1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15081 Window System, Dropping Type Power and Manual Performance/Stall Test Copyright 2011 General Motors Company All Rights Reserved June 2011 Originating Department: North American Engineering Standards Page 1 of 18 1 Scope Note: Nothing in this st
2、andard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To determine the operating performance characteristics of dropping, power and manual, window systems. 1.2 Foreword. 1.
3、2.1 Power window system operating performance tests can be used to obtain the following data: 1.2.1.1 Travel time. 1.2.1.2 Average run current. 1.2.1.3 Peak run current (excluding motor start up). 1.2.1.4 Average stall current. 1.2.1.5 Average stall voltage. 1.2.1.6 Peak stall current. 1.2.1.7 Avera
4、ge run voltage. 1.2.1.8 Peak run voltage. 1.2.1.9 Peak stall force. 1.2.1.10 Plots of current and voltage vs. time. 1.2.2 Manual window system operating performance tests obtain data for the spindle torques required for window travel. 1.3 Applicability. This procedure applies to all passenger cars,
5、light duty trucks and medium duty trucks having dropping, power or manual, window systems. The procedure also applies to midgates and endgates with dropping windows. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications
6、. None 2.2 GM Standards/Specifications. GMW15938 2.3 Additional References. EDS Window Performance software package Version 1.1. Front and Rear Side Closures Global Subsystem Technical Specifications (GSSTS). 3 Resources 3.1 Facilities. Major Facility: GMNA Body Test Lab or a similarly equipped test
7、 facility. 3.2 Equipment. 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 GMW15081 Copyright 2011 General Motors Company All Rights Reserved
8、 June 2011 Page 2 of 18 Note: The following list(s) include fixturing and instrumentation typically used by the GMNA Body Test Lab to perform this test. Other equipment may be substituted at the discretion of the testing facility as long as it provides the same data and/or data record, with equivale
9、nt accuracy as specified herein or by the requestor. Torque Transducer Power Window Performance Console Includes 0 to 20 V/50 A DC power supply, computer, printer, wiring harness to connect motor terminal to console, EDS window performance software Stall Force Gage (with sufficient wire to reach con
10、sole) Tape Measure 3.2.1 Fixturing. 3.2.1.1 A body is preferred (with all seals that interface with the doors) to provide upper door frame support and for door overcrown. Note: Headerless doors (doors with no upper frame) require a body for test purposes. If the test door is not on a body, it may be
11、 clamped to a fixture, such as a lab door cart, that will constrain it in approximate design position and prevent it from tipping. 3.2.1.2 Spindle adapter (if using the handheld torque transducer) (for manual window systems only). 3.2.1.3 Power window regulator motor assembly converted to a manual s
12、pindle drive assembly (if required). See 3.3.3 and Figure A1. 3.2.2 Instrumentation. 3.2.2.1 Power Window Systems. 3.2.2.1.1 Power window performance console, which includes 0 to 20 V/50 A DC power supply, personal computer, color printer for computer, wire harness that connects the regulator motor
13、terminal to the performance console and EDS Window Performance software package Version 1.1. or equivalent. 3.2.2.1.2 A stall force gauge and sufficient wiring to connect it to the power window performance console. 3.2.2.1.3 Marking pen. 3.2.2.1.4 Linear measuring device (tape measure). 3.2.2.2 Manu
14、al Window Systems. Manual window operating performance console or handheld torque transducer, torque display/calibration box, power supply, XY time base plotter (or equivalent data acquisition recorder) and proper wire connections. 3.3 Test Vehicle/Test Piece. 3.3.1 One (1) door assembly including a
15、 manual or power window system and a complete glass guidance system, including belt strips, run channels and any items affecting window system performance. 3.3.2 Vehicle body and associated door mounting hardware, weatherstrips, etc. (refer to 3.2.1.1). 3.3.3 A power window regulator motor assembly
16、converted to a manual spindle drive assembly (if necessary). See Figure A1. 3.3.4 It is recommended that the test parts/assembly be dimensionally certified before testing is started. 3.4 Test Time. The following is an estimate of the amount of time (work hours) needed to perform this procedure. Cale
17、ndar time: 1 day Test hours: 1 hour Coordination hours: 3 hours Note: These time estimates are approximate averages. Actual times vary considerably depending on early component failures (and subsequent availability of replacement parts), testing to varying multiples of cycle lives, varying requireme
18、nts for frequency of environmental test conditions, scheduling problems for test facilities, test equipment malfunctions, scheduling of overtime and/or multiple shifts, scheduling of “witnesses” for tests, actual readiness of test samples upon receipt, unique or additional requests for test details,
19、 running multiple samples (times shown are for 1 system), etc. 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 GMW15081 Copyright 2011 Gener
20、al Motors Company All Rights Reserved June 2011 Page 3 of 18 These times consider preparation and other downtime, actual test, and analysis of data in capturing a total calendar time. Report writing, approval, processing, etc., are not part of these times. 3.5 Test Required Information. The requesti
21、ng engineer is responsible for providing specifications appropriate to the particular vehicle line being tested (reference Vehicle Technical Specifications (VTS)/Subsystem Technical Specifications (SSTS) paragraph numbers). Testing worst case scenarios may uncover some potential problems. Discuss wi
22、th the requesting engineer if testing should include some worst case scenarios. Depending on which test is being performed and which level of parts or systems is being tested, consider if any of the following may apply tolerance stack-ups, build variations, misalignment, minimum/maximum fastener tor
23、que(s), lubrication, environmental extremes, location of customer representative load application, symmetry (Left Hand vs. Right Hand), color, mold or die source, etc. 3.5.1 Power Window Specifications. The following specifications or information are required to run this test. 3.5.1.1 Stall time (am
24、ount of time that power is supplied to the window system after the glass reaches a full up/full down position. 3.5.1.2 Power supply voltage settings (stall voltage or supply voltage). 3.5.1.3 Resistance of the wires between the power supply and the window motor (if a known supply voltage is used). 3
25、.5.1.4 Location(s) on the window glass to measure stall force. 3.5.1.5 If new seals are installed, the length of time the seals are to be in compression prior to running the performance test (4.3.1.2). 3.5.2 Manual Window Specifications. No specifications are required. Currently, at the GMNA Body Te
26、st Lab, the test equipment limits maximum stall torque to 5.6 Nm. 3.6 Personnel/Skills. Prior experience in setting up and running similar tests and experience in the use of the referenced test equipment are critical to achieving the estimated times shown in “3.4 Test Time”. 4 Procedure 4.1 Preparat
27、ion. 4.1.1 Sample Inspection. The test and requesting engineers should inspect the test items to ensure all material listed in 3.3 is of correct design level and assembled properly. 4.1.2 Sample Preparation. This test is normally run on the test subject in an “as received“ condition. If it is reques
28、ted to be run in a specifically adjusted condition, follow the applicable procedure(s). If installing a spindle modified power regulator assembly in a door, a hole may need to be drilled to allow spindle egress through the door inner panel. 4.1.2.1 Measure and adjust gap, flushness and seal margin d
29、imensions, if necessary (refer to GMW15938) to ensure the test material meets design specifications (required only if testing a door mounted on a body). 4.1.3 Facilities and/or Equipment Preparation. Record any instrumentation calibration information on Data Sheet A1. 4.2 Conditions. 4.2.1 Environme
30、ntal Conditions. Unless otherwise specified in this documents text or by the requesting engineer, the typical environmental conditions for this test are the temperature, humidity and pressure at the major test facility (3.1). Unless otherwise noted, these conditions are typically 22 +3 C, relative h
31、umidity of 40 +20% and atmospheric pressure equivalent to the local barometric pressure (which is variable during any given day and from day to day). 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on componen
32、t drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Setup Instructions. 4.3.1.1 If not mounted on a body, secure the door in approximate design position to a door cart. 4.3.1.2 It may be required to wait a specified length of time with the window glass in the full up position with n
33、ew seals before performing window performance tests. Reference 3.5.1.5. 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 GMW15081 Copyright 2
34、011 General Motors Company All Rights Reserved June 2011 Page 4 of 18 4.3.1.3 Motor temperature affects performance test results. If the power windows have been running durability tests, allow the motors to cool approximately 20 minutes before running performance tests. 4.3.1.4 Perform any functiona
35、l/operational tests/evaluations as requested by responsible engineer. If the window system has not been previously cycled, cycle the window “full up” and “full down” a minimum of 5 times prior to the start of test to assure proper operation and seating of all system components. As applicable, note a
36、ny irregular sounds or erratic operation indicating a potential problem with design, manufacture, or assembly and verify observations with the requesting engineer. 4.3.2 Test Operation Instructions. Note: Based on the window system to be tested, go to 4.3.2.1 (power) or 4.3.2.2 (manual). 4.3.2.1 Pow
37、er Window System. 4.3.2.1.1 If using the power window performance console to perform this test, plug the window performance console into a 120 V AC wall outlet. Press the green power button on the front of the console and the power button on the printer. Turn on the DC power supply at the bottom of
38、the console. 4.3.2.1.2 When prompted, enter the appropriate password. See a Body Test Lab support technician for the current password. The “Window Performance Test System, Live Status Info“ screen will then be displayed. See Figure A2. 4.3.2.1.3 On the toolbar, left click on “Edit“. From the dropdow
39、n menu, left click on “Setup Specs“. This causes the “Edit Setup Specifications“ screen to be displayed. 4.3.2.1.4 Enter Motor Maximum Stall Time (see 3.5.1.1) in the appropriate location. This value is typically 0.75 s. Enter the Test Temperature in the appropriate location. Test Temperature is for
40、 informational purposes only and is printed on the window performance plots. 4.3.2.1.5 Supply voltage can be set in one of two ways. If a known supply voltage is desired, enter that number in the location “Power Supply Voltage“. Alternatively, if a known motor stall voltage is desired, enter it in t
41、he location “Motor Stall Voltage“. 4.3.2.1.6 Left click on “OK“ to exit the “Edit Setup Specifications“ screen. Any changes made are automatically saved. 4.3.2.1.7 Make the proper electrical connections between the performance console and the regulator motor. If setting the power supply to a specifi
42、c voltage, use an electrical connection with a known resistance; otherwise, a short, 12 gauge wire harness with the proper matching connectors to minimize voltage drop is suggested (reference 3.5.1.3). 4.3.2.1.8 Left click on the “Up“ or “Down“ button in the area titled “Window Motor Control“ on the
43、 “Window Performance Test System, Live Status Info“ screen (Figure A2). Note: If the window travels in the opposite direction than desired, switch the polarity in the area entitled “Polarity“ on the “Window Performance Test System“ screen to correct. 4.3.2.1.9 If a known “Power Supply Voltage” was e
44、ntered in 4.3.2.1.5, skip to 4.3.2.1.10. If a known “Motor Stall Voltage” was entered in 4.3.2.1.5, left click on “Test“ in the toolbar. From the dropdown menu, left click on “Stall Voltage Adjust“. The “Stall Voltage Adjust Test“ screen is displayed. Note the advisories on this screen and left clic
45、k on “Continue Test“ when ready. This test will automatically adjust the supply voltage from the performance console to give the desired stall voltage. 4.3.2.1.10 Install the wire for connecting the stall force gauge and plug it into the front of the window performance console. Using 3.5.1.4 for a l
46、ocation, install the stall force gauge on the window at the glass center of gravity and mark its location (gauge location should be consistent during multiple testing). Position the stall force gauge so no rotation of the glass or gauge occurs during step 4.3.2.1.11. Do this by adjusting the tilt fe
47、et on the gage to make the gage align with the glass. See Figure A3. 4.3.2.1.11 On the “Window Performance Test System“ screen, left click on the “Cal“ button in the section entitled “Cal Load Cell“. Left click on “Test“ in the main window toolbar. From the dropdown menu, left click on “Stall Force“
48、. The “Stall Force Test“ screen is displayed. Note the advisories on this screen and left click on “Continue Test“ when ready. This will cause the window to rise until the stall force gauge seats into the upper glass run channel at which time the stall force will be measured. The window will then re
49、turn to a partially open position. When the window stops, remove the stall force gauge. 4.3.2.1.12 An option is now given to plot the stall force data. If this plot is desired, left click on “Yes“, otherwise, left click on “No“. See Figure A4 for a sample plot. 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 ENGINEE
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