1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15150 Clutch Pedal Lab Durability Copyright 2012 General Motors Company All Rights Reserved January 2012 Originating Department: North American Engineering Standards Page 1 of 6 1 Scope Note: Nothing in this standard supercedes applicable laws and r
2、egulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To determine the durability characteristics of clutch pedal assemblies when subjected to cyclic loads simulating multiple vehicle lives of actual vehicle ope
3、ration. Note: Clutch pedal durability testing can also be completed via GMW15335. However, if the pedal assembly has a return or over-center spring, either GMW15150 or GMW14377 must be used to achieve representative cycles on the spring and spring attachments. Durability testing of these parts canno
4、t be accelerated, as can the rest of the pedal assembly through the use of GMW15335. 1.2 Foreword. Not applicable. 1.3 Applicability. All passenger vehicles with manual transaxles or transmissions. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 E
5、xternal Standards/Specifications. None 2.2 GM Standards/Specifications. GMW14377 GMW15335 2.3 Additional References. None. 3 Resources 3.1 Facilities. GM, Supplier, or contracted test facilities. 3.2 Equipment. 3.2.1 Permanent or temporary fabricated environmental chamber capable of maintaining peda
6、ls at any specified uniform temperature between -40 C to 85 C 5 C. This chamber must allow application of simulated foot operated loads and resulting pedal motion. 3.2.2 A dry contaminate spray system capable of automatically or manually dispensing a specified quantity or duration of dry contaminant
7、 mixture (specified in Table A1) to portions of the pedals. Unless otherwise specified by GM Engineering, the spray shall be aimed at the pivots, push rod interfaces, sensors and other vulnerable areas in a manner that simulates worst case customer vehicle contamination. 3.2.3 Programmable controlle
8、r and data logger capable of monitoring the position determination devices and controlling the load actuator during cycling. The test controller/data recorder shall also be capable of recording outputs from position determination devices, applied forces, temperature, humidity, and other controlled p
9、arameters as specified by GM Engineering, and perform continuous near real time sensor diagnostic checks. 3.2.4 Equipment to supply voltages of 5.0 V 0.1 V to each position determination device, ground voltage of 0.0 V 0.1 V, and control the test environment as specified. 3.2.5 Test fixture that can
10、 accurately position a portion of an actual or simulated front of dash (FOD) including deflections, load actuators, environmental chamber, full travel floor stop (if part of the design, simulated or actual), floor pad, carpeting, floor mat, insulation, pedal stop, and/or other interior vehicle compo
11、nents. These 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 GMW15150 Copyright 2012 General Motors Company All Rights Reserved January 2012
12、 Page 2 of 6 components shall be used in the test based on if, or how, the design that is being tested interfaces with these components. Pedal packaging information math data shall be provided by GM. 3.2.6 Load actuator, capable of applying loads specified in 3.2.3. Loads shall be applied to the lat
13、eral center of pedal pad as specified by GM Engineering. Angle of application shall be five (5) degrees left to right in the horizontal plane for 50% of parts tested, and zero (0) degrees for the remainder. See Figure 1. Figure 1: Pedal Apply Angle Plan view 3.2.7 Load transducer that can measure ap
14、plied force to each test piece within 0 N to 200 N 5 N range. 3.2.8 Heating and cooling sources, i.e., heat gun, nitrogen, carbon dioxide (CO2), if needed to control test temperature. 3.2.9 A number of devices to be tested simultaneously that simulates clutch system master cylinder push rod peak loa
15、d, such as a spring. 3.2.10 Contaminant mixture consisting of the following: a. 0.14 kg (5 oz) Coarse Air Cleaner Test Dust b. 0.14 kg (5 oz) 400 Grit Alumdum c. 0.07 kg (2.5 oz) 150 Grit Alumdum d. 0.14 kg (5 oz) Rock Salt 3.2.11 Miscellaneous Equipment. Wire harnesses with appropriate connectors f
16、or links between connectors and controllers. 3.3 Test Vehicle/Test Piece. Number of samples to be tested per Component Technical Specification (CTS). 3.3.1 Interfacing components important for durability interaction such as push rod ball stud ends attached in a representative manner, i.e., same appl
17、y angles and no extra lubrication. 3.4 Test Time. Calendar time: 30 to 45 days Test time: 20 to 30 days Coordination time: 5 to 15 days 3.5 Test Required Information. 3.5.1 Validation performance requirements. 3.5.2 Reliability and durability goals as defined by the CTS shall be achieved. 3.5.3 Inte
18、rim and final test reports shall contain actual force values and plots, observations of any noise, unusual deflections, change in push rod or pedal travel, and unusual wear. 3.6 Personnel/Skills. Technician shall be competent and experienced at performing component durability tests on electro mechan
19、ical systems with applied environments. 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 GMW15150 Copyright 2012 General Motors Company All R
20、ights Reserved January 2012 Page 3 of 6 4 Procedure 4.1 Preparation. 4.1.1 Inspect all test hardware for damage. If any hardware is damaged, report damage to test engineer. Do not install on test. 4.1.2 Install test hardware in test buck or equivalent, per applicable design layout and Master Process
21、 Document (MPD) to simulate in car position. 4.2 Conditions. 4.2.1 Environmental Conditions. Not applicable. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, e
22、tc. 4.3 Instructions. 4.3.1 Perform Test Schedule per Appendix A, Table A1. 4.3.2 Force versus Displacement Plots shall be performed when specified in the Test Schedule. These plots are not to accurately represent in vehicle clutch plot characteristics, but are to document changes during the test at
23、 specified peak force. 4.3.3 Before, during, and after cycling, and force plots, inspect pedals for cracks, other distress, squeaks, rattles, and sticking. 5 Data 5.1 Calculations. Not applicable. 5.2 Interpretation of Results. Not applicable. 5.3 Test Documentation. A comprehensive test report shal
24、l document all equipment used, special procedures employed, description of pieces tested, force versus displacement plots recorded, undepressed and full travel push rod pin positions measured relative to FOD, gage length, all observations of deflections, cracks, or any notable component performance
25、characteristic, and any noise observed on the pedals at any time including squeaks and rattles. 5.3.1 Objective is for CTS requirements to be met which may include: Change in gage length (reference 1 mm) Maximum difference between apply, retract load, hysteresis (reference 10%) Maximum increase in a
26、pply force due to friction (reference 2 N) 6 Safety This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safe
27、ty and health practices and determine the applicability of regulatory limitations prior to use. 7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. CO2 Carbon Dioxide CTS Component Technical Specifications FOD Front of Dash MPD Master Process Documents 8 Coding System Thi
28、s standard shall be referenced in other documents, drawings, etc., as follows: Test to GMW15150 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 STANDA
29、RDS GMW15150 Copyright 2012 General Motors Company All Rights Reserved January 2012 Page 4 of 6 9 Release and Revisions This standard was originated in February 2006. It was first approved by the Global Chassis Team in March 2006. It was first published in March 2006. Issue Publication Date Descript
30、ion (Organization) 1 MAR 2006 Initial publication. 2 JAN 2012 Revised to current template. Section 3.2.6 and Figure 1 changed from right to left to left to right. Note regarding supporting documents in Section 1.1 added. (Pedal GSSLT) Copyright General Motors Company Provided by IHS under license wi
31、th General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15150 Copyright 2012 General Motors Company All Rights Reserved January 2012 Page 5 of 6 Appendix A Table A1: Test Schedules Event Cycle Count Temperature
32、 (C) Displacement Peak Force (N) FORCE PLOTS Force versus Displacement Plot 23 5 All As required to achieve full travel Undepressed, and full travel push rod pin gage length (position relative to the FOD) shall be measured 23 5 Undepressed, full travel 0 Apply 5 g of contaminant mixture to each bush
33、ing and/or sliding interface while depressing pedal All As required to achieve full travel CYCLING SCHEDULE 15 to 30 minute transition to specified temperature while cycling, with particular attention to occurrences of squeaks/noise (continuous cycling) 0 to 99 950 -40 5 Undepressed, full travel, un
34、depressed 178 Cycle 99 950 to 100 000 -40 5 Undepressed, full travel, undepressed 445 15 to 30 minute transition to specified temperature while cycling, with particular attention to occurrences of squeaks/noise (continuous cycling) 100 000 to 199 950 23 5 Undepressed, full travel, undepressed 178 Cy
35、cle 199 950 to 200 000 23 5 Undepressed, full travel, undepressed 445 15 to 30 minute transition to specified temperature while cycling, with particular attention to occurrences of squeaks/noise (continuous cycling) 200 000 to 299 950 80 5 Undepressed, full travel, undepressed 178 Cycle 299 950 to 3
36、00 000 80 5 Undepressed, full travel, undepressed 445 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 GMW15150 Copyright 2012 General Motors
37、 Company All Rights Reserved January 2012 Page 6 of 6 Event Cycle Count Temperature (C) Displacement Peak Force (N) 15 to 30 minute transition to specified temperature while cycling, with particular attention to occurrences of squeaks/noise (continuous cycling) 300 000 to 399 950 23 5 Undepressed, f
38、ull travel, undepressed 178 Cycle 399 950 to 400 000 23 5 Undepressed, full travel, undepressed 445 Cycle 400 000 to 499 950 23 5 Undepressed, full travel, undepressed 178 Cycle 499 950 to 500 000 23 5 Undepressed, full travel, undepressed 445 Cycle 500 000 to 599 950 23 5 Undepressed, full travel,
39、undepressed 178 Cycle 599 950 to 600 000 23 5 Undepressed, full travel, undepressed 445 Cycle 600 000 to 699 950 23 5 Undepressed, full travel, undepressed 178 Cycle 699 950 to 700 000 23 5 Undepressed, full travel, undepressed 445 Cycle 700 000 to 799 950 23 5 Undepressed, full travel, undepressed
40、178 Cycle 799 950 to 800 000 23 5 Undepressed, full travel, undepressed 445 Cycle 800 000 to 899 950 23 5 Undepressed, full travel, undepressed 178 Cycle 899 950 to 900 000 23 5 Undepressed, full travel, undepressed 445 Cycle 900 000 to 999 950 23 5 Undepressed, full travel, undepressed 178 Cycle 99
41、9 950 to 1 000 000 23 5 Undepressed, full travel, undepressed 445 Note: Test Cycle Count depends on the following: Repeat test schedule cycling and force plots until CTS reliability requirements are met. Weibull analysis should be used to generate a Weibull slope for suppliers design and to determin
42、e reliability projections. Force versus Displacement Plot End of test 23 5 Undepressed, full travel, undepressed As required to achieve full travel Undepressed, and full travel push rod pin gage length (position relative to the FOD) shall be measured End of test 23 5 Undepressed, full travel, undepressed As required to achieve full travel Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
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