SAE J2578-2023

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https://www.sae.org/standards/content/J2578_202301/

SURFACE VEHICLE

RECOMMENDED PRACTICE

J2578™

JAN2023

Issued 2002-12

Revised 2014-08

Reaffirmed 2023-01

Superseding J2578 AUG2014

Recommended Practice for General Fuel Cell Vehicle Safety

RATIONALE

This revision to SAE J2578 represents an evolution to requirements for the integration of hydrogen and electrical systems

for hydrogen and fuel cell vehicles (FCVs). Rationale for specific changes are summarized below:

•Sections 4.2.4.1 and 5.2 and Appendices C and D were updated to clarify and streamline verification test requirements

for hydrogen discharges from the vehicle. See Appendices C and D for detailed discussion of issues and recommended

verification procedures.

•Sections 4.2.4.2 and 4.2.5 and Appendix E were changed to clarify guidance with regard to locating hydrogen storage

systems within passenger, luggage, and cargo compartments to ensure that discharges from vents and Pressure Relief

Devices (PRDs) are properly managed and directed.

•Section 4.2.6 was modified and the new Appendix F was added to ensure that either the vehicle cannot be moved while

the fueling nozzle is connected or the fueling receptacle is properly installed, protected, and secured.

•Sections 4.2.6, 4.7, and 5.1 were updated to clarify fuel system labeling requirements and harmonize with vehicle

badging requirements in SAE J2990 for emergency responders.

•Sections 4.2.7, 4.4.3, 4.4.3.1, 6, and 7.2 were re-worded to clarify previously-defined issues and guidance.

•Section 4.4.3 and subordinate subsections were revised to account for Y-capacitors in high voltage circuits and their

effect on body current if the high DC and AC voltage circuits are touched.

•Section 5.2.2 and Appendix C was changed to extend allowable discharge scaling to smaller (micro) vehicles and not

just larger vehicles such as buses. Clarifications to the analytical bases of requirements were also made.

•Appendix A was modified to correct post-crash formulas, improve the explanations, and provide an alternative approach

for calculating the mass leakage rate.

•Appendix E was also modified to clarify guidance with regard to using Pressure Relief Devices (PRDs) in series.

SAE J2578 has been reaffirmed to comply with the SAE Five-Year Review policy.

FOREWORD

Vehicles manufactured with liquid hydrocarbon as fuels have a long history of creating appropriate safety countermeasures.

With the onset of new hydrogen fuel cell systems, new mechanical and electrical system safety design parameters will need

to be provided to vehicle developers. This SAE report establishes safety criteria and methodologies for fuel cell vehicle and

subsystem developers.

The purpose of this document is to identify the unique requirements and criteria for the integration of hydrogen fuel systems

(as defined in SAE J2579) and fuel cell systems into vehicles.

TABLE OF CONTENTS

1. SCOPE .......................................................................................................................................................... 4

1.1 Purpose ......................................................................................................................................................... 4

1.2 Field of Application ........................................................................................................................................ 4

2. REFERENCES .............................................................................................................................................. 4

2.1 Applicable Documents .................................................................................................................................. 4

2.2 Related Publications ..................................................................................................................................... 7

3. DEFINITIONS ............................................................................................................................................. 11

4. TECHNICAL SYSTEMS SAFETY GUIDELINES ....................................................................................... 16

4.1 General Vehicle Safety ............................................................................................................................... 16

4.2 Fuel System Safety ..................................................................................................................................... 18

4.3 Fuel Cell System Safety .............................................................................................................................. 22

4.4 Electrical System Safety ............................................................................................................................. 23

4.5 Mechanical Safety ....................................................................................................................................... 28

4.6 Fail-Safe Procedures .................................................................................................................................. 29

4.7 Safety Labels and Badging ......................................................................................................................... 30

5. OPERATION ............................................................................................................................................... 32

5.1 Owner’s Guide or Manual ........................................................................................................................... 32

5.2 Normal Vehicle Discharges ......................................................................................................................... 32

5.3 Inadvertent or Inappropriate Operation of the Vehicle ................................................................................ 34

5.4 Byproducts .................................................................................................................................................. 34

6. EMERGENCY RESPONSE ........................................................................................................................ 34

7. MAINTENANCE .......................................................................................................................................... 35

7.1 Service Manual ........................................................................................................................................... 35

7.2 Defueling Procedures .................................................................................................................................. 35

7.3 Facility Safety .............................................................................................................................................. 35

8. NOTES ........................................................................................................................................................ 35

8.1 Marginal Indicia ........................................................................................................................................... 35

SAE INTERNATIONAL

J2578™ JAN2023

2 OF 71

APPENDIX A POST-CRASH CRITERIA FOR COMPRESSED HYDROGEN SYSTEMS ............................................... 36

APPENDIX B GUIDANCE FOR CONDUCTING HIGH VOLTAGE TESTS ...................................................................... 50

APPENDIX C GUIDANCE FOR CONDUCTING DISCHARGE EVALUATIONS INTO SPACES SURROUNDING

VEHICLES .................................................................................................................................................. 54

APPENDIX D GUIDANCE FOR CONDUCTING LOCAL EXHAUST FLAMMABILITY AND TOXICITY

EVALUATIONS OF VEHICLE DISCHARGES............................................................................................ 61

APPENDIX E GUIDANCE FOR THE PACKAGING OF HYDROGEN SYSTEMS INCLUDING PRDS, SHIELDS,

AND FLOW BARRIERS .............................................................................................................................. 68

APPENDIX F TEST METHOD FOR DRIVE-AWAY PROTECTION ................................................................................. 71

FIGURE 1 POTENTIAL FLAMMABILITY OF HYDROGEN DISCHARGES IN AIR .................................................... 14

FIGURE 2 HIGH VOLTAGE SYMBOL ......................................................................................................................... 27

FIGURE 3 EXAMPLES OF BLUE DIAMOND HYDROGEN VEHICLE BADGING ...................................................... 32

FIGURE A1 PRESSURE LOSS WITH 606 G HYDROGEN LEAKAGE ......................................................................... 37

FIGURE A2 PRESSURE LOSS WITH 606 G HYDROGEN LEAKAGE ......................................................................... 38

FIGURE A3 TIME PERIODS FOR 5% PRESSURE LOSS ............................................................................................ 39

FIGURE A4 TEST PROCEDURE ................................................................................................................................... 40

FIGURE A5 HYDROGEN PRESSURE DENSITY CORRELATION ............................................................................... 41

FIGURE A6 LEAKAGE MASS CHARACTERISTICS OVER TIME ................................................................................ 42

FIGURE A7 HYDROGEN LEAKAGE FOR VARIOUS INITIAL TEST PRESSURE ....................................................... 42

FIGURE A8 LEAKAGE MASS IN 60-MINUTE AT DIFFERENT GAS TEMPERATURE ............................................... 43

FIGURE A9 HELIUM LEAKAGE OVER 60 MINUTES ................................................................................................... 44

FIGURE A10 HELIUM PRESSURE LOSS OVER 60 MINUTES ..................................................................................... 44

FIGURE A11 HELIUM PRESSURE LOSS OVER 60 MINUTES ..................................................................................... 44

FIGURE A12 TIME PERIODS FOR 5% PRESSURE LOSS ............................................................................................ 45

FIGURE A13 PRESSURE CHARACTERISTICS AND TIME PERIODS FOR 5% PRESSURE LOSS ........................... 46

FIGURE A14 TIME PERIODS FOR 5% PRESSURE LOSS ............................................................................................ 47

FIGURE A15 TIME PERIODS FOR 5% PRESSURE LOSS WITH A SAME PRESSURE SENSOR RANGE RATIO ... 47

FIGURE B1 ILLUSTRATION OF ELECTRIC SHOCK DUE TO CONTACT WITH A HIGH VOLTAGE SYSTEM

HAVING A LOW ISOLATION RESISTANCE ............................................................................................. 50

FIGURE B2 TYPICAL APPROACH FOR CONDUCTING THE HIGH VOLTAGE ISOLATION TEST FOR THE

VEHICLE IN NORMAL OPERATION ......................................................................................................... 50

FIGURE C1 CALCULATED STEADY-STATE HYDROGEN CONCENTRATIONS VS HYDROGEN EMISSION RATE

FOR VARIOUS AIR EXCHANGE RATES WITH STANDARD ENCLOSURE ........................................... 56

FIGURE C2 ALLOWABLE LEAKAGE AND PERMEATION FROM THE HYDROGEN STORAGE SYSTEM FOR

STANDARD VEHICLES AND FOR LARGER VEHICLES FOR 0.03 ACH ................................................ 57

FIGURE D1 TEST SETUP FOR DETERMINATION OF SUSTAINABLE IGNITION THRESHOLD .............................. 63

FIGURE D2 TEST SETUP FOR DETERMINING EFFECTS OF START-UP EMISSIONS (INJECTED VOLUME

METHOD SHOWN) ..................................................................................................................................... 66

FIGURE D3 TEST SETUP FOR DETERMINING EFFECTS OF SHUTDOWN EMISSIONS (INJECTED VOLUME

METHOD SHOWN) ..................................................................................................................................... 66

TABLE 1 SUMMARY OF ISOLATION REQUIREMENTS FOR IN-USE OF VARIOUS TYPES OF

HIGH VOLTAGE SYSTEMS ....................................................................................................................... 24

SAE INTERNATIONAL

J2578™ JAN2023

3 OF 71

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摘要：

SAE J2578-2023是由国际自动机工程师学会（SAE International）发布的最新版本燃料电池车辆安全标准，专为氢燃料电池电动汽车（FCEV）的设计、制造和运行提供全面的安全指南。该标准覆盖了从储氢系统、燃料电池堆、高压电气系统到车辆整体碰撞安全性等方面，旨在确保燃料电池车辆在正常使用、碰撞及极端条件下的安全性。与旧版相比，2023版本新增了对更高工作压力（如70 MPa储氢系统）的适应性要求，并完善了泄漏检测、自动氢截断、通风安全及热管理等内容。本文件为全球整车厂、零部件供应

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