NAVISTAR MPAPS L-6023-2014 Steering Wheel and Horn Pad Assemblies.pdf

1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 1 of 15 NAVISTAR, INC. Material, Parts, and Process Specifications

2、 (MPAPS) NUMBER: MPAPS L-6023 Former Designation: TMS-6023 TITLE: Steering Wheel and Horn Pad Assemblies CURRENT REV No.: 1404 DATE: April 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. 1402 Feb. 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED

3、 FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applic

4、ability of regulatory limits prior to use. Change Notice: Updated design requirements document in Sections 4.3.12 and 4.3.13 for switches; editorial changes. 1.0 APPLICATION This specification covers a steering wheel assembly consisting of a welded steel ring-spoke-hub assembly with covering providi

5、ng either a hard or a soft feel and a horn pad assembly. 2.0 SCOPE This specification applies to steering wheel assemblies constructed of welded steel inserts and molded covers. Grade A is a steering wheel manufactured with a butt weld. Grade B is a steering wheel manufactured with a spoke-to-hub we

6、ld. Grade C is a steering wheel manufactured with a swage fit between the hub and spoke. The hub is clinched in and the welds are a secondary means of retention of the hub to the armature. The clinched section (the swaged joint) is the primary means of retention. 2.1 Restricted Chemical Substances A

7、ll product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are

8、referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS A-6, Part 1 AATCC Test Method #8 NAVISTAR MPAPS B-50 NAVISTAR MPAPS D-28 NAVISTAR CEMS DT-10 NAVISTAR MPAPS DT-12 NAVISTAR MPAPS DT-16 AATCC Test Method #8 FMVSS 101 FMVSS 302 ISO 12103-A2 ISO 5011 NAVISTAR

9、 MPAPS P-9543 NAVISTAR TMS-9516 NAVISTAR MPAPS GT-31 NAVISTAR DR101142-00 NAVISTAR NDR-004 NAVISTAR SDS-SD-011 NAVISTAR TMS-7110 NAVISTAR TMS-7121 SAE J1455 NUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navis

10、tar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 2 of 15 4.0 FUNCTIONAL MATERIAL AND COMPONENT REQUIREMENTS 4.1 Material 4.1.1 Cover Material 4.1.1.1 Type I: Hard Rubber VOID;

11、no longer in use. 4.1.1.2 Type II: PP, K30 SA82 U YA3600 AC3 Z1, per MPAPS D-28; Z1- minimum Izod impact of 12.4 J at -18C per ASTM D758 4.1.1.3 Type III: PVC, A3 A45 A64 GB3 JA74 K9 L235 T140 U W 5742 YA120 AB1 AC1, per MPAPS D-28 4.1.1.4 Type IV: Steering wheel consists of a welded steel core with

12、 a micro-cellular integral skin polyurethane over mold. 4.1.1.5 Type V: Steering wheel consists of a welded steel core with a micro-cellular integral skin polyurethane over mold with wood grain or titanium inserts. Some Type V steering wheels may come with a leather cover sewn on it. 4.1.2 Color and

13、 Finish Shall be specified on the part drawing. 4.1.3 Substrate Materials 4.1.3.1 Steel per MPAPS A-6 Part I - Low Carbon Steel, Flat Rolled and Structural Shapes 4.2 Property and Performance Requirements for Steering Wheel All tests are to be performed at ambient temperature of 18 -24 C (65 -75 F)

14、and 50 % relative humidity unless otherwise specified. 4.2.1 90 /180 Bend Test For Welds On Steering Wheel Insert 4.2.1.1 Procedure Clamp welded section firmly in vise or other clamping fixture. At a distance of approximately 25.4mm (1 in) from the weld being tested, apply sufficient force to bend t

15、he member 90 in one direction. Reverse the direction and bend 180 in the opposite direction. See Figure 1. 4.2.1.2 Required The weld shall not fracture as a result of the first 90 bend. When bending in the opposite direction, the weld must not fracture within the first 90 (back to original position)

16、. If the weld fractures before completing the remaining 90 of the 180 bend, the fractured surface must display a minimum of 75% parent metal. NUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or re

17、produced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 3 of 15 Note: This test applies to the rim butt weld and spoke-to-hub welds. 4.2.2 Vertical Impact Test For Welded Inserts 4.2.2.1 Procedure M

18、ount finished insert by the hub on the base of the impact tester leaving the spokes and the rim unsupported. Insert is mounted in a horizontal plane with the hub down, rim up. Elevate the 45.36kg (100 pound) impact weight to a distance of 1.829 meters (6 feet) from the hub mounting surface. Release

19、the impact weight and allow it to fall vertically onto the insert rim. The resulting impact force is approximately 814Nm (600 ft lb), depending upon the height of the insert. 4.2.2.2 Required The impact force shall not cause the fracture of any weld on the insert. (see accompanying notes) 4.2.2.2.1

20、Note 1: When component is fixtured, the impact test is performed on different inserts at the locations depicted in Figure 2. Number of tests performed varies with the design of the insert. 4.2.2.2.2 Note 2: In-process tests are performed consecutively at the locations depicted in Figure 2. 4.2.2.2.3

21、 Note 3: Shearing of the metal (e.g., rim or spoke wire) does not constitute a failure of this test. 4.2.2.2.4 Note 4: For Grade C steering wheels, hub-to-armature weld failures under these circumstances do not indicate an inadequacy in the design or manufacture of the steering wheels. 90 0 180 0 Cl

22、amp Clamp Fig ur e 1 : 9 0 /180 Be nd Te st NUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume a

23、ll patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 4 of 15 4.2.3 Torsion And Bend Fatigue Test For Welded Inserts 4.2.3.1 Procedure Mount the finished insert on the test fixture using an appropriate shaft, and tighten securely to prevent rotation. Apply reversing loads of 112 N (25 lb.) to

24、the insert rim as shown in Figure 3. Both torsional loads and both bending loads are to be applied simultaneously in sequence. One load application and one reversal comprise one cycle. Operate the test fixture at a cycle rate of 95 to 105 cycles per minute. 4.2.3.2 Required 4.2.3.2.1 Grade A and B I

25、nsert shall pass 100,000 cycles without fracturing the rim, spoke or any weld. 4.2.3.2.2 Grade C Same as Grade A except hub-to-armature weld failures under these circumstances do not indicate an inadequacy in the design or manufacture of the steering wheels. Note: Production Validation tests are to

26、be performed to failure or two times the test bogie of 100,000 cycles (200,000 cycles), whichever occurs first. Figure 3: Torsion and Bend Fatigue Test L o a d L o a d H ub Ri m L o a d L o a d H ubR imI m pa c tFigure 2: Vertical Impact Test Typical Impact Locations For Common Designs NUMBER: MPAPS

27、 L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Pa

28、ge 5 of 15 4.2.4 Hub Push-Out 4.2.4.1 Procedure Support steering wheel insert by outer ring, leaving the hub unsupported. Apply an increasing axial load to the steering wheel hub through the plane of the hub, parallel to the steering column until the hub breaks free from the steering wheel armature.

29、 See Figure 4. 4.2.4.2 Required Insert shall withstand the 2,750 kg. (6050 lb) load without any weld fractures. When tested to failure, the fractured surface shall exhibit a minimum of 75% parent metal. Figure 4: Hub Push-Out Test 4.2.5 Tangential Rim Pull Test for Molded Steering Wheels 4.2.5.1 Pro

30、cedure 1) The molded steering wheel shall be mounted by the hub and securely tightened to prevent rotation. At the halfway distance between two spokes (typically the 12:00 position), a 90kg (200 lb) load shall be applied tangentially to the rim, held for one minute, and then released. See Figure 5.

31、Perform experiment on steering wheels with and without welds. 2) Model test in CAE on a steering wheel with and without welds. Calculate deflection of the rim under the specified load. 4.2.5.2 Required 4.2.5.2.1 Grade A and B Steering wheel shall not exhibit any cracking or breaking of the welds or

32、the molded covering material. No separation of the hub from the armature with or without welds. Calculated rim deflection must correlate to measured deflection within +/-5%. Results must be provided to Navistar Design Engineering for review. 4.2.5.2.2 Grade C Same as Grade A except hub-to-armature w

33、eld failures under these circumstances do not indicate an inadequacy in the design or manufacture of the steering wheels. Modeled rim deflection must correlate to measured deflection within 5%. Results must be provided to Navistar Design Engineering for review. No separation of the hub from the arma

34、ture with or without welds H ubRimL o a dNUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all

35、patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 6 of 15 4.2.6 Deflection Test For Molded Steering Wheels 4.2.6.1 Procedure 1) Condition the steering wheel at -29 C 1 C (-20 F 2 F) for 18 hours. Mount the steering wheel by the hub in the horizontal position (hub down, rim up) leaving the spo

36、kes and rim unsupported. Within three minutes after removing the steering wheel from the freezer, apply a 90kg (200 lb) load to the steering wheel, perpendicular to the plane of the steering wheel, at the 12:00 position. Apply the load with a 1935mm2 (3 sq. inch) pad within one minute. See Figure 6.

37、 2) Model the experiments in CAE. Calculate the rim deflection. 4.2.6.2 Required 4.2.6.2.1 Grade A and B Steering wheel shall not exhibit any cracking or breaking of the welds or the molded covering material. Calculated rim deflection must correlate to measured deflection within +/-5%. Results must

38、be provided to Navistar Design Engineering for review. 4.2.6.2.2 Grade C Same as Grade A except hub-to-armature weld failures under these circumstances do not indicate an inadequacy in the design or manufacture of the steering wheels. Calculated rim deflection must correlate to measured deflection w

39、ithin +/-5%. Results must be provided to Navistar Design Engineering for review. 4.2.7 30 Impact Test For Molded Steering Wheels 4.2.7.1 Procedure Mount the steering wheel by the hub at a 30 angle from vertical, with the 6:00 position down free-swinging sandbag weighing 80 kg (176 lb.). Sand bag dim

40、ensions to be approximately 254mm (10 in) diameter by 610mm (24 in) long. The sandbag shall be positioned so that the approximate center of the bag impacts the steering wheel, and so that its center of gravity approximates the impact location of the L o a d Hub Rim 1 2 : 0 0 L o a d Fig ur e 5 : R i

41、m P ull Te st Fig ur e 6 : D e f l e c t ion Te st NUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to a

42、ssume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 7 of 15 steering wheel rim. Elevate the sandbag to a height sufficient to obtain a free-swinging impact of 1085Nm (800 ft. lb.) and release abruptly. See Figure 7. 4.2.7.2 Required 4.2.7.2.1 Grade A and B Steering wheel shall not sha

43、tter, break or exhibit any weld fracture. 4.2.7.2.2 Grade C Same as Grade A except hub-to-armature weld failures under these circumstances do not indicate an inadequacy in the design or manufacture of the steering wheels. Figure 7: 30 Impact Test H ub Ri m 6 : 0 0 I m pa ct NUMBER: MPAPS L-6023 TITL

44、E: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 8 of 15 4

45、.2.8 Twist Retention This test measures the effectiveness of the rim and/or the adhesive in preventing the as-molded steering wheel material from turning or loosening on the insert rim. 4.2.8.1 Procedure Mount the steering wheel securely. Apply a torque to a 2.54 cm (1.0 in) section of the steering

46、wheel rim until it breaks free of the insert rim. The number of locations to be tested on a wheel is dependent upon the steering wheel design (Note: At least two locations per wheel to be tested). Test points to be located as far as possible from spoke to rim intersections. Three wheels to be tested

47、 under each of the following conditions: A. At room temperature. B. After a 10-day soak at 100% 10% humidity and 100 F 5 F. C. After a 10-day soak at 175 F 5 F. D. After three 3-day temperature cycles, consisting of the following steps, in any order or combination: 1. 24 hour soak at 175 F 5 F. 2. 2

48、4 hour soak at 100% 10% humidity and 100 F 5 F. 3. 24 hour soak at 20 F 5 F. Temperature and humidity transition times will not exceed one hour from start to stable readings. Tests to be performed within two hours after removal from soak environment. 4.2.8.2 Required The minimum applied torque requi

49、red to break the skin or over-mold material free of the insert rim shall be 20.4 .3 Nm (15 .2 ft lb). 4.2.9 Welding Resistance Welds Resistance welds must comply with requirements of TMS-9516. NUMBER: MPAPS L-6023 TITLE: STEERING WHEEL AND HORN PAD ASSEMBLIES REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Su