GMKOREA EDS-T-5438-2008 TEST OF COMPONENTS FOR FATC.pdf

1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards TEST OF COMPONENTS FOR FATC Do Not Use on New Programs. Being Replaced by GMW3172&14078 EDS-T-5438 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 (Superceded) EDS-T-5438TEST OF COMPONENTS FOR FATC PAG

2、E: 1/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T250 Program). It is Superceded for all future projects and replaced by GMW3172&14078. 1. PURPOSE This standard is to evaluate the fun

3、ctionality of components of Full Automatic Temperature Controller (hereinafter referred to as “FATC” for short) used in a vehicle. 2. SCOPE The standard is applied to a test to be performed on a component of FATC. 3. TEST CONDITIONS 3.1. Standard Test Voltage The voltage for the functionality and du

4、rability tests on FATC must be referred to the drawing or test specifications sheet. Unless otherwise specified for a test, the voltage will be 13.50.5V. But the test voltage must be actually applicable to a test sample. 3.2. Standard Test Status Unless otherwise specified, perform the test at a con

5、stant temperature and humidity as specified in KS A 0006(Standard Conditions for Test Place). 3.3. Number of Test samples The number of test samples is at least 15 principally, but adjustable by agreement when necessary. 4. TEST INSTRUMENTS AND EQUIPMENT 4.1. General Information Instruments to be us

6、ed for a test must be verified and calibrated by an authorized verification/calibration agency and be available within their validity term. 4.2. Constant Temperature and Humidity Chamber The constant temperature and humidity chamber must be available to keep a temperature between -40and +90 and its

7、capacity over 100 liters. At each temperature, the relative humidity must be adjustable up to 95%. The temperature tolerance must be within 2. 4.3. Vibration Tester This tester must be available for a test according to KSR 1034(Automotive Parts Vibration Testing Method). 4.4. Controller for Durabili

8、ty Test This controller must have the automatic circuit breakers capable of supplying and breaking electric power for EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 2/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology individual operation of each modules and b

9、e equipped to record the time and the number of occurrence by sensing them when defects are found. 5. Reliability Test 5.1. Exterior Test 5.1.1. Naked Eye Examination (1) Examine each module by the naked eye. (2) Check if there is any dangerous crack or defect found so that it may give rise to any f

10、unctional problem. 5.1.2. Dimensions Test (1) Use a pair of vernier calipers specified in KS B 5203. The test sample must correspond, in material, to the one specified on the design and its dimensions be the same as those indicated on the drawing. 5.2. Performance Test 5.2.1. Basic Performance (1) C

11、heck if the test sample meets the operating performance specified on the drawing. (2) Before performing (1), be sure to connect the test sample with HVAC module and check if they are unmatchable up to each other. 5.2.2. Self-Diagnosis Function (1) Check if the fail-safe and self-diagnosis functions

12、specified on the drawing are satisfactory. (2) Before performing (1), be sure to connect the test sample with HVAC module and check the self-diagnosis by running the fail mode specified on the drawing. 5.2.3. AUTO Performance (1) Set up the test equipment under the test conditions as specified on th

13、e drawing and then check the input and output valves against each other. (2) Unless otherwise specified on the drawing, the Auto performance must be defined by the agreement with the test-responsible department and the engineering design department before the test. 5.2.4. Power Consumption (1) Perfo

14、rm the test at a standard test voltage. (2) Separate ignition power cable and battery power cable when checking the power consumption. (3) Ensure that the power consumption cannot be over the permissible level as specified on the drawing. 5.3. Electrical Durability Test 5.3.1. Basic Voltage Test Con

15、nect an input unit and output unit to the test sample. Check whether the durability meets the conditions as described in “5.2.1” and “5.2.3” within the range A as shown in Fig. 1. The range B indicates storage area that must EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 3/9 ISSUED DATE: 1999. 10. 30 R

16、EVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology be free of any defect. The test must meet the basic performance after the range has moved from B to A. The test must be conducted under the condition that the test sample is kept at a temperature of -40(+85) for an hour and dehumidifie

17、d over 2 hours at a constant room temperature. The test must meet the basic performance in the 5 points of the operating area A. Figure 1 5.3.2. Voltage Variation Test (1) This test is to check whether the input/output unit works normally with the voltage variation on engine start-up and load variat

18、ion. (2) Set up the test samples as specified on the design. Apply each test voltage to the battery and ignition terminals according to each mode of A, B, and C and perform the test during 10 cycles. Ensure that each mode test meet the basic performance described in 5.2.1. 1) Test Temp. : Standard t

19、est temperature for a constant temperature and humidity 2) Test Voltage : 0(V) 13.5(V) 3) Total Test Cycles : 10 cycles 4) Test 1 Cycle EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 4/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology Figure 2 Figure 3 Figure

20、 4 5.3.3. Voltage Chattering Test (1) This test is to check whether FATC works normally with the voltage variation on engine start-up. (2) Apply to IGN. power terminal the following waveform of voltage as shown in FIG.5-1 and ensure that the test sample works properly during/after 10CYCLE. (3) In FI

21、G.5-1, T1= T2 = 20ms. The terminal using battery power must be configured as shown in FIG.5-2 so that EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 5/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology the IGN. S/W can be turned ON/OFF. 5.3.4. Reverse/Over Vol

22、tage Test (1) This test is performed to protect internal circuit of FATC from overvoltage that may happen to a car with its battery discharged, and from reverse voltage that acts as dielectric resistance on the test sample. (2) There must be no malfunction during the test after applying abnormal vol

23、tage as below. FATC must work normally with a normal voltage applied after the test. 1) Overvoltage a. Test Voltage : 24V b. Test Duration : 1 min. c. Test Temperature : Standard test temperature for a constant temperature and humidity 2) Reverse Voltage a. Test Voltage : -13V b. Test Duration : 1 m

24、in. c. Test Temperature : Standard temperature for a constant temperature and humidity 5.3.5. Dielectric Resistance Test When an alternative voltage of 60 Hz 500(V) is applied between the front panel part of FATC and the power input terminal for a minute, damage should not be done to FATC and FATC m

25、eet the basic performance. 5.3.6. Isolation Resistance Test When a direct voltage of 500(V) is applied between the front panel part of FATC and the power input terminal, the isolation resistance must be over 100 MOHM. 5.4. Environmental Test 5.4.1. High Temperature Placement Test (1) Set up the test

26、 sample as specified on the design. (2) Leave the test sample unconnected with an input unit and perform the test under the conditions given as below. Keep the sample for 2 hours at a given constant temperature and humidity and then connect the test sample to the input unit. Apply a normal voltage a

27、nd verify that the test sample meets the basic performance EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 6/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology and is not deformed and/or twisted. 1) Test Temp. : +85 2) Test Duration : 72 hrs 5.4.2. Low Temperat

28、ure Placement Test (1) Set up the test sample as specified on the design. (2) Leave the test sample unconnected with an input unit, and perform the test under the conditions given as below. Keep the sample for 2 hours at a given constant temperature and humidity. In this case, if there is a frost or

29、 moisture found on the surface, remove it. Then connect the test sample to the input unit. Apply a normal voltage and verify that the test sample meets the basic performance and is not deformed and/or twisted. 1) Test Temp. : -40 2) Test Duration : 72 hrs 5.4.3. High Temperature Operation Test (1) S

30、et up the test sample as specified on the design. (2) Connect the test sample connected with an input unit and keep the test sample at an ambient temperature of 75 for an hour. (3) Operate the sample for 72 hours in FULL AUTO mode in the state of ILL ON. Verify that there is no malfunction on the ou

31、tput unit with external sensor value variation once or more every day for the duration of the test. (4) For the duration of the test, there must be no malfunction. After Step (2), keep the sample for 2 hours at a room temperature. Then connect the test sample to the input unit and load. Apply a norm

32、al voltage and verify that the test sample meets the basic performance and is not deformed and/or twisted. 5.4.4. Low Temperature Operation Test (1) Set up the test sample as specified on the design. (2) Connect the test sample connected with an input unit and keep the test sample at an ambient temp

33、erature of -30 for an hour. Then operate the sample for 72 hours in FULL AUTO mode in the state of ILL OFF. (3) Verify that there is no malfunction on the output unit with external sensor value variation once or more every day for the duration of the test. (4) For the duration of the test, there mus

34、t be no malfunction. If there is a frost or moisture found on the surface, remove it. After Step (3), keep the sample for 2 hours at a room temperature. Then apply a normal voltage and verify that the test sample meets the basic performance and is not deformed and/or twisted 5.4.5. Temperature Cycle

35、 Test (1) Set up the test sample as specified on the design. (2) Set up the test sample under the conditions below with the temperature cycle as shown in Fig. 6 and connect it to a power input unit. Operate the test sample in FULL AUTO mode in the state of ILL OFF. Verify that there is no malfunctio

36、n on the output unit with external sensor value variation once or more every day in the working EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 7/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology section. 1) Test Temperature : -30 +75 2) Test Working Voltage :

37、 Standard Test Voltage 3) Total Test Cycles : 30 Cycles (3) For the duration of the test, there must be no malfunction in the sample. Keep the sample for 2 hours at a room temperature. Then connect the test sample to the input unit. Apply a normal voltage and verify that the test sample meets the ba

38、sic performance and is not deformed and/or twisted. Figure 6 5.4.6. Thermal Shock Test (1) Set up the test preparations as specified on the design. (2) Keep the sample for 2 hours at a temperature of -40 and perform 10 cycles under the condition of temperature cycle as shown in Fig.7. (3) After Step

39、 (2), keep the sample for 2 hours at a room temperature. Then connect the test sample to the input unit. Apply a normal voltage and verify that the test sample meets the basic performance and is not deformed and/or twisted 1) High Temperature Test : +85 2) Low Temperature Test : -40 Figure 7 5.4.7.

40、Moisture Resistance Test (1) Set up the test sample as specified on the design. EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 8/9 ISSUED DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology (2) Connect the test sample to the power input unit under the conditions below a

41、nd start the test. 1) Test Temp. : 602 2) Relative Humidity : 953% 3) Test Duration : 96hrs (3) Operate the test sample in FULL AUTO mode in the state of ILL OFF. Verify that there is no malfunction on the output unit with external sensor value variation once or more every day in the working section

42、. (4) For the duration of the test, there must be no malfunction in the test sample. After the test, remove moisture on the surface of the test sample and keep it for 2 hours at a constant temperature and humidity. Then connect the test sample to the power input unit and verify that the test sample

43、meets the basic performance. 5.5. Mechanical Environment Test 5.5.1. Vibration Test There must be no malfunction in the test sample for the duration of the test. After the test, connect the test sample to the power input unit and verify that the test sample meets the basic performance without noise,

44、 twist, and deformation. (1) Vibration Frequency : 66.7Hz (2) Vibration Acceleration : 4.5G (3) Virtual Vibration Conditions : up and down: 4 hrs, forward-backward/right-left : 2hrs. 5.5.2. Free Fall Test Make the test sample free-fall 2 times in each direction of X, Y, and Z at a height of 0.5 m. B

45、ut do not try its free fall with its front face perpendicular to the floor. Check which part affects its motion and where damage is done to it. Then connect the test sample to the power input unit and verify that the test sample meets the basic performance. 5.5.3. Working Durability Test (1) Connect

46、 MODULE A-HVAC with FATC S/W under the assumption that the connection is made in a complete car. Perform a working durability test on its system during the period of 70,000cycles. Determine working mode and durability of each component or unit by agreement with the test-responsible department, befor

47、e a test. (2) After the test, the sample must meet the performance described in 5.3.1. 5.6. FINAL TEST All the test samples, which have been put through the electric resistance and environment tests, must meet the performance indicated in 5.3.1. EDS-T-5438TEST OF COMPONENTS FOR FATC PAGE: 9/9 ISSUED

48、 DATE: 1999. 10. 30 REVISED DATE: 2008. 10. 27 VERSION: 4 GM DAEWOO Auto & Technology 6. INDIVIDUAL TEST PER ITEM Each test must be conducted principally according to the matrix of the table, but adjustable by agreement with the engineering design department, when necessary. Test Item 1 2 3 4 5 6 7

49、8 9 10 11 12 13 14 155.1. Exterior Test 5.2. Performance Test 5.3.1. Basic Voltage Test 5.3.2. Voltage Variation Test 5.3.3. Voltage Chattering Test 5.3.4. Reverse/OverVoltage Test 5.3.5. Dielectric Resistance Test 5.3.6. Isolation Resistance Test 5.4.1. High Temp. Placement Test 5.4.2. Low Temperature Placement Test 5.4.3. High Temperature Operation Test 5.4.4