GMKOREA EDS-T-5114-2008 CHARGING SYSTEM CAPACITY EVALUATION.pdf

1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards CHARGING SYSTEM CAPACITY EVALUATION Do Not Use on New Programs. Being Replaced by GMW15485 EDS-T-5114 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4(Superceded) EDS-T-5114CHARGING SYSTEM CAPACITY EVAL

2、UATION PAGE: 1/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. M300 Program). It is Superceded for all future projects and replaced by GMW15485 1. PURPOSE This standard aims at evaluatin

3、g appropriateness of the charging system capacity of passenger cars. 2. SCOPE This standard applies only to passenger cars or MPV. 3. CHARGING CIRCUIT MILLIVOLT DROP TEST 3.1. Test equipment 3.1.1. Electrical load checker (220V 150A) 3.1.2. Millivolt meter (030V, 0.5 Level) 3.1.3. Multi-range digita

4、l voltmeter 3.1.4. Wire harness (For measuring) 3.2. Test Method (Refer to Figure 1.) 3.2.1. Test equipment shall be allocated at convenient locations to conduct tests. 3.2.2. Turn all power to OFF (Key Off) and separate Regulator Connector from Alternator. 3.2.3. Connect Electrical Load Checker to

5、+ and terminals of the battery. 3.2.4. Jump connect Alternator output (B+) terminal and Alternator Rear Frame with appropriate wire/harness for 20A capacity. 3.2.5. Connect a milli-voltmeter to voltage testing terminal at Regulator harness and Alternator B+ terminal, supply 20A load, and measure dro

6、p in milli-voltage. (VRS mv Drop) 3.2.6. Connect a milli-voltmeter to voltage testing terminal at Regular harness and Battery + terminal, supply 20A load, and measure drop in milli-voltage drop (VR mv Drop). 3.2.7. Connect a milli-voltmeter to a Battery terminal and Alternator SRE frame, supply 20A

7、load, and measure milli-voltage drop in Ground Circuit. 3.2.8. Connect a milli-voltmeter to a Battery terminal and Alternator Engine Block, supply 20A load, and measure milli-voltage drop in Ground Circuit. 3.2.9. Connect a milli-voltmeter to Alternator SRE frame and Engine Block, supply 20A load, a

8、nd measure milli-voltage drop in Ground Circuit. EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 2/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology 3.2.10. Upon completion of milli-voltage drop measurements, turn off power to Electrical Load Checker

9、immediately and remove jump cables that connect Alternator Output (B+) terminal and Alternator SRE frame. 3.2.11. The evaluation criteria of milli-voltage drop are VRSmv Drop(MAX0.2V) and VRmv Drop(MAX 0.2V). 4. LOAD CURRENT TEST 4.1. Test Equipment 4.1.1. Electrical load checker (220V 150A) 4.1.2.

10、Millivolt meter (030V, 0.5 Level) 4.1.3. Multi-range digital voltmeter 4.1.4. Wire harness (For measuring) 4.2. Test preparation 4.2.1. Test shall be conducted in a laboratory of the constant temperature and humidity. 4.2.2. Test vehicle (1) Prepare the electric wiring diagram of the test vehicle. (

11、2) Identify normal operation of each load based on the electric wiring diagram of the test vehicle. (3) Record various data of the vehicle (engine & mission type, alternator & battery charging volume, etc) (4) Record the engine rpm and alternator rpm in idling. 4.2.3. Test equipment setting (1) Arra

12、nge the test equipment in a convenient place for test. (2) Remove the battery (+) (-) poles from the terminal. (3) Separate Alternator B+ terminal and Regulator Connector of the test vehicle from Alternator. (4) Connect Electrical Load Checker to wiring disconnected from the vehicles battery. 4.3. T

13、est procedure (See the Fig. 2) 4.3.1. Measurement of individual load (1) Turn on the P/S power, and measure the electric load indicated in Table 1. (2) When measuring the electric load, change the voltage from 12.2V, 12.6V and 13.5V to 14.5V and get the load to record it in Table 1. (3) Measure the

14、electric load in the order of B+ accessory ignition on engine run based on the needed power. (4) In engine run, be sure to remove the electrical load checker (+, -) and connect the battery cable to the battery and then separate them after start. (5) When measuring widely varying loads such as for wi

15、ndshield wipers, measure their peak values. (6) When measuring loads for Direction Indicators and Emergency Lamps, measure their peak values. EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 3/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology (7) When

16、measuring light switch load, the Instrument Panels illumination lamp shall be at its maximum brightness. 4.3.2. Measurement of combined load (1) Remove the electrical load checker (+, -) and connect the battery cable to the battery and then separate them after start. (2) In the engine idle state, sw

17、itch on the electric load of the mode designated in Table 2 (Night 1 or Night 2) in the vehicle. (3) When measuring the electric load checker, change the voltage from 12.2V, 12.6V and 13.5V to 14.5V and get the load to record it in Table 2. (4) Upon completion of test, make sure to reconnect Alterna

18、tor Voltage Regulator and Output B+ terminal to their original positions. 5. CHARGE/DISCHARGE LAB TEST 5.1. Test equipment 5.1.1. CR-7 (Data Acquisition System: Data logger that can be interfaced with PC). Use equipment that can measure temperature, voltage, and pulse. 5.1.2. Thermocouple (K & T Typ

19、e) & Electric wire 5.1.3. Laptop PC (RAM: 16MB min, HARD: 500MB min) 5.1.4. Multi digital voltage meter 5.1.5. Shunt (100A/50mv, 150A/50mv, 200A/50mv) 5.1.6. Inverter: Source DC 12V, Output AC 100V / 0.5 min. 5.1.7. Battery: 2EA (SOC 80% 1EA: for test, SOC 100% 1EA : for power supply to measuring in

20、struments) 5.1.8. Gravity meter: For measurement of battery gravity 5.2. Test place 5.2.1. Wind tunnel (hot chamber) (1) Temperature rise shall be allowed up to 38 & 40% RH (domestic) / 45 & 35% RH (hot climatic). (2) The chassis dynamo shall be furnished. (3) Measurement of the vehicle speed and en

21、gine rpm shall be ensured. (4) Sun load shall be possible. 5.3. Test preparation 5.3.1. Test vehicle (1) Test vehicle shall have traveled at least 3,000Km in principle. (2) Check each load and operating condition of the engine and transmission of the test vehicle. EDS-T-5114CHARGING SYSTEM CAPACITY

22、EVALUATION PAGE: 4/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology (3) Record various data of the vehicle (alternator & battery capacity, engine & transmission, etc.) (4) Check for specified oil and coolant and measure their amounts. (5) Record the engi

23、ne rpm and alternator rpm in idling. (6) Mount the prepared SOC 80% battery to the test vehicle. 5.3.2. Alternator preparation 1)With the temperature of a point 2.4cm from the air inlet of the alternator part set at 90 and 105, operate it for 30 minutes at 5000 rpm under the full load, and then meas

24、ure every 500 rpm within the range of 20008000 rpm. The mount the alternator that can generate normal output according to the design value of each model. 5.3.3. Test equipment setting (1) Remove the battery cable from the terminal. (2) Connect the shunt for current measurement, wire/harness for volt

25、age measurement and thermo couple for temperature measurement as in Fig. 3. 5.3.4. Attach the following sensors at required positions. (1) Ambient (2) Engine Room Center (3) Alternator Backplate (4) Battery Side (5) Battery Liquid (6) Engine Oil (7) Radiator Coolant (8) Fuse Box (Inner) (9) High Ten

26、sion Cable (Boots Middle Area) (10) DIS (Distributor) Module (11) SDM (Bottom) (12) Floor Panel Wire/Harness Surface (13) Battery Voltage (14) Alternator Voltage (15) Cooling Fan Voltage (16) Air Con Compressor Voltage (17) DIS Voltage (18) Alternator Output Current (19) Electric Load (20) Charge (2

27、1) Engine RPM (22) Vehicle Speed 5.3.5. When Engine RPM and Vehicle Speed are needed, make preparation to receive Pulse signal by connecting EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 5/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology Engine Tac

28、hometer Connectors or verifying ECM functions. 5.3.6. Prepare Data Acquisition System software according to pre-determined sensor points. 5.3.7. Connector Data Acquisition System and Sensor and verify Sensor functional status. 5.3.8. Set Dynamo to test vehicle and conduct Driving Resistance Calibrat

29、ion. 5.4. Test procedure 5.4.1. Turn on the data acquisition system and check its operating condition and sensor conditions. 5.4.2. Keep temperature at 38 & 40% RH (DOMESTIC) / 45 & 35% RH (hot summer) and wait until operating with high the cooling fan at no load and idle state. 5.4.3. Test shall be

30、 start at cooling fan high operating and test mode, sequence and test time shall be according to table 2. 5.4.4. For the Day mode, be sure to turn on the Sun Load. For vehicle running, the gear mode shall be at D position for AT vehicle and an appropriate gear level for MT vehicle. For vehicle idlin

31、g, the gear mode shall be at D position for AT vehicle and N position for MT vehicle. 5.4.5. For each mode average values of Charge/Discharge Test results shall be recorded in Table 3. Temperature measurements shall be recorded as their maximum, minimum and average values. 5.4.6. The Outside air mod

32、e shall be used when operating the A/C. 5.5. Evaluation standard 5.5.1. The evaluation standard for each mode shall conform to Table 5. 5.5.2. The CTCS mode shall be evaluated at 20 KPH at a day to night ratio of 1: 1, and the value at 15 KPH and 25 KPH shall be used for reference. When there are Da

33、y 1 and 2 modes, evaluate at Day: Night 2. 6. CHARGE/DISCHARGE FIELD TEST 6.1. Test equipment 6.1.1. Same as the Lab test equipment 6.1.2. Portable radio phone Capability: to send and receive signals up to 4km. 6.2. Test preparation 6.2.1. It is the same as the lab test. In field riding, every wire/

34、harness, thermocouple and test equipment shall be fastened securely to avoid data error. 6.2.2. Examine the test course sufficiently before test. EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 6/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology 6.2.3

35、. Two or more cars shall be used for he same course, same time and same mode in principle. 6.2.4. The test vehicle shall be the A/T and full option model. 6.2.5. Before starting test, the odometer reading and time shall be recorded. 6.2.6. Check if communication with other vehicles is normal. 6.2.7.

36、 The test course shall be determined depending on the circumstances through consultation with the test engineer. The CTCS course shall be a place in a severe traffic jam. 6.2.8. The alternator shall be prepared in the same manner as in 5.3.2. 6.3. Test procedure 6.3.1. The electric load shall confor

37、m to Table 2. 6.3.2. The data acquisition time shall be set to the shortest possible time. (max.: 1 second) 6.3.3. Test hours for each mode shall be conducted CTCS (DAY: 12001400, NIGHT: 18002000) and NO 55 CHARGE AT IDLE (DAY: 14001500, NIGHT: 20002100). Test time duration per test shall be for CTC

38、S 1-2 hours and for NO 55 and CHARGE AT IDLE at least 30 minutes in principle. 6.3.4. In CTCS mode, all loads necessary for a ride other than the designated electric load (Ex: direction indicating lamp, horn, passing switch, stop light or emergency light) may be used. 6.3.5. CHARGE AT IDLE mode test

39、 shall be conducted on asphalt surface and use Wind Blade if at all possible. 6.3.6. The Night 2 mode shall be used for Idle, CTCS, NO55 and Night modes. And the field test data shall be entered in Table 4. 6.4. Evaluation standard 6.4.1. CTCS, CHARGE AT IDLE, and NO 55 evaluation shall be done as f

40、ollows. 6.4.2. CTCS evaluation: BATTERY charge current shall be 0A. If BATTERY charge current is less than 0A, compare against competitor vehicles for evaluation. 6.4.3. CHARGE AT IDLE evaluation: BATTERY charge current shall be -25A If battery charge current is -25A -25A -35A -25A -25A -35A -25A -2

41、5A -35A 25KPH Charge to25KPH To be charged 0A 5A 0A 5A 5A 0A 5A 5A 0A 5A 0A It is based on time when ALT end temp. is 90 * To meet the above three. EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 12/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology FI

42、G 1. CHARGE CIRCUIT MILLIVOLT DROP TEST SHUT EVERYTHING OFF AND RECONNECT FOR THE CHARGING CIRCUIT MILLIVOLT DROP MEASIREMENTS AS FOLLOWS: + S I L P REGULATOR CONNECTOR HARNESS - - - - SENSE TERMINAL ALTERNATOR MILLIVOLT METER + - POWER SUPPLY TO 20 AMPS B+ MILLIVOLT METER VEHICLE BATTERY CABLES SEN

43、SE TO BATTERY MV #1 CURRENT SHUNT 0 TO 100mABATTERY NEGATIVE TO REAR FRAME ALSO, USE THE MILLIVOLT METER TO PROBE ENGINE BLOCK TO BATTERY NEGATIVE AND ENGINE BLOCK TO REAR FRAMESENSE TO ALTERNATOR MV #2 ATTACH JUMPER FROM THE BATTERY TERMINALTO THE REAR FRAME USEA WIRE WITH ALLIGATORCLIPS SUITABLE F

44、OR 20 AMPS EDS-T-5114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 13/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology FIG 2. ELECTRIC LOAD TEST (INDIVIDUAL & COMBINATION) ALTERNATOR ELECTRIC LOAD ELECTRICAL LOAD MEASUREMENT EQUIPMENT(150A / 150Mv) +-EDS-T-5

45、114CHARGING SYSTEM CAPACITY EVALUATION PAGE: 14/14 ISSUED DATE: 1995. 11. 20 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology FIG 3. CHARGE/DISCHARGE LAB & FIELD TEST ALTERNATOR SHUNT(150A/50mV) SHUNT(200A/50mV) SHUNT(100A/50mV)ELECTRIC LOAD BATTERY V ALTERNATOR VC/FAN V A/C COMP V AMBIENT ENGINE ROOM CTRALT BACK PLATE BATTERY SIDE BATTERY LIQUID CR-7 (DATA AQUISITION SYSTEM) VOLTAGE TEMPERATURE ENGINE RPM VEHICLE SPEED PULSE NOTE BOOK