GMKOREA EDS-T-5501-2008 BULINKER UNIT LOAD TEST.pdf

1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards BULINKER UNIT LOAD TEST Do Not Use on New Programs. Being Replaced by GMW15267 EDS-T-5501 ISSUED DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 1/14 ISSUE

2、D DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 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 It is Superceded for all future projects and replaced by GMW3172. 1. PURPOSE This standard aims at specifying the requirements, tes

3、t conditions and test method of the blinker used for automobiles manufactured by GMDAT to perform the test in a correct manner and obtain the accurate results. 2. SCOPE This standard applies to the blinker for automobiles. 3. DEFINITION OF TERMS 3.1. Blinker: The blinker refers to the blinker for au

4、tomobiles used in GMDAT which includes the turn signal flasher and the hazard flasher. It contains in it the device to interrupt the current to continuously operate the turn signal lamp. 3.2. Test load: The test load is the load used for the performance and durability test of the blinker and refers

5、to the rated load, which is applied and installed in the vehicle, and the equivalent inductance and resistor load. 3.3. Test voltage: The test voltage refers to the voltage used for the blinker performance and durability test which is specified in drawings or test standard. 4. TEST CONDITIONS 4.1. S

6、tandard test conditions Unless specified otherwise, test shall be performed at the normal temperature and normal humidity specified in KS A 0006 (Standard Conditions of Test Place). 5. TEST EQUIPMENT 5.1. General Measuring instruments used for test shall basically be calibrated by the national calib

7、ration institute and within the effective calibration period. 5.2. Constant power supply The constant power supply shall have been calibrated and the maximum load current shall meet the requirements in the drawings or test standard. In preparation against the possible over current at the test, it sh

8、all have a +50 % effective capacity 5.3. Voltmeter EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 2/14 ISSUED DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Class 0.5 or higher specified in KS C 1303 (Electric Indicating Instrument). 5.4. Ammeter Class 0.5 or higher sp

9、ecified in KS C 1303 (Electric Indicating Instrument). 5.5. Insulation resistance meter DC 500 insulation resistance meter specified in KS C 1301 (Generator Type Insulation Resistance Meter) and KS C 1302 (Battery Type Insulation Resistance Meter). 5.6. Voltage withstand tester A tester capable of g

10、enerating the high voltage specified in the drawings or test standard, adjusting the test time, memorizing the instantaneous high voltage rate and automatically interrupting the high voltage at a time of dielectric breakdown 5.7. Temperature chamber A chamber capable of maintaining the temperature f

11、rom 40 to +90, it shall have a minimum capacity of 15 liter and accuracy of 2.5 for each temperature level 5.8. Vibration tester A tester capable of performing the test according to KS R 1034(Vibration Test Method for Automobile Parts) and QT 126502 5.9. Drop tester A tester capable of performing th

12、e test according to QT 126502 5.10. Control box for durability test It shall be capable of automatically supplying and cutting off the voltage for precise operation and stop of the blinker, displaying the number of tests in the digital mode, automatically interrupting the voltage applied to the blin

13、ker when the test is over, detecting any defects during the test and recording the no. of cycles of durability test 6. APPEARANCE TEST 6.1. The appearance inspection shall be performed visually. 6.2. When observed visually, the blinker shall show no sign of harmful flaws, cracks, or other defects th

14、at may adversely affect the performance. 7. ELECTRIC PERFORMANCE TEST 7.1. Operating voltage test EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 3/14 ISSUED DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7.1.1. Operating voltage test at normal temperature (1) Construct

15、 the electric circuit as shown in Appendix1. (2) Increase the voltage of the DC power supply to apply the minimum operating voltage specified in the drawings or test standard to the blinker coil terminal. (3) Check if the contacts of the blinker touch with each other. (4) With the voltage kept appli

16、ed, increase the voltage to the maximum operating voltage range to check if the contacts of the blinker remain touching with each other. (5) The brake and make of the contacts shall be observed with the ohmmeter installed at both ends of the blinker load terminals. 7.1.2. Operating voltage test at h

17、igh temperature (1) Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the blinker inside the chamber. The starting point of storage may either when the sur

18、face temperature of the blinker becomes identical to the test temperature or after 5 minutes from storage of the blinker (3) Immediately after storing the blinker inside the temperature chamber for 1 hour, take it out and repeatedly perform the test in clause 7.1.1 with the electric circuit shown in

19、 Appendix 1. (4) The test time after taking the blinker out of the temperature chamber shall not last longer than 30 seconds. 7.2. Minimum operating voltage test 7.2.1. Minimum operating voltage test at normal temperature (1) Construct the electric circuit as shown in Appendix1. (2) After applying v

20、oltage with the DC power supply, increase the voltage level. (3) The voltage at the moment the contacts of the blinker touch for the first time is the minimum operating voltage. (4) Read the voltage at this moment with a voltmeter. (5) The moment of contact is judged with an ohmmeter installed betwe

21、en the load terminals. 7.2.2. Minimum operating voltage test at high temperature (1) Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the blinker inside t

22、he chamber. The starting point of storage may either when the surface temperature of the blinker becomes identical to the test temperature or after 5 minutes from storage of the blinker (3) Immediately after storing the blinker inside the temperature chamber for 1 hour, take it out and repeatedly pe

23、rform the test in clause 7.2.1 with the electric circuit shown in Appendix 1. (4) The test time after taking the blinker out of the temperature chamber shall not last longer than 20 seconds. 7.3. Return voltage test EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 4/14 ISSUED DATE: 1988. 08. 11 REVISED DATE:

24、 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7.3.1. Return voltage test at normal temperature (1) Construct the electric circuit as shown in Appendix1. (2) After applying voltage with the DC power supply, increase the voltage level so that the contact of the blinker remain in contact. (3) Wi

25、th the contact of the blinker remaining in contact, reduce the voltage and read the voltage with a voltmeter at the moment the contacts of the blinker is disconnected for the first time. (4) The moment of disconnection is judged with an ohmmeter installed between the load terminals. 7.3.2. Return vo

26、ltage test at low temperature (1) Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the blinker inside the chamber. The starting point of storage may eithe

27、r when the surface temperature of the blinker becomes identical to the test temperature or after 5 minutes from storage of the blinker. (3) Immediately after storing the blinker inside the temperature chamber for 1 hour, take it out and repeatedly perform the test in clause 7.3.1 with the electric c

28、ircuit shown in Appendix 1. (4) The test time shall not last longer than 30 seconds. 7.4. Exciting current test 7.4.1. Construct the electric circuit as shown in Appendix 2 7.4.2. Apply the test voltage specified in the drawings or test standard to the to the blinker coil terminal. 7.4.3. Read the c

29、urrent flowing through the blinker coil with an ammeter. 7.4.4. The test time shall not last longer than 30 seconds. 7.5. Voltage drop test 7.5.1. Construct the electric circuit as shown in Appendix 3. 7.5.2. In constructing the electric circuit, the test load shall meet the requirements of the rate

30、d load and rated capacity specified in the drawings or test standard. 7.5.3. Operate the blinker with the test voltage. 7.5.4. With an ammeter, check if the current capacity of the test load meets the test conditions. 7.5.5. Measure the voltage drop between the blinker load terminals with a voltmete

31、r. 7.5.6. The value of voltage drop to be reported shall basically be that after 5 measurements. 7.6. Operating temperature range test 7.6.1. High temperature operating test (1) Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test EDS-T-5501BULI

32、NKER UNIT LOAD TEST PAGE: 5/14 ISSUED DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology standard. (2) After the temperature of the chamber reaches the test temperature, store the blinker inside the chamber. The starting point of storage may either when the surface

33、temperature of the blinker becomes identical to the test temperature or after 5 minutes from storage of the blinker. (3) Immediately after storing the blinker inside the temperature chamber for 1 hour, take it out and repeatedly perform the test in clause 7.1.1. (4) The test time shall not last long

34、er than 30 seconds. 7.6.2. Low temperature operating test Same as clause 7.5.1. 7.7. Insulation resistance test 7.7.1. Have the lead line of the insulation ohmmeter connected to the blinker surface. 7.7.2. Measure the insulation resistance between the insulated parts of the blinker, or between the t

35、erminals, and between the terminal and other conducting parts. 7.8. First blinking time test 7.8.1. Construct the electric circuit as shown in Appendix 4. 7.8.2. Apply the test voltage to the blinker. 7.8.3. Connect a channel of an oscilloscope to the power supply and another to the load terminal to

36、 obtain the waveforms displayed on two channels and then measure the time span up to the point the waveform of the load terminal cuts off that of the power source. 7.8.4. The time span shall not be longer than 0.2 second. 7.9. Blinker frequency test 7.9.1. Construct the electric circuit as shown in

37、Appendix 4. 7.9.2. Apply the test voltage specified in the drawings or test standard to the blinker. 7.9.3. The blinking frequency of the blinker shall be 85 +/ - 15 times for a minute. 7.9.4. The test time shall start from the point the test voltage is applied to the blinker under the adjusted load

38、 condition. 7.9.5. After the test, repeat the test in 7.1.1. 7.10. Percentile blinking test 7.10.1. Construct the electric circuit as shown in Appendix 4. 7.10.2. Apply the test voltage specified in the drawings or test standard to the blinker. EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 6/14 ISSUED DAT

39、E: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7.10.3. The percentile blinking frequency is calculated by following equation and shall stay at 38% 55%. 100+=Pause time Startingtime Startingfrequency blinking percentile The7.10.4. The test time shall start from the

40、point the test voltage is applied to the blinker under the adjusted load condition. 7.11. Lamp shut off test 7.11.1. Construct the electric circuit as shown in Appendix 4. 7.11.2. Apply the test voltage specified in the drawings or test standard to the blinker. 7.11.3. After one lamp is removed of t

41、he loads, the blinking frequency shall be twice or more of the value specified in clause 7.9 but shall not be larger than 280 times. 7.11.4. The test time starts from the moment the test voltage is applied to the blinker under the adjusted load conditions. 8. TEMPERATURE EXPOSURE TEST 8.1. Adjust th

42、e temperature of the temperature chamber to the test temperature specified in the drawings or test standard. 8.2. After the temperature of the chamber reaches the test temperature, store the blinker inside the chamber. The starting point of storage may either when the surface temperature of the blin

43、ker becomes identical to the test temperature or after 5 minutes from storage of the blinker. 8.3. After elapse of a certain time, take the blinker out of the temperature chamber and expose it to normal temperature for an hour. 8.4. In the same method as in 8.1 and 8.2, proceed with test in other te

44、mperature ranges. 8.5. After the temperature storage test, conduct the appearance test in clause 6 and electric performance test in clause 7 to check for the presence of external defects in the blinker and faulty functions. 9. DURABILITY TEST 9.1. Unless specified otherwise, test shall be performed

45、at the normal temperature and normal humidity specified in KS A 0006 (Standard conditions of test place). Special requirements in the test standard and drawings shall be met if any. 9.2. Construct the electric circuit as shown in Appendix 5 and mount the blinker in the vehicle conditions. The electr

46、ic wire used for the durability test shall meet the requirements for the rated load capacity in Appendix 6. EDS-T-5501BULINKER UNIT LOAD TEST PAGE: 7/14 ISSUED DATE: 1988. 08. 11 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 9.3. After adjusting the test voltage with a voltmeter,

47、 check with an ammeter if the current of the test load meets the test requirements. Interrupt the power supply for a moment. 9.4. Apply voltage to the control box for durability test and set the “operation” and “stop “, “test duration” and “total number of test cycles conducted” to correspond to the

48、 test conditions. 9.5. On completing setting, apply the test voltage to the blinker and operate the control box. 9.6. While proceeding with durability test, conduct routine checks according to Form 1. 9.7. If faults are found during the test, record the phenomenon of faults and the total number of o

49、peration in Appendix 7 and keep it. 9.8. After the durability test, conduct the electric performance test in clause 5. When thus specified in the drawings or test standard, only needed items may be performed selectively. Unless specified otherwise, however, the electric performance test specified in clause 7 shall be repeated. 10. VIBRATION TEST 10.1. Install the blinker to the vibrating stand of the vibration tester. 10.2. After adjusting the vibration tester to meet the test standard, perform test for a specified time in three directions: longitudinal, lateral and vertical. 10.3. T