Automotive Mechanical Engineering

Automotive Electricity I

THEME:
Standards for the manufacture of Batteries and Relays

TEACHER:
Ing. Lauro Barros
MEMBERS:
Byron Chimbo
Kevin Ordoñez
Diego Villa
Paul Guillcatanda
GROUP:

N.- 5

DATE:

December 11, 2015

YEAR
 2015-2016

OBJECTIVES
GENERAL OBJECTIVE
Know the existing and updated regulations used for the
construction of a battery and a relay.
SPECIFIC OBJECTIVES
Know the INEN, SAE, IEC, ISO standards for battery manufacturing.
Know the Ecuadorian Technical Standards for the construction of batteries and
relays.
Know the rules used for the entry review of foreign spare parts
to Ecuador.

INTRODUCTION
Batteries are terms originating from the early days of the study of
electricity when several elements or cells were combined in the first case one
on top of another 'stacked' and on the second side by side 'in battery' as it
he currently continues doing so, thus increasing the magnitude of the electrical phenomena and
to study them systematically. The battery that converts directly the
chemical energy into electrical energy through a redox reaction.
They have two electrodes, each made of a different material, the positively charged one
the one called cathode and the one that is negatively charged is called anode.

A relay is an electromechanical device that allows us to switch a line.

medium or high power electric through a low power electronic circuit. The
The main advantage and the reason it is widely used in electronics is that the line
the electrical part is completely isolated from the electronic part that controls the relay. It is
say, we can build an electronic circuit (a timer, a photoresistor, etc.)
and, through a relay, control any type of device connected to the electrical network.

STANDARDS FOR BATTERY MANUFACTURING

Battery manufacturing standards:

Thelead-acid batteriesthey fall into this category, at least in part) refer to the
Same. There are standards that specifically refer to product performance that
we are interested, others refer to its safety features when operating it (which does not
it is necessarily related to the fulfillment of our expectations regarding
to performance) and, finally, a third set refers to the management system of the
company, whether in terms of quality, environment or safety and
occupational hygiene.

It is very common that, when dealing with a manufacturer, nowadays.

Figure 1: Battery Production

ISO 9001 standard. This is a standard that refers to the performance of the system.
quality management of the company. Being a general standard regarding institutions (it
you can apply to a commercial company or a sports club) nothing assures us that the
manufactured products or provided services meet certain specifications
techniques. Let us clarify in passing that the expression 'has certified' means that a third party
(like our institute IRAM) verified, through an audit, that the precepts of the
The norm is indeed being fulfilled. And, obviously, it does not have the same value as the
the company affirms it or that an independent third party declares it.
IEC standard, we will be in the presence of something much more specific, if what we
It is interesting to know if the electrical switch, for example, will work or not for installation.
in our circuit, or if the battery we want to buy will have the capacity that
we need. Again, let's clarify that the manufacturer's statement will have a lot
more value if this compliance has been verified with tests carried out in a
independent and prestigious laboratory or institution, so it is not
from a mere 'self-declaration'.
National standards and international standards. Among the former, we will mention
the IEEEBSI (from the United Kingdom), DIN (from Germany), and JIS (from Japan). (From the States
United) the IEC and ISO.
The most well-known international standard regarding lead-acid industrial batteries
the IEC 896, also identified as IEC 60896 and EN 60896. We remember
IEC is the acronym for the International Electrotechnical Committee, based in Geneva, and
represented by the Argentine Electrotechnical Association in our country.
IEC 60896-1
General requirements and test methods for lead-acid batteries of the type
ventilated. It is extremely important when conducting nominal capacity tests,
adaptation to float voltage operation, cycling, load retention, resistance
internal and short-circuit current.
IEC60896-2
General requirements and testing methods for VRLA lead-acid batteries.
Like the previous one, it is widely used for performance testing in
This type of products (the tests are similar to those of IEC 60896-1 standard).
IEC 61056-1
General requirements and functional characteristics for lead-acid VRLA batteries
laptops. Testing methods, and their equivalent in the Japanese standards system: JIS C-
8702-1. This standard applies to all small VRLA batteries such as Vision, NP,
etc. used in UPS, alarm and fire systems, emergency lighting,
etc.
IEC 60254
General requirements and test methods for lead-acid batteries for use in
electric traction. Dimensions of the cells and terminals Other commonly used standards and
cited in the public tender documents are the BS. We mention BS 6290,
practically identical to IEC 60896.
BS 6290-1
General specification requirements for stationary lead-acid batteries of the type
ventilated.
IEEE Standards.
IEEE-450 for vented batteries and its equivalent for sealed batteries, IEEE-1188. One
quick overview of the topics addressed in them (the latest editions are from the year 2002 for
the 450 and from the year 1996 for the 1188) are the following: maintenance, scheme of
tests, procedures to perform the tests, criteria for battery replacement
recycling and disposal at the end of the useful life and various annexes.
IEEE484 - IEEE 485
This set contains the best practices for sizing and designing the
installation of stationary lead-acid batteries whose charge is variable. This usually
to occur, as a typical example in substations and transformer stations. It is a
highly practical standard as it includes application examples.
IEEE 937
Best practices for the installation and maintenance of lead-acid batteries
for photovoltaic systems.
IEEE 1013
Best practice for sizing lead-acid batteries for systems
photovoltaics. In addition to the theory, it includes highly effective worksheets.
tools for designing.
IEEE 1189
It is a complement to the already mentioned 1188 and contains a 'Guide for selection of
VRLA batteries for stationary applications
Manufacturing standards according to INEN 1499
5.1 The lead-acid batteries must meet the following requirements:
5.1.1 Exterior appearance. The batteries must not show any deformations.
notables, their edges must be clean and there must be no drippings from
sealant material.

5.1.2 Boxes
 [Link] The battery boxes must be made of material
insulating and resistant to the action of the electrolyte.
The material must be suitable to prevent the appearance of
fissures, cracks, etc.
[Link] The boxes will not allow electrolyte leaks in case of being
wet charge batteries and the entry of foreign substances when
dry load.

5.1.3 Tapas

[Link] The covers must be made of insulating material and

resistant to the action of the electrolyte.
[Link] The material must be suitable to prevent the appearance of
fissures, cracks, etc.
They can be individual for each cell or a single one that covers.
all the cells.
[Link] The shape and size must be such that they fit
perfectly in the box.
5.1.4 Corks

[Link] The plugs must be made of insulating material and

resistant to the action of the electrolyte.
 [Link] The cell caps must be designed in such a way
so that when they are placed they do not exceed the height of the
battery terminals, allow gas circulation, prevent leakage
of the electrolyte and the entry of foreign substances into the cells.
5.1.5 Sealant compound

Its consistency must be such that once applied, it does not flow.
on the sides of the box, do not react with the battery elements and
it does not crack over time or with changes in temperature.
[Link] When using thermal sealing, it must maintain with the
use of the battery or the passage of time, the original characteristics
of the box and lid material.

5.1.6 Terminals

[Link] The positive terminal must be marked on its upper part

in bas-relief (+), the negative (-).
[Link] The positive terminal may be painted red and the negative one
in black.
[Link] When a single cover (monotapa) is used, with the aim of
indicate the polarity of the terminals, it must be marked in relief with
the signs (+) or (-), near their output.

5.1.7 Electrolyte
 [Link] The electrolyte of the accumulators is an aqueous solution
sulfuric acid that must meet the specified requirements in the
Standard INEN 1 527.
5.1.8 Nominal voltage.
The nominal voltage of the fully charged battery, measured
on its terminals with a voltmeter with an accuracy of 0.1 V should not
is less than the value specified in Table 2 (second column).
5.1.9 Battery capacity determined according to INEN Standard 1 498
(numeral 3.3) will not be less than indicated in Table 2 (third column).
5.1.10 Acceptance of load. The acceptance of load of the batteries
determined according to numeral 3.2 of the INEN 1 498 Standard shall not be
less than the value indicated in Table 2 (fourth column).
5.1.11 Fast discharge. The value of the fast discharge of a battery,
Determined according to numeral 3.4 of the INEN 1 498 Standard, it should not
must be less than that indicated in Table 2 (fifth column).
5.1.12 Degree (life cycles). The degree of a battery, measured in
life units, according to numeral 3.5 of the INEN Standard 1 498, not
must be less than that indicated in Table 2 (sixth column).
5.1.13 Reserve capacity.
The value of a battery's reserve capacity, measured in minutes, of
According to numeral 3.7 of the INEN Standard 1 498, it should not be less than
indicated in Table 2 (seventh column).
5.1.14 Vibration.
A battery subjected to vibration testing must comply with the number
3.6 of the INEN 1498 Standard.
5.2 For the requirements: capacity C, load acceptance, fast unloading, and capacity
A tolerance of -3% with respect to the values established in the reserve is accepted.
Table 2.

STANDARDS FOR THE MANUFACTURE OF RELAYS

HELLA is a company certified in various relevant fields, such as for example

DIN EN ISO 9001:2008, ISO/TS 16949:2009, ISO14001. The relays from HELLA are
They comply with the ROHS standards (2002/95/EC) and REACh.
Explanation and purpose of its application

Main components of an electromechanical relay

Figure 2: Parts of a relay

1 Contact fields
2 Induced
3 contact pins for spool thread
4 Switching Contacts
5 copper wire spools
6 Iron core (in the coil)
7 flat connector (charging) made of electrolytic copper with tinned surface
8 Flat connector (coil) made of CuZn (brass) with galvanized surface
9 Motherboard
10 Coil body
11 Joches

Mini-relays
Mini-relay according to ISO 7588-1, flat plug according to ISO 8092-1. Configurations of
Contact: Working relay, switch, max. 40 A connection power (contact of
working relay), nominal voltage: 12 V, 24 V areas of application, among others: Headlights,
starter motors, fuel pumps, fan motors, horns and
buzzers.

Micro-relays
Micro-relay according to ISO 7588-3 (1988), flat plug according to ISO 8092-1. configurations
Contact: Work relay, switch, max. 20 A connection power (contact of
work relay), nominal voltage: 12 V, 24 V areas of application, among others: Pumps
fuel, air conditioning, windshield wiper installation, engine of the
windshield wipers.

High power relays

Larger size mini relay variant, flat plug according to ISO [Link]
Contact: Work relay, switch, max. 60A connection power, voltage
nominal: 12 V, 24 V application areas, among others: Battery separation relay,
starter motor, spark plugs, ignition, windshield heating.

Solid state relays

Mini relay semiconductor according to ISO 7588-1, flat plug according to ISO 8092-
1. contact configuration: Working relay, max. 22 A power connection (contact
closing relay), rated voltage: 12 V areas of application, among others: Pump of
brake booster vacuum, daytime running lights.

Battery separation relay

Bistable electromechanical relay with one or two coils. Contact configuration
Work relay, switch, max 180 A of connection power, rated voltage 12 V
areas of application, among others: Separation of the battery from the onboard network in case
of accident or for maintenance tasks, maintenance of the battery charge
through the disconnection of the standby power

Isolation
Objective of the EN / IEC 61810-1 standard on relays
IEC 61810-1 applies to basic electromechanical relays (on-off relays)
unspecified time) planned to be incorporated into devices. She defines the
functional requirements and those related to security for applications in all
the fields of electrical engineering and electronics, such as:
Industrial equipment in general
Electrical devices
Electric machines
Electrical appliances for household and similar use
Devices for information technology and for offices
Devices for building automation
Devices for automation
Devices for electrical installations
Medical devices
Control and command devices
Telecommunications
Vehicles
Transport (for example, railways)

Functions and isolation of the relay:

One of the main functions of a relay is to connect and disconnect different
electric circuits and generally ensure a high level of electrical separation
among several circuits. It is therefore necessary to take into account the level of insulation
specified in the application and relate it to the relay specifications. In the
in the case of electromechanical relays, the isolation areas to be considered
they are generally:
The insulation between the coil and all the contacts.

Catalog data - 'Insulation between coil and contacts'.

The isolation between physically adjacent but electrically separated contacts
of a multipolar relay.

Catalog Data - "Isolation" between adjacent contacts.

The isolation between the open contacts applies to the NO contact with the coil on.
rest and at NC contact when the coil is excited.
Catalog data - 'Insulation' between open contacts.
Isolation coordination:

According to the EN 61810-1 and IEC Standards

60664-1:2003, the insulation characteristics of a relay can be described with two
characteristic parameters: the nominal Voltage for impulses and the Degree of
pollution.

To ensure the correct isolation coordination between the relay and the application, the
team designer (relay user) must establish what the appropriate value of the
Nominal tension to the impulses and the level of contamination for the microenvironment in
which is going to operate the relay.

Knowing these two values, you must then look for the relay that fits (coordinates) with them.
with the application for having isolation characteristics equal to or greater than those that
needs, table 'Isolation' from the section 'General Characteristics'.
Tension sustained to impulse: to establish the appropriate tension sustained to impulse
the specific standard of the device should be applied, which should prescribe the values; such as
alternative, it can be set in the appropriate tables, knowing the Voltage
nominal of the power supply system and the overvoltage category.
Overvoltage category: described in IEC 60664-1 and summarized in the notes.
An alternative may be specified in the device standard.
Pollution level: it is necessary to specify it considering the immediate surroundings of the relay.
It is advisable to verify that the specifications of the relay meet the same (or better) standards.
values of voltage withstand for impulse and degree of pollution
Minimum distance between relays recommended for their installation on a printed circuit board:
It is the minimum distance between relays that is recommended when mounting several relays in
a printed circuit board to ensure they operate within the values
specified.

Pair of tightens:
It is the maximum tightening torque of the terminal connection screws, according to EN
60999, is 0.4 Nm for M 2.5 screws, 0.5 Nm for M3 screws, 0.8 Nm for screws
M 3.5, 1.2 Nm for M4 screws. The catalog shows the test value.
Normally, the value can increase by 20%.
You can use tips with a Philips or flat head.

Minimum cable section:

All terminals allow a minimum section of 0.2 mm.
Maximum cable section:
Maximum section of the connection cable (rigid or flexible) that can be connected to a
borne. When terminals are used, the section must be reduced (for example from 4 to 2.5
from 2.5 mm to 1.5 mm from 1.5 mm to 1 mm.
Connection of several cables:
According to EN 60204-1, it is permitted to introduce 2 or more cables simultaneously into the
same terminal. All Finder products have terminals capable of accommodating 2 or more
cables, with the exception of the quick connection terminals.

Cage terminals:
The threads are held in cage terminals, which guarantee an effective grip on the threads.
rigid, flexible and with toes (not forked).
Bornes a pletina:
The threads are held by the pressure of a plate, which ensures effective holding.
for rigid threads and with forked tips. Less effective for flexible threads.
Quick connection terminals:
The thread is secured by the force of a spring. A single, rigid thread, coiled or
with a toe cap, it holds very effectively

Figure 3: Table of standards

Compliance with the incandescent thread test according to EN 60335-1

The European standard EN 60335-1: 2002 prescribes in paragraph 30.2.3 that the parts
isolated parts that support connections with currents over 0.2 A and the insulated parts
within a distance of 3 mm from them, they must meet the following 2 requirements
fire resistance

GWFI (Glowing Wire Flammability Index) of 850°C, or exceeding

from the glow wire flammability test at 850°C (according to EN 60695-2-12:
2001
2. GWIT (Glow Wire Ignition Temperature) of 775°C according to EN
60695-2-13: 2001. This requirement can be met by conducting a GWT (test with
incandescent wire according to 60695-2-11: 2001) at a temperature of 750°C with a
duration of the flame less than 2 seconds.

EN 61812-1 for electronic timers;

EN 60669-2-1 for electronic pulse relays and staircase timers.
EN 61000-6-2 (generic standard on immunity in industrial environments) for others
industrial electronic products.
EN 61000-6-1 (generic standard on immunity in domestic environments) for others
household electronic products

MEASUREMENT OF CONSUMPTION
Consumption will be measured under the following conditions: 1) Rest; 2) Excitation; 3)
Operation. Both in the measurement circuit and in the auxiliary. For the circuits of
the nominal design value will be used for measurement, and the timer can be adjusted in
a typical operating value. For these circuits and under the excitation condition
a value equal to 95% of the excitation current in steady state can be adopted.
permanent. For the auxiliary circuit, the consumption will be determined within the required limits
for the auxiliary source. For these tests, IEC Standard No. will be taken as a reference.
255-3 of the year 1971.

Conclusions:

It was concluded that the standards were created for the unification of the
characteristics of materials, sizes, strength, colors, etc.
It could be concluded that for the construction of batteries as relays there are
different standards that require certain characteristics in order to obtain their
approval.
It could be concluded that different regulations are required for entry in each country.
products such as batteries or relays for the well-being of your population.

bibliography

[Link]
Ed. Paraninfo, Madrid

Power electronics
M.J. Fisher
PWS-KENT
Power electronics, circuits, devices and applications
H. Rashid Muhammad
Prentice Hall

General Physics
V.427 - 63