 However if the pure electric range of the vehicle measured in accordance with Annex D is higher than one full emission test cycle on the request of the HES manufacturer supplier the Type I test for condition A may not be carried out In such cases the value of M1i shall be taken as zero for calculation of final results A 2 3 1 and A 2 3 2 In this case vehicle preconditioning prescribed in paragraph A 2 1 2 can be omitted at the request of HES manufacturer supplier 19 52 Draft AIS 123 F1 February 2013 A 3 3 Discharge of REESS A 3 3 1 In the case of OVC HEV
59. tion etc for safe operation of batteries 48 52 4 15 4 16 4 16 1 4 16 2 4 16 3 Draft AIS 123 F1 February 2013 Compliance Plate Each HES retrofitted vehicle shall be fitted with the Compliance plate It will be suitably located in an approachable location Compliance Plate shall provide the following information about the HES and its installation Date of Installation Vehicle Reg Number Hybrid System Identification Number Manufactured by Installed by Labels Identification label in front and rear Label conforming to the specifications AIS 123 shall be affixed on left side of the front and rear safety glass so as to ensure visibility from the front and rear side of the vehicle Vehicles installed with HES shall have identification label as follows Labels conforming to the specification given in 4 15 2 of this Standard shall be affixed in a vertical position on the left side of the front amp rear safety glass and shall ensure visibility from the front and rear sides The label shall be in position at all times shall be in good condition and the shape colouring and lettering shall be easily identifiable Label shall be coloured white and sized 80 mm x 80 mm square Label shall have on them the text xEV in a central position not less than 20 mm high coloured blue The label shall have a blue border 1 mm wide 5 mm inside the outer edge and running parallel to it The 80 mm

CMVR Type Approval of Vehicles Retrofitted with Hybrid Electric

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