GMW GMW14081-2013 Fuel Pump Module Specification Issue 4 English.pdf

1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW14081 Fuel Pump Module Specification Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 1 of 35 1 Introduction Note: The program specific technical specification may include additional program specific requirements t

2、hat are not referenced in this standard and may supercede any requirements included in this standard. In the case of any conflicts between this standard and the program specific technical specification, the program specific technical specification takes precedence. Note: Nothing in this standard sup

3、ercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This standard establishes the component level requirements for in-tank fuel pump module (FPM) assemblies. This standard document s

4、hall be used in conjunction with application specific documents based on template CG969 to define fuel pump module requirements for an individual application. These documents complement other requirements included in the Statement of Requirements (SOR). 1.2 Mission/Theme. The fuel pump module is a c

5、omponent delivering fuel and sensing fuel quantity. The fuel pump module shall carry out these functions while meeting specific requirements of the customer, the powertrain and other interfaces, mandated safety and emission standards, and corporate objectives. 1.3 Classification. The FPM is intended

6、 for use in vehicles sold worldwide. Fuel/mechanization classifications used within this document are defined in 1.3.1 thru 1.3.11. More than one classification may apply to a given application. The term “FPM” may refer to primary or secondary/transfer module. See program document(s) for specific re

7、quirements. 1.3.1 Electronically Regulated Fuel System (ERFS). The FPM flow and pressure are controlled by a remote electronic control module which varies voltage via pulse width modulated input. 1.3.2 Mechanically Regulated Fuel System (MRFS). The FPM pressure is controlled with a mechanical regula

8、tor internal to the assembly. 1.3.3 Return Fuel System. The FPM pressure is controlled remotely (typically by a fuel rail-mounted regulator which may be referenced to engine manifold pressure) with unused fuel returned to the FPM lower module. 1.3.3.1 Return Fuel System, Forced Air. The FPM pressure

9、 is controlled remotely (typically by a fuel rail-mounted regulator which may be referenced to engine manifold pressure) with unused fuel returned to the FPM lower module. Pressure is based on state of turbo or super charging which influences manifold pressure. 1.3.4 E85 Flex Fuel System. The FPM is

10、 designed for use in markets where ethanol content up to 85% may be available. 1.3.5 E100 Flex Fuel System. This FPM is designed for use in markets where ethanol content up to 100% ethanol, including up to 6% water and high levels of contamination, may be available. This system does not include an i

11、ntegral fuel filter. 1.3.6 China Fuel System. The FPM is designed for use in markets where methanol content and high levels of contamination may be available. This system does not include an integral fuel filter. 1.3.7 Pump Diesel System. The FPM delivers diesel fuel at a positive pressure. This sys

12、tem does not include an integral fuel filter. 1.3.8 Suction Diesel System. The FPM delivers diesel fuel via vacuum generated by an engine-mounted pump. This system does not include an integral fuel pump. 1.3.9 Electronic Commutation (EC) System. The FPM flow and pressure are controlled by a remote e

13、lectronic control module which varies voltage via 3 phase input. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14081 Copyright 2013 Gen

14、eral Motors Company All Rights Reserved February 2013 Page 2 of 35 1.3.10 Dual FPM System. This FPM architecture is a single pump design for use in systems with more than one fuel chamber where an active fuel transfer feature, an auxiliary (secondary or transfer) module, and fuel transfer line are a

15、dded to move fuel from one chamber to another chamber. The primary module typically houses the active fuel transfer feature to draw fuel from the secondary module into the primary reservoir. Fuel transfer line may be permanently fixed to the primary module or connected using quick connect device. 1.

16、3.10.1 Transfer Module. A secondary or transfer module designed to complement a primary fuel module in a dual FPM system. This component typically features a fuel transfer inlet, fuel level sensor, and flange which may incorporate tank venting features. 1.3.11 Auxiliary Fuel Tank Systems. The FPM is

17、 designed for an intermittent use gasoline or diesel system where the primary energy source is electricity or a gaseous fuel such as Liquefied Petroleum (LPG) or Compressed Natural Gas (CNG). This system may remain unpowered for extended periods of time or powered only at initial starts or high powe

18、r demand situations and may require unique packaging due to space limitations. See program document(s) for specific requirements. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ABNT NBR 15754 INMETRO 301/11 SAE

19、J1645 SAE J2587 ASTM A313 ISO 1431-1 SAE J1696 ASTM D903 ISO 12103-1 SAE J1985 ASTM D4169 SAE J905 SAE J2044 2.2 GM Standards/Specifications. 9985784 GMW8466 GMW15312 GMW15982 GMW3059 GMW14106 GMW15357 GMW15984 GMW3091 GMW14264 GMW15359 GMW16331 GMW3097 GMW14800 GMW15570 GMW16600 GMW3103 GMW14872 GM

20、W15626 GMW16848 GMW3172 GMW14914 GMW15841 GMW3191 GMW15272 GMW15862 GMW4700 GMW15311 GMW15973 2.3 Additional References. 13581768 CG2308 GMPT-3-005 GMPT-6-005 15256371 CG2503 GMPT-4-002 GMPT-6-015 15708574 CG3047 GMPT-4-008 GMPT-6-017 15776434 CG3048 GMPT-4-015 GMPT-6-019 25764424 CG3052 GMPT-4-019

21、GMPT-6-022 88988992 CG3053 GMPT-5-014 GMPT-6-025 CG969 CG3054 GMPT-5-020 GMPT-6-030 CG1752 CG3055 GMPT-5-022 GMPT-6-032 CG1854 CG3056 GMPT-5-036 GMPT-6-037 CG2021 GMPT-2-017 GMPT-6-001 3 Requirements 3.1 System/Subsystem/Component/Part Definition. The FPM shall supply fuel to the engine and measure

22、fuel height in tank. It may also include provisions to sense tank vapor-space pressure, manage fuel vapor generation and transport, control tank fuel-fill shutoff, transport fuel to auxiliary devices, filter fuel, and/or regulate fuel pressure. 3.1.1 Appearance. See program document(s). Copyright Ge

23、neral Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14081 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 3 of 35 3.1.2 Cont

24、ent. The FPM Bill of Materials (BOM) shall be developed based upon this document accompanied by program-specific documents. 3.1.2.1 Physical Content. The FPM BOM shall describe all components, materials, surface treatments (including surface treatment thicknesses, other qualifications). 3.1.2.2 Func

25、tional Content. See program document(s). 3.1.3 Ambient Environment. The following paragraphs specify the environmental conditions that the FPM will be exposed to during its lifetime. 3.1.3.1 Operating Environment. The FPM shall be capable of operating in the environments described in Tables 1 and 2

26、without adverse effect to functional performance. Table 1: Operating Conditions Relative Humidity 2 to 100% Barometric Pressure 56.9 kPa(g) to 106.3 kPa(g) Grades 30% Ozone 0.40 ppm Ambient Temperature, Normal Operation -48 C to +55 C Ambient Temperature, Extreme Operation Up to +70 C (continuous),

27、200 h at +80 C Gasoline Fuel -40 C to +70 C E100 Fuel -10 C to +70 C Diesel Fuel -40 C to +90 C 300 h at +90 C (up to 5 h continuous exposure), 4 h at +110 C (up to 1 h continuous exposure) Altitude -150 m to 4600 m Wind 100 km/h (vehicle at rest) Electromagnetic GMW3091, GMW3097 Internal Pressure 0

28、 kPa(g) to 1000 kPa(g) Operating Voltage, MRFS 7.5 Vdc to 15.5 Vdc Operating Voltage, ERFS 3.75 Vdc to 12.0 Vdc (RMS) Voltage, Reverse 13.5 Vdc (2 minutes) Voltage, Jumpstart 26.0 Vdc (1 minute) Overvoltage 18 Vdc (1 hour) Overvoltage, Demagnetization 18 Vdc (5 second bursts at -40 C) Hard Starts (S

29、tandard) Up to 60 000 on/off cycles Hard Starts (Stop/Start Hybrid) Up to 350 000 on/off cycles Soft Starts (Hybrid Vehicle) Up to 1 500 000 on/off cycles ERFS Pulse Width Modulation (PWM) control frequency 15 or 25 kHz RMS = Root Mean Square Table 2: Corrosive Environment Sodium Chloride 78 mg/cm2/

30、yr average, 185 mg/cm2/yr maximum Calcium Chloride per GMW16600 Zinc Chloride per GMW16600 3.1.3.2 Fuel Environment. Fuels to which the fuel pump module may be exposed in are defined in GMW15311, Specification for Fuel Storage and Handling Subsystem. Test fuels referenced in this document are summar

31、ized in Table 3 and described in GMW14914. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14081 Copyright 2013 General Motors Company Al

32、l Rights Reserved February 2013 Page 4 of 35 Table 3: Test Fuels GMPT Number Description GMPT-6-001 Stoddard Solvent GMPT-6-025 CE10 Fuel “C” with E10 GMPT-6-005 TF-1 Baseline gasoline containing E10 GMPT-2-017 High Altitude Hot Fuel Handling GMPT-3-005 California Phase 2 - Summer GMPT-4-008 E25 Gen

33、eral Purpose GMPT-6-022 Corrosive E22 Tier 2 GMPT-4-015 M15 General Purpose Validation Fuel GMPT-6-017 Gasoline Containing Elemental Sulfur GMPT-6-015 Low Lubricity GMPT-6-019 Oxidized Gasoline GMPT-4-002 E85 General Purpose Summer GMPT-6-030 Testing Fluid with 15% Methanol GMPT-6-032 E85 Conductivi

34、ty GMPT-4-019 Brazil E100 Cert Fuel GMPT-6-037 E100 Conductivity GMPT-5-020 Ultra Low Sulfur B20 Biodiesel 80/20 Unadditized GMPT-5-022 Ultra Low Sulfur Diesel Containing Elemental Sulfur GMPT-5-036 Deposit Forming and Peroxide B20 Blend GMPT-5-014 Ultra Low Sulfur Diesel for Extreme Cold Starting S

35、AE J1696 Standard Fuel Filter Test Fluid 3.1.4 Interfaces. 3.1.4.1 Fuel Tank Opening Interface(s). The FPM flange shall be designed in accordance with GM common strategy per the following standards based on opening size. See program document(s) for specific requirements. 130 mm: 15256371 95 mm: 1577

36、6434 115 mm: 25764424 3.1.4.2 Steel Tank Isolation Interface. FPMs shall include provisions to accommodate isolation between the reservoir and tank surfaces defined in 3.2.1.39.6, Reservoir Isolation. 3.1.4.3 Electrical Interface. FPM shall feature either a standard 4 terminal interface or 8 termina

37、l interface. The 4 terminal interface shall mate with connector 88988992 and 8 terminal interface shall mate with connector 13581768. Terminal layouts are described in Figure 1. See program document(s) for specific requirements. Copyright General Motors Company Provided by IHS under license with Gen

38、eral Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14081 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 5 of 35 Figure 1: Top Side Electrical Interfaces 3.1.4.4 Interior Electrical

39、Interfaces. FPM flange bottom-side electrical interface geometry shall feature connections consistent with GMW3191 and are subject to GM approval. Fuel level sensor connections shall be serviceable at the underside of the flange. 3.1.4.5 Mechanical Interface(s). Quick connect compatible liquid and v

40、apor ports shall comply with SAE J2044 with exceptions provided in Figure 2. Underside flange quick connect ports shall be of common geometry compared to topside flange ports except overall length may be up to 40 mm. Plastic port geometry shall be optimized to minimize stress at a given load, applie

41、d at the end of and perpendicular to the port, to less than 0.44 MPa/N for a inch port and less than 0.70 MPa/N for a 5/16 inch port (for example at a 12.5 N applied load: less than 5.5 MPa for a inch port and less than 8.7 MPa for a 5/16 inch port). Plastic exterior port and flange geometry shall b

42、e of a common material and single piece construction. If applicable, port conductivity features to comply with ESD requirements shall be managed from the interior surface of the flange and not influence interface mechanical strength or durability performance (reference 3.2.1.20 to 3.2.1.22). See pro

43、gram document(s) for specific requirements. Figure 2: Quick Connect Port Geometry P +PG ndS -S+O P +OP G ndS+S -OO4 Pin Cod ing ABrus hedSi ngle FL SO O pen (Spare)no ter mi nal,c av i ty ov er - mol dedWUVS1+S1 -S2+S2 -S1+S1 -Co di ng CBrus hl es s Si ngl e FLSCo di ng DBrus hl es s Dual FLSP G ndP

44、 G ndT ermi na l Pin Out V ie w : Into F la ng e - Integ ral Co nn ecto rOOWUV32.12mmA ll owabl e Bl endi ng Zone: p or t ge om etry s hal l b e cons trai ned withi n thi s zone to av oi d qu ick connector in terference11mmZ one Bound ary: R 5.5mm* I.D . op ti mi ze d for s trength Copyright General

45、 Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14081 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 6 of 35 3.1.4.6 Electri

46、cal Performance Interface. The FPM supplier shall complete CG3053 template to characterize electrical performance. 3.1.4.7 ERFS Calibration Interface. If applicable, the FPM supplier shall complete CG3055 template per instructions defined in CG3054 to characterize performance to duty cycle input. 3.

47、1.4.8 Brushless Pump Control Interface. If applicable, the FPM supplier shall complete CG3056 template to characterize brushless motor control performance. 3.1.5 Usage Definition. See GMW15311. 3.1.6 Packaging Constraints. The standard FPM lower module (all components affixed to lower module) shall

48、be designed to fit within a cylinder of 125 mm height. 3.2 Product Characteristics. The following apply to all requirements unless otherwise specified. Measurement: Voltage: External interface, 0.1 Vdc. Current: External interface, 0.1 A. Pressure: FPM fuel feed port (external) or FPM return port (e

49、xternal, if applicable). Fuel flow: Reported in liters per hour (L/h) ( 2%). Conversion Factors: Gasoline: 1 g/s = 4.86 L/h (sg: 0.74 g/mL). E85: 1 g/s = 4.62 L/h (sg: 0.78 g/mL). Diesel: 1 g/s = 4.24 L/h (sg: 0.85 g/mL). Input/Environment Control: Applied voltage: 0.1 Vdc (performance). Applied voltage: 0.25 Vdc (durability). Applied Pressure: 3 kPa(g). Temperature (environment): 2 C. T