1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2007 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org J2604 ISSUED OCT2007 SURFACE VEHICLE RECOMMENDED PRACTICE Issued 2007-10 Recommended Test Procedure for Powered Gas Brake Control Systems RATIONALE Not applicable. 1. SCOPE This test procedure is for qualification te
5、sting of powered gas/brake control systems to assure compliance with the Recommended Practices for these assistive devices. A powered gas/brake control system which passes all of the tests shall be considered to be in compliance with the Recommended Practices. The control shall pass all tests denote
6、d by a “shall” in the Recommended Practice or the Recommended Test Procedure. All the results of all tests and requirements denoted by a “should” shall be noted, but failure to comply will not constitute failure to pass the test. 1.1 Testing Protocol Two production samples of the powered gas/brake c
7、ontrol system and a documentation package shall be submitted to the testing facility designated to perform the testing. The test facility will be designated by the manufacturer. 1.1.1 Installed System A complete installed system shall be available for continuous use during the course of testing. The
8、 vehicle shall have the complete installation of the powered gas/brake control system as it would be delivered to the user including all labeling and manuals. 1.1.2 Uninstalled System A complete uninstalled system shall be supplied for bench testing and study of individual components. All parts of t
9、he original equipment system which are modified in any way, and all additional parts that make up the powered gas/brake control system installation (labels, gauges, hoses etc.) shall be supplied. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this specification t
10、o the extent specified herein. Unless otherwise indicated, the latest version of SAE publications shall apply. SAE J2604 Issued OCT2007 - 2 - 2.1.1 SAE Publications Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outsi
11、de USA), www.sae.org. SAE J2603 Powered Gas/Brake Control Systems 2.1.2 FMVSS Publications Available from the Superintendent of Documents, U.S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320. FMVSS 124 Accelerator Control Systems (CFR V 571.124) FMVSS 135 Passenger Car Brake
12、Systems (CFR V 571.135) 3. RECEIVING INSPECTION Inspect the unassembled system to determine that the following items have been provided and meet the referenced Recommended Practices. The inspections should be documented on an appropriate report form with photocopies or photographs as required. 3.1 P
13、ackaging Inspect the shipping packages and all parts of the powered gas/brake control system inside the packaging for compliance with Recommended Practice SAE J2603 Section 4.19. 3.2 Powered Gas/Brake Control System Users Manual Inspect the manual for compliance according to the following table by r
14、eferring to Recommended Practice SAE J2603. Item of Inspection Recommended Practice Paragraph Special Considerations Control Description 6.5.1 User Operation 6.5.2 Recommended Maintenance 6.5.3 Special Purpose Tools 6.5.3 Manufacturer Address 6.5.4 Caution to Check Brakes 6.5.5 Shift to Neutral and
15、Turn Off Engine 6.5.6 Warranty Information 6.5.7 3.3 Powered Gas/Brake Control System Installation Manual Inspect the manual for compliance according to the following table by referring to SAE J2603. Item of Inspection Recommended Practice Paragraph Special Considerations EMI Provisions 4.9 Furnishe
16、d Peripheral Components 6.5 Do in conjunction with Parts List (below) Modified OEM Parts 6.6 Do in conjunction with Parts List (below) Warning Label 6.4 If not on gas/brake control Vehicle Applicability 7.1 Fluid Schematic Flow Diagrams 7.2 Electrical Diagrams 7.3 Parts List 7.4 Do in conjunction wi
17、th Furnished Components and OEM Parts (above) Maintainability 7.5 No Operator Adjustments 7.6.1 Components Attached to Control Box 7.6.2 SAE J2604 Issued OCT2007 - 3 - Item of Inspection Recommended Practice Paragraph Special Considerations Labels 7.6.3 Lockout 7.6.4.1 Interlocks 7.6.4.2 Dynamics Co
18、nsiderations 7.6.5 User Information 7.6.6 Means of Shifting to Neutral Turning Off the Engine/Motor 7.6.7 3.4 Furnished Components Determine whether all parts identified in the Installation Manual parts list and special purpose tools for user maintenance, are in fact furnished by the manufacturer by
19、 inspection of the unassembled system. Note the absence of any items required for assembly and installation. Notify the manufacturer immediately of any discrepancies before attempting assembly or installation. (SAE J2603 Section 4.15.2, SAE J2603 Section 5.5) 3.5 Modified OEM Parts As part of the Fu
20、rnished Components Inspection of paragraph 3.4, determine that any OEM parts or other purchased components which have been modified and are included in the installation parts kit have permanent warning labels or other markings on the part (or assembly of parts) indicating that they have been modifie
21、d and shall not be replaced with OEM parts. (SAE J2603 Section 5.6) 3.6 Other Documentation Inspect other documentation included with the unassembled system for compliance according to the following table by referring to Recommended Practice SAE J2603. Item of Inspection Recommended Practice Paragra
22、ph Special Considerations Input Force Requirements 4.1.1 Failure Analysis 4.1 Components Selected for Backup 4.1 Identification of Components 4.4.1 Means to Disconnect Components 4.2.4.2 EMI Interference 4.9 Torque Specifications for All Mounting 4.4.2 Fasteners Static Load for Full Brake 6.1.4.2.1
23、Static Load for Full Accelerator 6.1.4.2.2 Recall Plan 8.2 NHTSA Registration 8.3 3.7 Identification Marking Inspect every major assembly of the powered gas/brake control system for permanent markings with the manufacturers name, trademark, or other recognizable logo. Such marks shall be on the exte
24、rior of the product. These marks shall include parts numbers keyed to parts lists and/or diagrams. At least one major component of the powered gas/brake assembly shall have the serial number of the system where it can be seen without disassembly. (SAE J2603 Section 8.1) 4. VISUAL AND TACTILE INSPECT
25、ION OF THE INSTALLED SYSTEM Inspect the installed system and the vehicle in which it is installed to ensure that the system meets the requirements of SAE J2603, according the following table by referring to Recommended Practice SAE J2603. The inspections should be documented on an appropriate report
26、 form with photocopies or photographs as required. The report should follow the format of the Test Procedure (including order and paragraph numbering). SAE J2604 Issued OCT2007 - 4 - Item of Inspection Recommended Practice Paragraph Special Considerations Control Box Components 4.25.1 Sufficient Sla
27、ck 4.25.2 Positive Attachment 4.25.3 Chafe Protection 4.25.4 Vehicle Interface 4.24 Attachment 4.22 Effect on Performance 4.11 Clearances for Maintenance 4.21 Compatibility with Drivers without 4.12 a Disability Injurious Exposures 4.13 Operator Safety 4.14 Cleanliness 4.20 Driver Vision 4.21 Mainta
28、inability 4.15.1 Maintenance 4.15.3 Accommodation for Wear 4.16 Environmental Resistance 4.17 Mechanical Finish 4.8 Shift to Neutral and Turn Off Engine 4.5 Inadvertent Operation 4.5.2 Protection of Hoses and Tubing 5.2 Fasteners 5.4.1 Structural Fasteners Warning Label 6.4 Control Shutoff Operation
29、 6.6 Control Shutoff Location 6.6.1 Control Shutoff Interlock 6.6.2 Control Shutoff Override 6.6.3 Labels 6.8 Identification Markings 8.1 5. PERFORMANCE TESTS The following tests call for certain detailed test procedures to assure conformance with the associated Recommended Practice J2603 for powere
30、d gas/brake control systems. 5.1 Vehicle Tests 5.1.1 Braking Performance Test The following test procedures will be used to determine that the powered gas/brake control system does not degrade the braking performance of a fully functional OEM braking system and can function effectively with a degrad
31、ed OEM braking system. They shall be conducted using the road surface conditions stipulated in Federal Motor Vehicle Safety Standards 135, Sections 6.1 (Ambient Conditions) and Section 6.2 (Road Test Surface). 5.1.1.1 The first test calls for a comparison of performance between using a powered gas/b
32、rake control system and not using that modification on the same vehicle. The tests comparing the OEM and the modified system should be completed “back to back“ or within 24 hours of each other. The test vehicle shall have an ABS braking system. a. The vehicle shall be accelerated to 48 Kilometers pe
33、r hours (30 miles per hour) and maintained at that speed while approaching a cone on the ground (speedometer accuracy is sufficient). b. As the driver passes the cone the driver shall activate the brakes in such a manner as to stop the vehicle as quickly as possible including initiation of ABS. c. T
34、he distance from the cone to the point on the ground below the center of front wheel of the stopped vehicle shall be measured. SAE J2604 Issued OCT2007 - 5 - d. This test shall be repeated 10 times using the powered gas/brake control system and 10 times using the OEM brake pedal (without using the p
35、owered gas/brake control system. Each stop shall be done no sooner than 5 minutes after the previous stop. e. The mean and the standard deviation of the group of 10 stops for each configuration shall be calculated. f. If any of the 10 stopping distances for either configuration (using the powered ga
36、s/brake control or using the OEM brake pedal) varies by three feet from the mean of the stopping distances for that configuration, the set of 10 stops shall be repeated for that configuration. g. The mean of the stopping distances using the powered gas/brake control shall not be over one standard de
37、viation (of the OEM data) greater than the mean of the stopping distances for the vehicle using the OEM brake pedal. (See notes at end of document for definitions of mean and standard deviation.) (SAE J2603 Section 4.1) h. After the 10thrun in a successful series in “d” above (success being determin
38、ed in “f” above) an 11thrun shall be made. The force and distance traveled by the control handle for a stop equivalent to the OEM (as determined by “g” above) shall not exceed the forces and distances supplied by the control manufacturer (SAE J2603 4.1.1). A force measuring device may be needed to m
39、easure the force on the control handle. (Note to tester: The tests using the powered gas/brake control and not using the OEM brake pedal shall be done as close together in time and vehicle mileage as possible and shall use the same tires, roadway, brake system components, approximate wind conditions
40、, etc.) NOTE: For use in 5.1.1.1 above, the mean and standard deviation are defined as follows. The mean for a set of trials is the sum of all of the stopping distances in the 10 trials, divided by the number of trials (10). The standard deviation for a set of trials is the square root of the value
41、found when the mean for each trial is subtracted from each of the stopping distances in that trial, that difference is squared, all of the squared values are added together and that total is divided by the number of trials (10). 5.1.1.2 With the engine off, the brake line(s) associated with the oper
42、ation of the front brakes (or either line if it is a diagonal brake backup system in the OEM master cylinder) shall be removed. A force measuring device under the brake pedal shall be used to measure the force exerted at the brake pedal pad by the powered control system actuator at the end of the pe
43、dal travel. The powered gas/brake control brakes shall be applied and a load equivalent to a minimum of 500 N (112.4 pounds) on the brake pedal pad shall be measured, regardless of where the force is actually applied by the gas/brake control. (SAE J2603 Section 4.1.2) 5.1.2 Limitation on Maximum Out
44、put 5.1.2.1 In a stationary vehicle, with the engine off and the connection from the gas pedal to the OEM accelerator control system replaced by a force measuring device) the control lever shall be moved to the maximum movement for the gas control motion. The output force to the accelerator pedal, a
45、s measured by a transducer mounted between the control actuator and the pedal shall not exceed 222 N (50 pounds). (SAE J2603 Section 4.8) 5.1.2.2 In a stationary vehicle, with the engine on, the control lever shall be moved to the maximum movement for the brake and the output force to the OEM brake
46、system noted. This shall be done in the partial brake failure mode described in FMVSS 135 (S 7.11). The maximum force output of the powered gas/brake control to the OEM pedal as measured by a transducer mounted between the control actuator and the brake shall not exceed 1330 N (300 pounds). (SAE J26
47、03 Section 4.8) 5.1.3 Primary Backup System The tester shall identify the components being backed up per SAE J2603 Section 5.2.4.1 (See RTP 3.6). The tester shall install (or have the manufacturer install) the means to disconnect the components being backed up on the test vehicle per SAE J2603 Secti
48、on 4.2.4.2 (See RTP 3.6). SAE J2604 Issued OCT2007 - 6 - 5.1.3.1 Automatic Activation of Primary Backup for Brakes The control system components being backed up (as determined by the failure analysis submitted in 3.6 above) shall be disconnected. The vehicle shall be accelerated to 48 Kilometers per
49、 hours (30 miles per hour) (speedometer accuracy is sufficient) and maintained at that speed for 10 seconds. The brakes shall then be applied on the powered control using the backup system provided to stop the vehicle. 5.1.3.1.1 The primary backup braking performance test of RTP 5.1.1.1 shall be repeated three times (as opposed to 10 times) (this test may be done at the same time as RTP 5.1.1.1. The braking shall pass the test with the s
