GMKOREA EDS-T-5704-2008 JUNCTION BOX TEST STANDARD.pdf

1、GM DAEWOO Auto Projector 4. TEST ITEMS 4.1. Basic Performance Test 4.1.1. External Dimensions (1) Test Method: Measure each dimension using slide caliper or projector. (2) Evaluation Criteria: Evaluate according to basic drawing rules. 4.1.2. Connector Insertion (1) Test Method: Evaluate while inser

2、ting connector with hand. (2) Evaluation Criteria 1) Connector should be inserted smoothly. EDS-T-5704JUNCTION BOX TEST STANDARD PAGE: 2/8 ISSUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 2) You should be able to hear the click sound to verify connector ins

3、ertion. 4.1.3. Bad Connection (1) Test Method 1) Shake the sample front-and-back, left-to-right. 2) Conduct test with Penetration Connector and Spare Fuse in use. (2) Evaluation Criteria 1) There shall be no bad splicing or looseness within J/B. 2) There shall not be any harmful splicing between box

4、 and cover. 4.2. Mechanical Performance Test 4.2.1. Fuse Insertion Force (1) Test Method: Align the Fuse and its Insertion Unit on one line, fix Fuse onto Tension Tester, insert into Holder five times at the speed of 205mm per minute, and compute the average of measurements. (2) Evaluation Criteria:

5、 MINI Fuse: Maximum 9.2Kgf 90N, MAX Fuse: Maximum 18.4Kgf 180N 4.2.2. Fuse Separation Force (1) Test Method: Fix Fuse to Tension Tester while Fuse and its Insertion Unit are assembled, pull out at the speed of 205mm per minute, measure the load when Terminal pulls out of the Box five times, and comp

6、ute the average. Configure Terminal according to the above specification, apply 8 kgf of load at the oblique angle direction of 30 from the horizontal level, repeat five times and verify that the terminal does not come out of the Box. (2) Evaluation Criteria 1) Vertical - Minimum 8Kgf 78.4N 2) There

7、 shall not be Terminal separation from the Box at 30Angle - 8Kgf load. 4.2.3. Terminal Holding Force (1) Test Method: Insert a terminal with 85SQ or bigger wire connected into the Box and make connection. Pull it out vertically at the speed of 20mm per minute and measure the breaking strength of Ter

8、minal separating from the Box using either Pull Gage or Elastic Force Gage. Configure the Terminal based on the above specification, apply a load of 8 kgf along 30 from the horizontal level, and verify that the Terminal does not come out of the Box. (2) Evaluation Method 1) Vertical - Minimum 8Kgf 7

9、8.4N 2) There shall not be Terminal separation from the Box at 30Angle - 8 Kgf load. 4.2.4. Strength of Fixation Area of J/B (1) Test Method: Keep J/B in Constant Temperature Chamber at 03 for 12 Hours, take it out and immediately evaluate as follows. 1) Attach the Fastener properly. 2) Tighten Bolt

10、 or Nut under the following conditions. EDS-T-5704JUNCTION BOX TEST STANDARD PAGE: 3/8 ISSUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology - Bolt: M6 - Nut: M5 - Torque: M5 - 65Kgf.cm / M6 - 110Kgf.cm 3) Apply a force of 10 Kgf at Fixation Area vertically unde

11、r the above conditions. (2) Evaluation Criteria: There shall be no damage. 4.2.5. Connector Insertion Force (1) Test Method: Measure the force when inserting Housing with Female Terminal assembled and J/B Counterpart Object at the speed of 205mm. (2) Evaluation Criteria: Evaluation shall be done acc

12、ording to Table 1. No. of Terminals Terminal Size Insertion Force Maximum 6P 070, 090 250 or greater Maximum 6Kgf 58.8N Maximum 10Kgf 98N 7P 12P 070, 090 250 or greater Maximum 10Kgf 98N Maximum 15Kgf 137.2N 13P or greater - Maximum 15Kgf 137.2N RELAY ISO MINI 280 MINI Maximum 12Kgf 117.6N Maximum 1

13、0Kgf 98N 4.2.6. Connector Separation Force (1) Test Method: Measure the force when separating the Housing with Female Terminal assembled and J/B Counterpart Object at the speed of 205mm. (2) Evaluation Criteria: Evaluation shall follow Table 2. No. of Terminals Terminal Size Force Maximum 6P 070, 09

14、0 250 or greater 1Kgf 9.8N 5Kgf 49N 1Kgf 9.8N 10Kgf 98N 7P 12P 070, 090 250 or greater 1Kgf 9.8N 9Kgf 88.2N 1Kgf 9.8N 14Kgf 137.2N Bus Terminal 1Kgf 9.8N 14Kgf 137.2N 4.2.7. Strength of Connector Locking Area (1) Test Method: Measure the load when the Connector Locking Area is either unlocked or dam

15、aged while pulling the Connector at 30 angle from the horizontal plane of axial direction with Connector in junction without a Terminal. (2) Evaluation Method 1) Axial Direction - Minimum 10Kgf 98N 2) 30Oblique Direction Locking device shall not be separated or damaged. 4.2.8. Shock Resistance (1) T

16、est Method: Keep the J/B in Constant Temperature Chamber for 12 hours at 03, take it out and EDS-T-5704JUNCTION BOX TEST STANDARD PAGE: 4/8 ISSUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology immediately make evaluation as follows. Drop the J/B with designated

17、 harness attached from the height of 0.5M onto a concrete floor with 10mm thick rubber cladding. (2) Evaluation Criteria 1) There shall be no damage. 2) Fuse, Spare Fuse, Cover or Fuse Puller shall not come out of J/B. 4.3. Electrical Performance Test 4.3.1. Insulation Resistance (1) Test Method: Me

18、asure the resistance between adjacent Terminals, between adjacent Base Wires, at Terminal, Distribution Panel and the Casing while applying DC 500V to a J/B with designed Fuse and Relay assembled properly. (2) Evaluation Criteria: Minimum 100 or greater 4.3.2. Voltage Endurance (1) Test Method: Appl

19、y DC 1,000V to the J/B with specified Fuse assembled for one minute and observe any insulation damage between adjacent holes and adjacent patterns. (2) Evaluation Criteria: There shall be no insulation damage. 4.3.3. Temperature Rise (1) Test Method 1) Attach wire and fuse onto J/B and apply the cur

20、rent equivalent to actual load. When each conductance areas temperature reaches stable levels, measure the temperature. 2) Measurement points shall be 10 or more and be selected from points where preliminary test temperatures were relatively higher. 3) The exterior temperature of vehicle interior pa

21、rts shall be 403 and the direction of their installation shall be similar to actual vehicle installation. 4) The load for each of the following circuits shall be applied based on actual vehicle values and additional items shall depend on measurement points. a. Head Lights (Bright) b. Engine Control

22、Unit (ECU) c. Audio d. Illumination e. Windshield Wiper - First Stage f. Rear Window Heater g. Blower Fan h. A/C Compressor i. Radiator Fan j. Fog Lamp k. Fuel Pump 5) Attach a thermocouple for measuring temperature at measurement points using Epoxy. EDS-T-5704JUNCTION BOX TEST STANDARD PAGE: 5/8 IS

23、SUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6) The thermocouple attachment location shall be at the neck of Female Connector (refer to Figure 1.) (2) Evaluation Criteria 1) Temperature Rise: Under maximum 403 2) Voltage Drop: Maximum 14 mV/A or less 3) T

24、here shall be no deformation of J/B. 4.3.4. Overflow Current (1) Test Method 1) Apply Overflow Current to target circuit of J/B with wire and fuses attached. When applying Overflow Current, replace the target fuse with a Shunt and the load shall be applied at 135% of the Fuse load for 30 minutes. 2)

25、 Selection of Fuses for measurement shall be based on consultation between the Tester and the Designer. (2) Evaluation Method 1) There shall be no fire ignition, deformation or discoloring of the J/B. 2) Voltage Drop: Maximum 14 mV/A or less 4.3.5. Voltage Drop (1) Test Method 1) Apply 1A of current

26、 to target circuit with specified parts (Harness, Relay, and Fuse) assembled to J/B, and measure the Voltage Drop. Here, voltage drop at Fuse Endpoints shall be excluded from measurement. 2) Measurement Points (Refer to Figure 2.) EDS-T-5704JUNCTION BOX TEST STANDARD PAGE: 6/8 ISSUED DATE: 1997. 12.

27、 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (2) Evaluation Method: Maximum 14 mV/A or less (INTER CONNECTION: Maximum 1mV/A) 4.4. Environmental Performance Test 4.4.1. Cold Endurance (1) Test Method 1) Cold Endurance Test shall be performed with wire and fuse installed on J

28、/B and the J/B installed onto a Bracket under vehicle conditions. 2) After exposing the J/B at -403 for 120 Hours, leave it at room temperature until the ambient temperature reaches room temperature. (2) Evaluation Method 1) Appearance: There shall be no harmful deformation. 2) Bad Connection: There

29、 shall be no bad connection or looseness in J/B. 3) Voltage Drop: Maximum 14mV/A (per connection circuit) 4.4.2. Hot Endurance (1) Test Method 1) Hot Endurance Test shall be performed with wire and fuse installed on J/B and the J/B installed onto a Bracket under vehicle conditions. 2) After exposing

30、 the J/B at 1253 for 120 Hours, leave it at room temperature until the ambient temperature reaches room temperature. (2) Evaluation Method 1) Appearance: There shall be no harmful deformation and in particular, verify looseness of the Cover. 2) Bad Connection: There shall be no bad connection or loo

31、seness in J/B. 3) Voltage Drop: Maximum 14mV/A (per connection circuit) 4.4.3. Humidity Tests (1) Test Method 1) With designated wiring assembled to J/B, set Temperature at 403 and Moisture at 90 95% RH, and hang J/B in mid air so as to prevent water drop contact for 96 hours. 2) During the test per

32、iod, apply DC 12V for 24 hours at a time between Terminals and measure Current Leakage. (2) Evaluation Criteria: Current Leakage: Maximum 3mA 4.4.4. Thermal Shock Tests (1) Test Method 1) Thermal Shock Test shall be conducted with wires and fuses attached on J/B and the J/B installed on a bracket un

33、der vehicle conditions. 2) Expose the sample at 903 for 30 minutes and at -403 for 30 minutes. Repeat this process for 120 times. Here, the temperature change shall be done within five minutes. (2) Evaluation Criteria 1) Appearance: There shall be no harmful deformation. EDS-T-5704JUNCTION BOX TEST

34、STANDARD PAGE: 7/8 ISSUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 2) Bad Connection: There shall be no bad connection or looseness in J/B. 3) Voltage Drop: Maximum 14mV/A (per connection circuit) 4.4.5. Temperature- Moisture Tests (1) Test Method 1) Condu

35、ct Moisture Test with wiring attached to J/B and install J/B onto a bracket under vehicle conditions. 2) Conditions a. Moisture: 95 98% RH b. Temperature: -403 703 c. 1 Cycle: . 16 Hours +403 . 2 Hours -403 . 2 Hours +703 . 4 Hours +253 d. Frequency: 15 Cycle (360 Hours) (2) Evaluation Criteria 1) A

36、ppearance: There shall be no harmful deformation. 2) Bad Connection: There shall be no bad connection or looseness in J/B. 3) Voltage Drop: Maximum 14 mV/A or less 4) Temperature Rise: Maximum 403 or less 5) Insulation Resistance: Minimum 100 or greater 4.4.6. Integrated Environment Tests (1) Test M

37、ethod 1) Integrated Environment Test shall be conducted with wires and fuse attached to J/B and the J/B installed on a bracket under vehicle conditions. 2) Test Conditions a. Temperature: -303 703 b. Moisture: 80 95% RH c. Vibration . Frequency: 11.7 200Hz . Duration: 20 Min./ Cycle(11.2Hz 200Hz 11.

38、7Hz) . Vibration count per acceleration: 2.2G (21.57m/s2)d. Load: Apply actual load condition On for 45 minutes then Off for 15 minutes. e. 1 Cycle . 16 Hours +603 . 2 Hours +603 -303 . 2 Hours -303 . 4 Hours -303 +603 f. Frequency: 12.5 Cycles (300 Hours) EDS-T-5704JUNCTION BOX TEST STANDARD PAGE:

39、8/8 ISSUED DATE: 1997. 12. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (2) Evaluation Criteria 1) Appearance: There shall be no harmful deformation. 2) Bad Connection: There shall be no bad connection or looseness in J/B. 3) Voltage Drop: Maximum 14mV/A or less 4) Temperatur

40、e Rise: Maximum 403 under 5) Insulation Resistance: Minimum 100 6) Instantaneous Short-Circuit: At 1 sec, 100 or less (Refer to Figure 3.) 5. NUMBER FO TEST SAMPLES Test Samples Test Fields Designations 1 2 3 4 5 6 7 8 9 10 11Basic Test External dimensions Connector Insertion Bad Connection X X X X

41、X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Mechanical Performance Fuse Insertion Force Fuse Separation Force Terminal Holding Force Strength at Box Fixation Area Connector Insertion Force Connector Separation Force Strength of Connector Locking AreaShock Resistance X X X X X X X X X X

42、 X X X X X X X X X X X X X X X X X X X X X X Electrical Performance Insulation Resistance Voltage Endurance Temperature Rise Overflow Current Voltage Drop X X X X X X X X X X X Environmental Performance Cold Endurance Tests Hot Endurance Tests Humidity Endurance Tests Thermal Shock Tests Integrated Environment Tests X X X X X X X X X X