GMW GMW16619-2011 Headlamp Washer Systems High Pressure Pump Issue 1 English《前照灯洗涤器系统的高压泵 第1次出版(英文版本)》.pdf

1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW16619 Headlamp Washer Systems High Pressure Pump Copyright 2011 General Motors Company All Rights Reserved November 2011 Originating Department: North American Engineering Standards Page 1 of 13 1 Scope Note: Nothing in this standard supercedes appl

2、icable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. This specification stipulates the requirements, the general test conditions and the test methods for operational, material tests, and the du

3、rability test for high pressure pumps for headlamp washer systems, referred to as the pump. In addition to the requirements of this specification, the pump shall fulfill the lawful requirements of the countries in which it is used when assembled to a high pressure headlamp washer system. 1.2 Forewor

4、d. Not applicable. 1.3 Applicability. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. DIN 500 EN 10204 SMS 2983 E DIN 400509 ISO 1431-1 VDA 260 ECE R45 SAE 30201 2.2 GM Standards/Specifications. G

5、ME 14090 GMW3097 GMW3191 GMW3059 GMW3103 GMW3286 GMW3091 GMW3172 GMW14729 2.3 Additional References. Japanese Industrial Standard D5704 1970 3 Resources 3.1 Facilities. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2

6、 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this specification shall be determined correctly with respect to its physical definition. As required by the indicated test methods, test specifications and DIN standards, etc.

7、 Temperature Cabinet. Recirculating air temperature cabinet with air extraction system, explosion proof. Test Space: Suitable chambers: Two passages, diameter 50 mm Temperature range: -40 C+ 120 C, continuously adjustable Permissible temperature deviation: 3 C Temperature constancy: 3 C spatially an

8、d temporally Rate of acceleration of temperature for the empty tempering chamber: 1 C/minute (recommended value) 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 E

9、NGINEERING STANDARDS GMW16619 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 2 of 13 3.2 Equipment. 3.2.1 Electromagnetic oscillation table with control unit for oscillation test. 3.2.2 Durability Test Equipment. Suitable test equipment for procedure of durability test

10、consists of a counter and time switch. The durability test equipment is a device used to operate the pump for the total number of durability test cycles according to preset operating and break times. Upon completion of the specified number of cycles, the durability test equipment shall shut off auto

11、matically. 3.2.2.1 As required by the indicated test methods and specifications. 3.2.2.2 Devices for attachment and mounting of the pumps to be tested. 3.2.2.3 Voltage Stabilizer. Range of voltage: 0 V thru 15 V continuously adjustable Range of current: 0 A thru 100 A, current limiting continuously

12、adjustable 3.2.2.4 Voltmeter for measuring range 0 V thru 20 V direct current voltage, class of accuracy 0.5 or better with corresponding compensating resistance. 3.2.2.5 Ammeter for measuring range 0 A thru 20 A direct current, class of accuracy 0.5 or better with corresponding shunt. 3.2.2.6 Digit

13、al displayed overpressure measuring instrument with analog output (printer and recorder output), limiting value stressable, instrument range 0 kPa thru 400 kPa, resolution 2 kPa minimum. 3.2.2.7 Time Switch with Counter. The time switch with counter is a device used to operate the pump for the total

14、 number of cycles according to preset operating and break times. Upon completion of the specified number of cycles, the time switch and counter unit shall automatically shut off. Time Switch attributes are located in Table 1. Table 1: Time Switch Requirements Attribute Value Input and output voltage

15、 0 V thru 15 V Rise time of output voltage 0.1 s Decay time of output voltage 0.1 s Intervals variable: continuously 1 s thru 30 s Break intervals variable continuously 1 s thru 30 s Reading accuracy 0.5 s Counter frequency 0.1 Hz, range: 2000 pulses 3.2.2.8 Over Pressure Measuring Instrument. Over

16、pressure measuring instrument for example, sensitive pressure gauge, grade 0.6, with an indicating range of 0 kPa thru 400 kPa and a scale division of 2 kPa. Electro dynamically working data receiver and electric indicating instruments that can be inserted. 3.2.2.9 Wire. 3.2.2.9.1 Wire having an app

17、ropriate length consisting of a twisted twin core wire (composed of twin, snaked, electric leads) with a cross section of 1.5 mm2 to connect the time switch, respectively durability test equipment with the pumps. The connecting elements, (e.g., cable shoes, pin plugs) on the ends of the wires shall

18、be faultless connected with the wires. The combining elements at the ends of the electric leads must be soldered with the electric leads. 3.2.2.9.2 Wire having an appropriate length consisting of a single wire with a cross section of 16 mm2 to connect the time switch, respectively durability test eq

19、uipment with the voltage stabilizer. The connecting elements, (e.g., cable shoes, pin plugs) on the ends of the wires shall be faultless connected with the wires. The combining elements at the ends of the electric lead must be soldered with the electric lead. This cable is necessary only at the endu

20、rance test of the pumps. 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 GMW16619 Copyright 2011 General Motors Company All Rights Reserved

21、November 2011 Page 3 of 13 3.2.2.10 Oscillating Table with Oscillator. The oscillating table with oscillator, called shortly oscillating table, is a device with which oscillations are executed respectively in a vertical direction and two horizontal directions standing vertically one after another, t

22、emporally independent of each other. The oscillator must be so designed that the oscillating table executes oscillations corresponding to this data: Frequency: 10 Hz to 50 Hz sine, continuously adjustable, accuracy of reading 0.5 Hz Frequency drift: 60 s/octave 30 s/octave Oscillating amplitude: 0.2

23、 mm thru 0.7 mm adjustable, Accuracy of reading: 0.02 mm 3.2.2.11 Test Medium. As described, water (tap water) or a mixture of 50% by volume water and 50% by volume isopropanol is used. The amount of the test medium shall assure that the pump is filled with water throughout the test. 3.2.2.12 Test N

24、ozzle. A test nozzle is required for the function test according to 4.7.3 and 4.7.4. The nozzle shall allow reproducible measurements of the pump parameters. The nozzle dimensions are stated in Figure 1. For the durability test the production nozzles may be used. Figure 1: Test Nozzle, Material: Sta

25、inless Steel 3.2.2.13 Control Valve. The regulating valve forms a unit with the nozzle. If not otherwise specified, the opening pressure of the control valve shall be 125 kPa 15 kPa and the closing pressure shall be 60 kPa. Released production parts shall be used for the tests. 3.2.2.14 Time Relay.

26、The time relay limits the on time of the pump to 0.53 s 0.04 s per actuation. For the test, released production parts are to be used. 3.2.2.15 Set of Hoses. A set of fabric hoses to connect the components of the headlamp washer filled with the test medium. Released production hoses shall be used for

27、 the test. The connections between the single components shall be as short as possible. When possible, rigid tube connections of the same inner diameter are also allowed. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networ

28、king permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16619 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 4 of 13 3.3 Test Vehicle/Test Piece. 3.3.1 Test Samples. Unless otherwise specified, for initial sample approval and release according

29、to this specification, at least 20 pumps shall be supplied with a specific test report to EN 10204-2.3. The test samples shall be sequentially numbered. The specific test report shall contain the specified values; the supplier determined actual values, drawings with specified material, and operation

30、al information. 3.3.2. Quantity of Test Sample. For the sampling and release testing to this test specification, minimum five consecutively numbered pumps are to be delivered in the connection with a works test certificate to DIN 500 49, Pt. 2.3. It is expected that the values of all required charac

31、teristic sizes represent the range of tolerance of the production scattering width at the proposed test samples. If this pre-supposition is not satisfied by the test samples, the range of tolerance of production scattering width for all required characteristic sizes must be given in the works test c

32、ertificate, and also the individual measured values. 3.4 Test Time. Calendar time: 84 days Test hours: 2000 hours Coordination hours: 48 hours 3.5 Test Required Information. Samples of components or material released to this specification shall be tested for conformity with the requirements of this

33、specification and approved by the responsible GM department prior to the start of delivery of production level components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the prod

34、uct. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation of any change or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier

35、prior to start of delivery of the modified or changed product. In some cases a shorter test can be agreed to between the responsible GM department and the supplier. 3.5.1. Test Results. With reference to this specification, the test results shall be represented in a test report. 3.5.2. Deviations fr

36、om Test Procedure. Deviations from the requirements of the test procedures shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports etc. 3.6 Personnel/Skills. Not applicable. 4 Procedure 4.1 Preparation. The tests shall be carried out accord

37、ing to the test sequence (Appendix A). The allowed sequence at the tests shall be observed to realize comparable results. In addition to the requirements, the requirements defined to the individual parts of this specification shall be confirmed. The number and sequence of testing per pump are specif

38、ied at the end of this test specification. 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, etc

39、. 4.2.3 Conditioning. Unless otherwise specified in the relevant tests, the tests shall be performed in the as-received condition at +23 C 3 C without any special preconditioning. 4.3 Instructions. 4.3.1 Visual and Dimensional Check. In the as-received condition, the pump shall not show any visible

40、damages or defects which could adversely affect the function or appearance. The dimensions and tolerances specified on the drawings and/or releases shall be fulfilled from all parts of the pump. Formal defects, damages or scarcities, such as pores, bubbles, cracks, material overlaps, binding defects

41、 and burrs which could impair the strength, the function or the appearance of the pump are not permissible. The pump must be so designed that it is protected against impurities such as mud, and turnings which could impair the function of the assemblage. The pump shall be protected against contaminat

42、ions, e.g., dirt, chips and the like which could impair its function until it is installed. 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

43、GMW16619 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 5 of 13 4.3.2 Marking. The pump shall be marked on a suitable place with the GM logo to GME 14090, the date of manufacture to GME 14090, the manufacturers symbol, and the part number according to the material code

44、VDA 260. On parts of the pump with current connections shall be marked the rated voltage UN = 12 V. All markings shall be readily legible and permanent and may not impair the function of the pump. 4.3.3 Materials. 4.3.3.1 All materials used for the pump shall fulfill the drawing specifications and m

45、aterial specifications, as well as the requirements of the releases; in particular materials susceptible to hydrolysis, such as Acetal- Homopolymerisat or thermoplastically polyester shall not be used. If parts of the pump consist of materials susceptible to stress cracking such as polyamide 66, the

46、se shall be protected against contact with crack initiation medium. Parts of the pump which are in direct contact with the washing solution shall be made of materials which correspond with material SAE 30201 regarding their corrosion behavior. Brass or bronze shall not be used under any circumstance

47、s. These requirements do not apply to metal parts which shall be ferromagnetic due to their function. Such parts shall not show any corrosion after 240 h exposure to high humidity environments to GMW14729. 4.3.3.2 The pump shall be resistant to the test medium used during the function tests. This ap

48、plies also for commercial cleansers and additives used by the customer. Particles of the pump washed out by the cleanser shall not adversely affect the function of the pump. 4.3.3.3 Ozone Resistance of Elastomer Parts of the Pump. The ozone resistance of elastomer parts of the pump shall be tested a

49、ccording to ISO 1431-1. For conditioning, the test pieces shall be stored at +23 C 3 C for 48 h in an ozone free environment in unloaded condition. At the evaluation, the tested parts shall fulfill the grade 0 requirements. 4.3.4 Current Connections. The current connections shall comply with GMW3191. 4.3.5 Environmental Protection. Restricted and Reportable Substances for Parts to GMW3059. 4.4 Pum