NAVISTAR TMS 7131-2005 Driver Air Bag (DAB) (Revision C).pdf

1、INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB) REVISION: C WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: August 2005 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REV

2、ISION 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 applicability of regul

3、atory limits prior to use. Change Notice: Modified UV specification in Section 4.2.2. Reference: File 16-13 Keywords: Driver Air Bag 1.0 APPLICATION This specification covers the driver airbag module assembly which consists of an inflator assembly, a cushion assembly, a housing assembly, and a cover

4、 assembly with a total mass of approx. 1.5 kg The inflator assembly is a non-azide pyrotechnic that produces gases to fill the cushion and is activated by the initiator (squib) that is permanently secured to the side of the inflator assembly. The inflator shall be equipped with an integral two-way c

5、onnector that will incorporate an internal shorting clip to eliminate a direct path to the initiator bridge wire to prevent inadvertent deployment due to radiant energy or during shipping and handling. The airbag module shall be operational under the following conditions: -30C to 80C, zero to 95% re

6、lative humidity, and 61 kPa to 105 kPa. 2.0 SCOPE This specification covers the general requirements, property and performance requirements, qualification, KCC and quality control, and dimensional tolerances for International air bags. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest is

7、sue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard QS-9000 (ISO 9001) ASTM B-117 FMVSS-302 INTERNATIONAL IQR Quality Standard ASTM D-1683 MIL-STD-1576 Method 2117 INTERNATIONAL Manufactur

8、ing Std. D-13 ASTM D-2136 MIL-STD-1576 Method 2201 INTERNATIONAL Eng., Design Standard A-16 ASTM D-5428 SAE J323 CFR 29, Part 1910 ASTM D-5822 SAE J551/11 AATCC Evaluation Procedure 1 ECE R16 TMS-9543 AATCC Test Method 8 TMS-9544 INTERNATIONAL CEMS GT-31 This document is restricted and may not be se

9、nt outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation. AUGUST 2005 Page 1 of 10 NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB)

10、REVISION: C 4.0 GENERAL REQUIREMENTS 4.1 Construction The airbag assembly shall be fabricated in such a manner that criteria of appearance, fit and adherence to drawing tolerances and material specifications shall be observed. The cover shall be free from flash or roughness at the die parting line,

11、gate, or vent point. The cover exterior surface shall be uniform in appearance and must be free of die, tool, sink marks, bubbles and pits. Color, texture and finish of production material supplied must match master samples of the pre-production material originally approved and on file in the Master

12、 Fabric Book at Industrial Design Department at TDTC. 4.2 Property And Performance Requirements for Cover Assembly 4.2.1 Low Temperature Bend Test: ASTM D-2136 or SAE J323, Method A 4.2.1.1 Method: Bend around a 3mm (1/8 in) diameter after 4 hours at -30C (-22F) 4.2.1.2 Required: The coating shall r

13、emain flexible and shall not crack or check. 4.2.2 Accelerated Weathering per CEMS GT-31 All material shall qualify to one of the two following tests: 4.2.2.1 Xenon Arc: 4.2.2.1.1 Interior parts, per Method A for a minimum of 1200 kj. 4.2.2.2 Fluorescent UV: 4.2.2.2.1 Interior parts, per Method F fo

14、r a minimum of 1000 kj. 4.2.2.3 Required (Either Method): There shall be no sign of color alteration greater than a E of 3, or any other form of degradation. A minimum rating of 3.0 per AATCC Evaluation Procedure 1, is required 4.2.3 Cover Seam Strength Test: ASTM D-5822 4.2.3.1 Method: Measure the

15、seam strength of the specimens in accordance with ASTM D-1683. 4.2.3.2 Required: Seam strength of specimens must be 300N (67.4 lb.) minimum. 4.2.4 Thermal Cycle and Humidity Test 4.2.4.1 Method: Test samples will run 5 cycles of the following environmental stages with a 2 hour ramp between stages: a

16、) 23 hours 50C 2C with 95% relative humidity b) 1 hour 21C 2C with 50% relative humidity c) 8 hours -35C 2C with 50% relative humidity d) 1 hours 21C 2C with 50% relative humidity e) 15 hours 85C 2C with 95% relative humidity f) 1 hours 21C 2C with 50% relative humidity 4.2.4.2 Required: All samples

17、 must not show any evidence of degradation after completion of the 5thcycle. 4.2.5 Abrasion Resistance Test: ASTM D-3884 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers a

18、re required to assume all patent liability. 2005 by International Truck and Engine Corporation. AUGUST 2005 Page 2 of 10 NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB) REVISION: C 4.2.5.1 Method: Rotary Platform, Double Head Method (Taber Abrader) Run 1000 cycles using a 500 gram load. 4.2.5.2 Require

19、d: There shall be no appreciable color change of the abraded surface and the appearance shall be comparable to the approved master samples. Weight loss shall not exceed 0.05 grams. 4.2.6 Rubbing Wear Test: CEMS DT-10 4.2.6.1 Method: Mount the cover assembly in “truck position” and apply a reciprocat

20、ing rubbing motion per CEMS DT-10. 4.2.6.2 Required: There shall be no appreciable color change of the abraded surface and the appearance shall be comparable to the approved master samples after 1000 cycles. Report the color transference by AATCC Number and describe the extent of the wear pattern. 4

21、.2.7 Paint Adhesion Test: CEMS GT-5A 4.2.7.1 Method: Using the samples from the UV Resistance Test, brush off any debris and measure the paint film thickness. Then perform paint adhesion test per CEMS GT-5A. 4.2.7.2 Required: Adhesion rating must have a 4B (95% adhesion) classification or higher. 4.

22、2.8 Chemical Resistance: CEMS DT-12 4.2.8.1 Method: Expose cover material to the following chemicals: (1)water, (2)Peerless Chemical Liquid Soap M1034 or equivalent, (3)0.1N HCl, (4)SAE J313 No. 1-D diesel fuel oil, (5)SAE J313 No. 2-D diesel fuel oil, and (6)SAE 10W-30 motor oil, as per CEMS DT-12.

23、 4.2.8.2 Required: Sample surface shall not show any evidence of degradation. 4.2.9 Perspiration Test 4.2.9.1 Method: Prepare the following solution: Glacial Acetic Acid 25 grams Sodium Chloride 25 grams Butyric Acid 15 grams Isovaleric Acid 15 grams Water 420 grams 4.2.9.2 After aging the solution

24、for 24 hours, place a 50 x 50 mm (2 x 2 in) gauze pad on the cover assembly surface and saturate with the synthetic perspiration solution. Allow to set for 15 minutes and remove the pad. Test the paint immediately for softening by pressing a fingernail under moderate pressure into the film. A cycle

25、shall consist of the 15 minute application plus the fingernail test. 4.2.9.3 Required: The coated cover assembly shall complete ten cycles min. without softening (leaving a fingernail imprint), discoloring, separating, staining, swelling or blistering. 4.2.10 Heat Aging Test 4.2.10.1 Method: Mount t

26、he sample cover to a module assembly and expose the sample to 100C 2C for 500 hours. 4.2.10.2 Required: All samples must not show any evidence of degradation. 4.2.11 Flammability Resistance: TMS-9544 (FMVSS 302) This document is restricted and may not be sent outside International Truck and Engine C

27、orporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation. AUGUST 2005 Page 3 of 10 NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB) REVISION: C Material supplied to this speci

28、fication shall meet all requirements of TMS-9544 and of Federal Motor Vehicle Safety Standard #302 Flammability of Interior Materials. The supplier shall provide certification of compliance in accordance with requirements of TMS-9543. 4.2.12 Cleanability Cover shall be easily cleaned with a mild soa

29、p 1 cycle = 24 hours 2) 1 cycle of Random Vibration* performed for each axis (X, Y, and Z) in the Legend: Temp. Humidity steering wheel plane (Figure 1) at the beginning of Life Cycle for a total of 3 cycles. The remaining 11 cycles will be performed without vibration. * For Random Vibration, stress

30、 units with the following amplitude spectrum (Table 1). Figure 2. Environmental Life Cycle Profile (Random Vibration, Temperature Cycle, and Humidity) Table 1. Amplitude Spectrum for Random Vibration Fore/Aft and Lateral (X and Y axis) Vertical (Z axis) f (Hz) A (g2/Hz) f (Hz) A (g2/Hz) 10 0.066506

31、10 0.081269 12.5 0.20506 12.5 0.23993817 0.210602 25 0.119969 22 0.038795 40 0.03096242 0.000299 47 0.001548 342 0.000887 100 0.001935660 0.000111 112 0.000387 787 0.000022 175 0.0003641187 0.000998 185 0.001703 2000 0.000006 295 0.000155357 0.001548780 0.000023 1140 0.0000661430 0.0030962000 0.0000

32、04 4.5.5 Dust Test NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB) REVISION: C 4.5.5.1 Method: Expose assemblies for 5 hours at 21C per ECE R16. 4.5.5.2 Required: The assemblies shall be deployed and meet the acceptance requirements per Deployment Test, Section 4.5.1 4.5.6 Salt Spray 4.5.6.1 Method: Ex

33、pose assemblies for 24 hours of salt fog per ASTM B-117. 4.5.6.2 Required: The assemblies shall be deployed and meet the acceptance requirements per Deployment Test, Section 4.5.1. .4.5.7 Effluent Emissions Test 4.5.7.1 Method: The DAB and SPS assemblies shall be deployed in the all-fire level in a

34、100 ft tank with the effluent levels measured. 4.5.7.2 Required: The assemblies shall maintain structural integrity and the effluent levels shall not exceed the limits specified in table 2. Table 2. DAB & SPS effluent limits (100 ft3Tank) Constituent Formula Gas Limit (ppm) Ammonia NH3 100 Benzene C

35、6H6 167 Carbon Dioxide CO22000 Carbon Monoxide CO 400 Chlorine Cl2 1.67 Formaldehyde HCHO 3.30 Hydrogen Chloride HCl 8.30 Hydrogen Cyanide HCN 8.30 Hydrogen Sulfide H2S 16.70 Nitric Oxide NO 33.30 Phosgene COCl2 0.33 Sulfur Dioxide SO216.70Nitrogen Dioxide NO26.70 5.0 QUALITY All DAB and SPS module

36、assemblies shall be clean, free of objectionable odor, be of uniform quality, and shall match the color, finish, and texture of preproduction samples on file in the Industrial Design Dept at TDTC. They shall be so fabricated that criteria of fit and adherence to specifications and tolerances are mai

37、ntained. Provisions to insure the dimensional integrity of the module/assembly shall be included in the quality control plan for this product 5.1 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between International and the supplier. Unless specif

38、ic exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* KCC1. Dimensional Gage 2. Total Weight * Other Characteristics for inclusion in the control plan may be specified on the engineering draw

39、ing and/or purchase order. * See Engineering Design Standard A-16 This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by Int

40、ernational Truck and Engine Corporation. AUGUST 2005 Page 9 of 10 NUMBER: TMS-7131 TITLE: Driver Air Bag (DAB) REVISION: C 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to INTERNATIONAL Truck and Engine are required to be registered to QS-9000 Quality System Require

41、ments. INTERNATIONAL will also accept ISO 9000 or TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies

42、of registration certificates to the INTERNATIONAL Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processin

43、g practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering at TDTC and Purchasing and Supplier Development, of the proposed change(s

44、). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either pe

45、rform and report results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the quality cont

46、rol manager of the using International plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Packing, shipping and identification shall be in accordance with Manufacturing Std. D-13. 8.0 DESIGNATION ON DRAWINGS Air Bag Assembly, per TMS

47、-7131 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Materials Engineering and Technology Dept. Truck Development and Technology Center (TDTC) 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringNav-I This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2005 by International Truck and Engine Corporation. AUGUST 2005 Page 10 of 10