1、STANDARD FOR IN-TANK ELECTRIC FUEL PUMPSThe research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the Society of Automotive Engineers, Inc. (SAE) nor the United States Council for Automotive Research (USCAR) certifies the com
2、pliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes.Copyrigh
3、t 1999, USCARAll rights reserved. Printed in U.S.A.Issued August 1999SAE/USCAR-13QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8545 FAX (724) 776-0243TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790SAE WEB ADDRESS: http:/www.sae.orgSUMMARY OF CONTENTS1.0 SCOPE1.1 Hazardous Material Contro
4、l2.0 OUTLINE2.1 General3.0 REFERENCE DOCUMENTS AND DEFINITIONS3.1 Symbols3.2 Part Drawing3.3 Application Specific Requirements3.4 Development Tests4.0 GENERAL REQUIREMENTS4.1 Record Retention4.2 Sample Documentation4.3 Sample Sizes4.4 Materials and Process Standards4.5 Measurement Resolution4.6 Test
5、 Repeatability and Calibration4.7 Conformance Determination4.8 Disposition of Samples4.9 Quality Control4.10 Pump Performance Stabilization4.11 Assembly Plant Performance5.0 PERFORMANCE TESTS5.1 Pump Output5.2 Pressure Relief Valve Maximum Pressure5.3 Start-Up Current5.4 Module Fill Performance5.5 M
6、odule Prime5.6 Radial/Axial/Torsional and HydraulicPressure Pulsation5.7 Subjective Noise Evaluation5.8 Check Valve Noise5.9 Hot Fuel Handling5.10 Pressure Rise Time5.11 RFI/EMI (C)5.12 Anti-Ignition6.0 DURABILITY TESTS6.1 Cold Magnet Knockdown6.2 Thermal Cycle Durability Test6.3 Pressure Cycling6.4
7、 Vibration6.5 Dry Operation6.6 Corrosion Resistance6.7 Contaminated Fuel (Dust Resistance)6.8 Over Pressure6.9 Exposure to Humidity6.10 Operational Durability6.11 Over Voltage7.0 CONTROL7.1 Product Change7.2 Production PartsAPPENDICESA FIGURESB GLOSSARY OF TERMSSAE/USCAR-13 August 1999STANDARD FOR I
8、N-TANK ELECTRIC FUEL PUMPS-2-1.0 SCOPE:This standard covers the operational characteristics, environment, durability procedures, and test procedures for in-tank electric fuel pumps for automotive gasoline applications. Specific performance and test criteria used in conjunction with this procedure ar
9、e specified on the pump drawing. Particular sections of this document may be required for all applications. This standard is intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking, and in-process controls, and should in no way adversely inf
10、luence other inspection operations.1.1 Hazardous Material Control:Products furnished to the customer and products and processes used by suppliers to manufacture those products must conform to employee and consumer health, employee safety, and environmental requirements.2.0 OUTLINE:2.1 General:Diagra
11、ms are provided where necessary to clarify the details of the test procedures. Use fig. 1 for general setup unless otherwise specified. A glossary of terms and equipment are provided in Appendix A. All test procedures and apparatus must meet all applicable codes and shall be the responsibility of th
12、e supplier to design such equipment.3.0 REFERENCE DOCUMENTS AND DEFINITIONS:Requirement Hierarchy - In the event there is a conflict between this standard, part drawings, and other related standards or specifications, prioritize the order in which requirements are determined as follows:1st - Applica
13、ble part drawing(s)2nd - Application Specific Requirements3rd - USCAR Standards4th - Design Verification, Production Validation and Continuing Conformance Requirements5th - Other related standards and specifications3.1 Symbols:Safety, noise, emission, or theft prevention significance will apply to t
14、his standard only when the corresponding drawing depicts the standard with the respective symbol. To determine which portions of a specification have safety, noise, emission, or theft prevention significance, a review of the part drawing may be necessary.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK
15、ELECTRIC FUEL PUMPS-3-3.2 Part Drawing:The part drawing for the fuel pump should contain or reference the following:A. All dimensional requirements- Wherever possible the applicable electrical connector should be used in conducting the test sequences contained in this document to simulate actual in-
16、vehicleconditions.- The circuitry shall be terminated using connectors that comply with SAE/USCAR-2,Standard for Automotive Electrical Connection Systems, and the SAE/USCAR-12,Wiring Component Design Guidelines.B. Performance requirementsC. Supplier part numberD. Reference to applicable portions of
17、this and other specificationsE. The typical mating connector and terminalsF. Federal Motor Vehicle Safety Standard (FMVSS) Requirement, if applicable3.3 Application Specific Requirements:The application specific requirements shall identify the parameters that differ from the general specifications i
18、n this document. The application specific requirements may or may not be an integral part of the part drawing.3.4 Development Tests:Development tests are frequently used to evaluate specific areas of the design. They are a tool for evaluating design alternatives, proposed improvements, cost reductio
19、n proposals, or determining root causes of field problems.3.4.1 Validation Tests: Validation tests or sample approval tests are acceptance-type tests. Consideration shall be given to the inherent repeatability or subjectivity of certain tests outlined by this specification before designation as a va
20、lidation or compliance test.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-4-4.0 GENERAL REQUIREMENTS:4.1 Record Retention:The supplier shall maintain a central file for the storage of laboratory reports and calibrationrecords. A record retention policy concerning these records sha
21、ll comply with QS-9000.Customer specific files shall be made available to any and all customer personnel upon request, including but not limited to representatives from the following functions: product engineering, purchasing, quality, and reliability.4.1.1 Objectives of Record Retention: The follow
22、ing are the main objectives for record retention:A. Retain records that will evidence compliance so that the supplier can appropriatelyrespond when or if product compliance is challenged. Files shall exist for the storage of all laboratory records, data, and calibration records. The files shall be a
23、vailable at any time for audit or inspection.B. Retain records as needed to assist in evidencing the exercise of “due care“ in matters relating to product compliance to government requirements or product liability.C. Comply with statutory requirements for the maintenance and retention of specific re
24、cords to substantiate compliance with legal requirements.4.1.2 Retention Methods: Method of retention must conform to the suppliers corporate procedures and may include retention of original documents, the use of film, or electronic storage equipment. Records must be stored so that they are accessib
25、le in a reasonable amount of time. Storage areas should provide adequate protection from unauthorized access, moisture, and fire.4.2 Sample Documentation:Engineering test samples shall be identified by part number and serial number unless otherwise noted.4.2.1 Required Data Package:4.2.2 Master Samp
26、les: Master samples for performance, noise, or construction, if required by the customer, will be provided at the time of approval.4.3 Sample Sizes:Sample sizes will be documented in the application specification.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-5-4.4 Materials and Pr
27、ocess Standards:Suppliers are expected to subscribe to appropriate Materials and Process Standards that are called out by this specification.The supplier shall not change any material or process requirements subsequent to Design Verification approval without the written consent of the customers rele
28、asing department.Unless otherwise specified or required by law, suppliers should use the most recent versions of any applicable reference documents or standards.4.5 Measurement Resolution:Meters and gages used in measurements of the test sample shall be capable of measuring to one count less than th
29、e specified value. For example, even though a 0.1 mm and 0.10 mm might be the same diameter, calipers capable of 0.01 mm resolution may be used to measure the first wire but a micrometer with 0.001 mm resolution is required to measure the second wire.4.6 Test Repeatability and Calibration:Repeatabil
30、ity studies shall be performed on all laboratory equipment after initial calibration and before use for product evaluation. Individual gages and meters must be calibrated to the manufacturers specifications on a regular basis.4.7 Conformance Determination:Test conformance shall be determined by the
31、performance requirements of the test being performed. All samples shall satisfy the performance requirements regardless of age, cycles, or temperature, unless otherwise noted on the part drawing.4.8 Disposition of Samples:Should a premature test nonconformance occur, contact the requesting party to
32、determine if the test is to be continued to gain additional product experience or if testing is to be suspended. When contact cannot be immediately made, the type of test shall determine the disposition of the samples. If the test order indicates that the test is investigative in nature, continue un
33、til the requesting party or parties are available. If the test order is for sample approval or validation, stop the test until the requesting party can be contacted.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-6-4.9 Quality Control:A supplier who furnishes finished parts is respo
34、nsible for the quality of all components of the shipped assembly or end item, whether component parts are processed/manufactured by the supplier or purchased from another source. If required, parts shall be purchased only from customer-approved sources.4.10 Pump Performance Stabilization:Before test
35、ing, pumps must be run to a stabilization condition. The amount of time required for stabilization will depend on the pump technology. Its expected that this will not exceed 24 h.4.11 Assembly Plant Performance:The fuel pump must meet minimum performance requirements dictated by the assembly drawing
36、 as received by the customer.5.0 PERFORMANCE TESTS:Prior to performance measurements, the fuel pumps shall be run on the test stand at test voltage and pump outlet pressure (according to the approved specification) to stabilize the functional data.5.1 Pump Output:Measure flow and current at the foll
37、owing conditions: Emission Test Fuel 20C 2C, -30C 2C 12.0 0.1V Pump Outlet Pressure (per approved specification)5.1.1 Forward Check Valve Leakage (if required):5.1.1.1 Procedure: Test leakage in the forward direction after soaking in emission test fuel for 10 min. (See test setup in fig. 2.) An air
38、test may be substituted for the In-Process test with suitable correlation data (r2 0.9 and n 30 samples) and approval from the customer.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-7-5.1.2 Reverse Check Valve Leakage: The fuel pump check valve shall not exceed the leakage rate sh
39、own in the chart when tested in the reverse direction after soaking in emission test fuel for 10 min. (See test setup in fig. 3.)Perform all tests at -30C, 20C, and 40C, 2C.5.2 Pressure Relief Valve Maximum Pressure:The maximum pressure the fuel pump is allowed to achieve is 1000 kPa (145 psig) at 1
40、5.2 0.1V and zero flow (dead-head).5.3 Start-Up Current:5.3.1 Procedure:A. Set up test according to fig. 7. Repeat three times with 10 s intervals to ensure prime and air purge. Ensure the third time start up is under fuel pump outlet pressure. Use emission test fuel.B. Apply 12.0 0.1V to the pump t
41、erminals using a power supply capable of 40 A minimum at 24 0.1V and energize the pump with a step function of 5 ms or less to close the circuit.C. Record the peak current using an appropriate wave form analyzer or equivalent.5.3.2 Acceptance Criteria: The instantaneous start-up current at 12.0 0.1V
42、 and 20C 2C on the third start up shall not exceed the value as indicated according to approved specification for the applicable pump assembly operating in emission test fuel.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-8-5.4 Module Fill Performance (if required):This requirement
43、 only applies to fuel pumps with an integral aspirator jet tube as specified on the pump drawing. The flow output from the aspirator outlet shall exceed the minimum requirement specified on the pump drawing when a minimum 63.5 mm (2.5 in) fluid head height is maintained above the centerline of the a
44、spirator.5.5 Module Prime (if required):The pump must purge itself of air and vapor and generate the pump outlet pressure in less than 10 s after the application of 12.0 0.1V to the pump. Test each sample pump for each temperature in the Temperature Chart of section 5.5.2.5.5.1 Test Conditions: Fig.
45、 4 defines the test stand schematic and depicts the fuel level and pump orientation during reprime.5.5.2 Temperature Chart:5.5.3 Test Procedure:A. Position the fuel pump module in the fuel tank at its designed height and orientation angle. If the pump is part of a fuel pump module, it must be tested
46、 within the module for this test.B. Pour 11.4 L (3.0 gal) of emission test fuel, with a Reid Vapor Pressure (RVP) raised to 83 kPa (12 psig) into the tank.C. Apply 12.0 0.1V to the pump and run the pump as described below until run-out(5.5.3 D, E, F, G, & H).D. Set pressure to pump outlet pressure.E
47、. Heat or cool the fuel to the desired temperature.F. Drain 7.6 L (2 gal) of fuel from the tank.SAE/USCAR-13 August 1999STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS-9-5.5.3 (Continued):G. Open flow control valve and set flow rate at 9.1 kg/hr (20 lb/hr).H. Run the pump until the fuel pressure has fallen
48、 below 1/3 of the pump outlet pressure. Turn off fuel pump and fuel heating system.I. Add into the tank fresh 83 kPa (12 psig) minimum RVP emission test fuel, mixed with 10% ethanol, to the level of 12 mm from step F simulating 3.8 L (1.0 gal). The newfuel temperature shall correspond to the fuel pu
49、mp temperature value in the “Temperature Chart“ of section 5.5.2.J. Measure the pump prime by applying 12.0 0.1V to the pump while recording the pump current and pressure traces with a two-channel strip chart recorder, or equivalent.5.6 Radial/Axial/Torsional and Hydraulic Pressure Pulsation:5.6.1 Production Testing by the Supplier: The pump shall not exceed the radial/axial/torsional vibration and outlet hydraulic pressure pulsation shown on the print. Test the pump at the applied voltage and operating pressure according to approved specification.5.7
