GMKOREA EDS-T-5428-2008 THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT.pdf

1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5428 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 (Superceded) THE TEST OF

2、ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 1/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced

3、by GMW3172. 1. PURPOSE This standard aims at correctly evaluating performance of components of the intelligent switching unit used for passenger cars manufactured by GM DAEWOO Auto & Technology Company (hereinafter referred to as the “GMDAT“). 2. SCOPE This standard applies to components of the inte

4、lligent switching unit applied to the automobiles 3. DEFINITION OF TERMS 3.1. Intelligent switching unit It receives inputs of various function switches to have the micro-computer automatically control such output loads as the motor, lamp and warning buzzer according to the pre-determined program. 3

5、.2. RKE (remote keyless entry) receiver It receives the high frequency from the radio transmitter to perform door opening/closing specified in drawing. 3.3. Immobilizer It has ECM cut off engine starting when it is tried with means other than the peculiar key for the vehicle. 4. TEST CONDITIONS 4.1.

6、 Standard test condition Test voltage used for module performance and durability test, it is the voltage specified in drawings or test specifications. Unless specified otherwise, it is 12.0 1V for RKE receiver and immobilizer functions and 14.0 0.2V for other functions. 4.2. Standard test condition

7、Unless specified otherwise, test is conducted under the normal temperature and humidity condition specified in KS A006 (Test Place Standard Condition). 4.3. Quantity of samples At least 15 DVP and PVP samples shall be provided for test in principle. 5. TEST EQUIPMENT 5.1. Generals THE TEST OF ELECTR

8、IC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 2/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology Measuring instruments used for test shall basically be calibrated by the national calibration institute and within the effective calibration p

9、eriod. 5.2. Thermostatic chamber Capable of maintaining temperature from -40 to +90, it shall have a minimum capacity of 100 liter. It shall also be able to control relative humidity at each temperature up to 95% with permissible error not exceeding +2 per temperature. 5.3. Vibration tester It shall

10、 be capable of performing test to KS R 1034 (Automobile Components Vibration Test method). 5.4. Control device for durability test It shall be capable of automatically supply and cut-off voltage for unit operation, detect defects and record progress time and no. of cycles in durability test. 6. TEST

11、 PROCEDURES 6.1. Appearance test 6.1.1. Visual test (1) Conduct visual inspection. (2) When observed visually, the unit shall show no sign of harmful flaws, cracks, or other defects that may adversely affect the performance. 6.1.2. Dimension test Specified samples based on KS B 5203 (Venire calipers

12、) shall be used. Samples shall meet material requirements of the design specifications and dimensional requirements in drawings. 6.2. Performance 6.2.1. Basic performance test At the standard test voltage, operating characteristics of basic functions specified in DWG shall be within the allowable ra

13、nge. 6.2.2. Operating Temperature & voltage (1) At supply operating voltage of 9 16 V, operating temperature -40+85,operating characteristics of basic functions specified in DWG shall be within the allowable range. (2) Unless specified otherwise, measuring shall be conducted at 3 or more test voltag

14、es (9V, standard voltage, 16V). 6.2.3. Leakage current (1) Unless specified otherwise, it shall be measured at the battery power line with standard test voltage of 12.6 0.1V. THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 3/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2

15、008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology (2) Test shall be conducted with the ignition power line OFF. (3) The measured current shall not exceed the allowable range specified in DWG. 6.2.4. Current consumption (1) It is conducted with the standard voltage supplied. (2) Measurement shall be

16、 made separately for ignition power cables and battery power cables. (3) The measured current shall not exceed the allowable range specified in DWG. 6.2.5. RF (radio frequency) reception sensitivity of remote key function Test items consist of reception sensitivity, reception bandwidth and reception

17、 selection degree and test shall be conducted to EDS-T-5427. The test results shall not exceed the allowable range specified in DWG. 6.3. Electric resistance test 6.3.1. Source voltage change test (1) This test is to confirm if the unit operates normally according to the varying source voltage at en

18、gine starting. (2) After the following test voltage cycle is applied to the battery and ignition source terminals with the sample constructed to the design specifications, basic performance requirements in 6.2.1 shall be met. 1) Test temperature: Normal temperature and normal humidity (standard test

19、 temperature) 2) Test voltage: 6(V) 12(V) 3) Total test cycles: 10 cycles 4) 1 test cycle 6.3.2. Source voltage chattering test (1) This test is to confirm if the unit operates normally according to the varying source voltage at engine starting. (2) After the following test voltage cycle is applied

20、10 cycles respectively to the battery and ignition source terminals for each source voltage chattering type with the sample constructed to the design specifications, basic performance requirements in 6.2.1 shall be met 1) Test temperature: Normal temperature and normal humidity (standard test temper

21、ature) 2) Test voltage: 6V 14V (B TYPE: 0V 14V) THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 4/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology 3) Type A source voltage chattering cycle (1 cycle) 4) Type B source voltage

22、 chattering cycle (1 cycle) 6.3.3. Over voltage/reverse-voltage (1) This test is conducted to check if the unit inside circuit is protected from over voltage and reverse voltage that may occur at battery discharge. (2) At test, the unit shall be wired in the vehicle condition. For the system furnish

23、ed with an inside protection circuit, the inside protection circuit (fuse) shall be inserted before the unit is operated. (3) When power to the sample is cut off by the action of the inside protection circuit (fuse), immediately replace the fuse with a new one of the same type. (4) After the followi

24、ng abnormal voltage is applied, basic performance requirements in 6.2.1 shall be met. Over voltage A Test voltage: 180.2V Test time: 60 minutes Test temperature: Normal temperature and normal humidity (standard test temperature) Over voltage B Test voltage: 240.2V Test time: 1 minute Test temperatur

25、e: Normal temperature and normal humidity (standard test temperature) Reverse voltage Test voltage: -14 0.2V Test time: 1 minute Test temperature: Normal temperature and normal humidity (standard test temperature) THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 5/10 IS

26、SUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology 6.3.4. Short circuit When the standard test voltage is applied between the ground and the input and output terminals with both of them shorted 1 minute, the internal circuit shall not be damaged and basic perfo

27、rmance requirements in 6.2.1 shall be met. 6.3.5. Dielectric resistance When AC 500 V is applied for 1 minute between the connector pin and case, the internal circuit shall not be damaged and basic performance requirements in 6.2.1 shall be met. 6.3.6. Insulation resistance test When DC 500 V is app

28、lied between the connector pin and unit case, the insulation resistance shall not be smaller than 20 M ohm. 6.4. Weather environmental test 6.4.1. High temperature exposure (1) Construct the sample to the design specifications. (2) When 6.2 is conducted following 1 hour drying under the normal tempe

29、rature and humidity after exposure to the following conditions, the sample shall operate normally and basic performance requirements in 6.2.1 shall be met. Test temperature: +852.5 Test time: 96 hours 6.4.2. Low temperature exposure (1) Construct the sample to the design specifications. (2) When 6.2

30、 is conducted following 2 hour drying under the normal temperature and humidity after exposure to the following conditions, the sample shall operate normally and basic performance requirements in 6.2.1 shall be met. Test temperature: -402.5 Test time: 96 hours 6.4.3. High temperature & humidity oper

31、ating test (1) Construct the sample to the design specifications. (2) Under the test temperature and humidity conditions, supply power to the unit in the no-load state (battery and ignition). (3) When the initial performance is measured following 2 hour drying under the normal temperature and humidi

32、ty after exposure to the following conditions, the sample shall operate normally and basic performance requirements in 6.2.1 shall be met. Test temperature: +403 Relative humidity: 95 3 % Test time: 250 hours THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 6/10 ISSUED

33、DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology Test operating voltage: 120.2 V 6.4.4. Temperature operation test (1) Construct the sample to the design specifications (2) After exposure to the following conditions the sample shall operate normally and basic perf

34、ormance requirements in 6.2.1 shall be meet Test temperature: -402.5, 2hour +852.5, 2hour Total test cycles: 30 cycles Temperature change time: 2K/minute 6.4.5. Thermal shock (1) Test shall be performed alternating between high temperature and low temperature and temperature change duration of the t

35、hermostatic chamber shall not exceed 30 seconds. (2) When the initial performance is measured following 2 hour drying under the normal temperature and humidity after exposure to the following conditions, the sample shall operate normally and basic performance requirements in 6.2.1 shall be met High

36、temperature test temperature: 852.5 Low temperature test temperature: -402.5 Total test cycles: 20 cycles 1 test cycle THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 7/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology 6.4.6

37、. Salt spray test This test is conducted to clause 6.3 of EDS-T-5235 and after test basic performance requirements in 6.2.1 shall be met. During test, the power to the sample shall be cut off. 6.5. Mechanical environment test 6.5.1. Vibration resistance test (1) This test is conducted on the vibrati

38、on tester in the vehicle condition. Supply power to the unit in the no-load state (battery and ignition). (2) Vibration of 3.2G (rms) is applied to vehicle interior parts under the following conditions with the sample mounted to the vibrator in the vehicle condition. (3) During test under the follow

39、ing conditions, performance drop caused by parts separation, rattle noise or noise resulting from resonance shall not be developed. After test, each performance value shall stay within the allowable range. Test time: total 6 hours, respective 2 hours for X, Y, Z directions Vibrating condition (RANDO

40、M) THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 8/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology Break Point Power Spectral Density (G2/Hz) Frequency Hz 1 0.040 10 2 0.10 203 0.10 404 0.002 8005 0.002 1000 6.5.2. Free

41、fall test This test is conducted on a concrete floor. free-fall the sample onto the concrete floor from a height of 0.5m once for each of corner, right/left and front/back sides. There shall be no harmful influence on performance or external deformation. 6.5.3. Mechanical shock test This test is con

42、ducted to clause 6.2.2 of EDS-T-5235 and after test basic performance requirements in 6.2.1 shall be met 6.6. Operation durability test 6.6.1. Construct the relevant input/output loads equivalent to the vehicle condition. 6.6.2. Operate the sample for 1000 hours according to the sequence specified i

43、n the drawing under the initial loading condition at the maximum operating temperature and standard operating voltage. 6.6.3. During and after test, each part shall operate normally and each performance value shall stay within the specified allowable range (1) Test temperature: -40 +852.5 (2) Test v

44、oltage: 14V0.2(V) (3) Test temperature frequency: refer to Thermal life cycle below (4) Operating durability frequency (5) No of operation and frequency shall be determined following agreement and reflected in DWG. THE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 9/10 I

45、SSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology -50 -30 -10 10 30 50 70 90 0 20 40 60 80 100 120 140 160 180 200 220Temp.Temps(time) Thermal life cycleTemps(time) Temperature T=0 -40 T=20 H -40 T=22H +40 T=102H +40 T=104H +60 T=184H +60 T=186H +85 T=206H +8

46、5 T=208H -40 Voltage 14(V) 12(V) 0(V) POWER WINDOWROOM LAMP DEFROSTERWIPER &WASHERHAZARDWARNINGIMMO.1cycleRKEFunctionTHE TEST OF ELECTRIC COMPONENTS FOR INTELLIGENT SWITCHING UNIT EDS-T-5428PAGE: 10/10 ISSUED DATE: 1998. 07. 03 REVISED DATE: 2008. 10. 21 VERSION: 4 GM DAEWOO Auto & Technology 7. UNI

47、T TEST ITEM FOR EACH SAMPLE Test clause Test designation S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S156.1. Test(visual& Dimension test) X X X X X X X X X X X X X X X 6.2. performance test X X X X X X X X X X X X X X X 6.3.1 Source voltage change test X X X X X X 6.3.2 Source voltage chattering

48、test X X X X X X 6.3.3 Over voltage/reverse-voltage X X X 6.3.4 Short circuit X X X 6.3.5 Dielectric resistance X X X 6.3.6 Insulation resistance test X X X 6.4.1 High temperature exposure X X X 6.4.2 Low temperature exposure X X X 6.4.3 High temperature & humidity operating test X X X 6.4.4 Tempera

49、ture operation test X X X 6.4.5 Thermal shock X X X 6.4.6 Salt spray test X X X 6.5.1 Vibration resitance test X X X 6.5.2. Free fall test X X X 6.5.3. Mechanical shock test X X X 6.6. Operation durability test X X X 6.2.2. Operating Temperature & voltage X X X X X X X X X X X X X X X Note1) The above X represents the unit test item for each sample.