1、 Specification for Testing Automotive Halogen Light Sources The 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 (USCA
2、R) certifies the compliance 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 the
3、ir purposes. Copyright 2006, USCAR ISBN: 0-7680-1665-7All rights reserved. Printed in U.S.A. Issued March 2001 Revised January 2006 SAE/USCAR-14 Revision 2QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8518 FAX (724) 776-3036 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SUMMARY OF CONT
4、ENTS 1 SCOPE*.32 SAFETY PRECAUTIONS33 REFERENCE STANDARDS .44 DIAGRAMS AND DEFINITIONS.54.1 APPENDICES 55 GENERAL REQUIREMENTS .55.1 RECORD RETENTION 55.2 SAMPLE DOCUMENTATION AND RETENTION.65.3 POWER SOURCES 65.4 EQUIPMENT TOLERANCES.65.5 MEASUREMENT ACCURACY 75.6 TEST REPEATABILITY AND CALIBRATION
5、75.7 TEST DEFAULT CONDITIONS .85.8 TEST SHARING WITHIN BULB FAMILIES85.9 TEST FAILURE PROCEDURE 85.10 CONTROL PLANS95.11 RELIABILITY PROGRAMS AND METHODS 95.12 HAZARDOUS MATERIAL RESTRICTION .96 PHYSICAL PERFORMANCE106.1 PHYSICAL DIMENSIONS.106.2 MEAN SPHERICAL CANDELA (MSCD)106.3 EXTERNAL VISUAL EX
6、AMINATION 116.4 COLOR.126.5 LEAK/SEALABILITY THROUGH TERMINALS AND SEAL136.6 DEFLECTION 13SAE/USCAR-14 Revision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 2 - 6.7 FLUID COMPATIBILITY*146.8 TERMINAL RETENTION*.156.9 RESONANT FREQUENCIES*.166.10 AGED RESONANT FREQUENCY
7、* 176.11 SALT SPRAY.186.12 OUTGASSING TEMPERATURE REQUIREMENT .187 DURABILITY .187.1 LABORATORY LIFE AT 14.0 VDC* .187.2 LUMINOUS INTENSITY MAINTENANCE* .197.3 VIBRATION DURABILITY* .207.4 SHOCK* .227.5 AGED VIBRATION DURABILITY*237.6 TERMINAL REQUIREMENTS*257.7 DRL (SAE J2087)*.258 QUALITY/RELIABIL
8、ITY PROGRAMS268.1 RELIABILITY GROWTH.268.2 ONGOING QUALITY IMPROVEMENTS 268.3 QUALITY/RELIABILITY IMPROVEMENT TOOLS .269 REPORT REQUIREMENTS279.1 CALIBRATION SHEETS 279.2 DATA REQUIREMENTS 27APPENDIX A: GLOSSARY OF TERMS*.28APPENDIX B: FLUID SOURCES* .30APPENDIX C: REVISIONS*.31SAE/USCAR-14 Revision
9、 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 3 - 1 SCOPE* The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under th
10、e following conditions. New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test The completion of one calendar year, accept as noted in the following Test Schedule Table.Test Title YearlyPhysical Dimensions X Mean Spherical Candela (MSCD) X Exter
11、nal Visual Examination X Color X Leak/Sealability Through Terminals and Seals X Deflection X Fluid Compatibility Terminal Retention X Resonant Frequencies Aged Resonant Frequency Salt Spray Outgassing Temperatures Requirement Laboratory Life at 14.0 VDC X Luminous Intensity Maintenance X Vibration D
12、urability Shock Aged Vibration Durability Terminal Requirements DRL (SAE J2087) 2 SAFETY PRECAUTIONS Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped. Wear appropriate eye protection, gloves, and shielding when performing any t
13、ests on bulbs covered by this specification. Use precaution in handling a bulb that has recently been energized. These bulbs operate at a very high temperature. SAE/USCAR-14 Revision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 4 - Protect operating lamps from contact
14、with liquid and moisture. Liquid contacting a hot bulb can cause it to shatter. Hold the bulb only by the base. Do not touch the glass portion of the bulb with bare hands.This specification may involve hazardous materials, operations, and equipment. This specification does not purport to address all
15、 the safety concerns associated with its use. It is the responsibility of whoever uses this specification to consult and establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.3 REFERENCE STANDARDS DaimlerChrysler, Ford, and General M
16、otors Advanced Product Quality Planning and Control Plan Reference Manual Measurement Systems Analysis Reference Manual (AIAG) Potential Failure Mode and Effects Analysis Reference Manual (SAE J1739) DaimlerChrysler, Ford, and General Motors Production Part Approval Process Manual ANSI (C78.390) AST
17、M B117 (Standard Practice for Operating Salt Spray Fog Testing Apparatus) DaimlerChrysler, Ford, and General Motors Quality System RequirementsQS-9000ManualSAE J1330, Photometry Laboratory Accuracy Guidelines SAE J578, Color Specification SAE J1383, Performance Requirements for Motor Vehicle Headlam
18、ps SAE J2087, Daytime Running Lamps for Use on Motor Vehicles Unless otherwise specified or required by law, suppliers shall use the most recent versions of any applicable reference documents or standards.SAE/USCAR-14 Revision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES
19、 - 5 - 4 DIAGRAMS AND DEFINITIONS 4.1 Appendices Diagrams are provided at the end of this specification to clarify the details of the test procedures. A Glossary of Terms is also included in the Appendix.5 GENERAL REQUIREMENTS 5.1 Record Retention Supplier must maintain a file for the storage of lab
20、oratory reports and calibration records, and establish a record retention policy concerning these records in accordance with QS-9000 and PPAP requirements. These records need not follow a standard format, but must present the required data in an orderly, professional manner. The file must be made av
21、ailable to any and all customer personnel upon request, includingbutnot limited torepresentatives from the following areas: product engineering, purchasing, quality, and reliability. 5.1.1 Objectives of Record Retention Following are the main objectives for retention of test documents or records: 1.
22、 Retain records that will evidence compliance so that the supplier can appropriately respond when or if product compliance is challenged. Files must exist for the storage of all laboratory records, data, and calibration records. The files must be available at any time for audit or inspection. 2. Ret
23、ain records as needed to assist in evidencing the exercise of “due care“ in matters relating to product compliance, government requirements, or product liability.3. Comply with statutory requirements for the maintenance and retention of specific records.5.1.2 Retention Methods Methods of retention m
24、ay include retention of original documents, the use of film, or the use of electronic storage equipment. Records shall be stored so that they are accessible in a reasonable amount of time. Storage areas should provide adequate protection from unauthorized access, moisture, and fire. SAE/USCAR-14 Rev
25、ision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 6 - 5.2 Sample Documentation and Retention Engineering test samples must be identified by ANSI Trade Number and serial number unless otherwise noted. Documentation must identify the type of test performed and describe
26、special tests that are not a part of this specification. (Reference QS-9000 and PPAP requirements.) 5.2.1 Required Data Package Supplier must submit the data package for the appropriate level of submission to the customers responsible engineer and purchasing division for approval signatures. 5.2.2 S
27、ample Retention Samples tested to attain part approval must be retained by the bulb manufacturer for a period of time specified in the PPAP Manual. 5.3 Power Sources Supplier must use voltage regulated DC power sources for all tests to simulate an automotive battery and charging system. 5.3.1 Output
28、 Current The power source must be capable of supplying a continuous output current as required by the design loads, including inrush current. Where required to simulate automotive inrush current conditions, an automotive battery or batteries with sufficient cold cranking amps may be connected in par
29、allel with the power supply. 5.3.2 Output Voltage The power source must be capable of supplying an output voltage that must not deviate more than 1.0 volt from the nominal setting over the entire load range (including surges). The power source must recover 63% of its maximum excursion within 5.0 mil
30、liseconds. Ripple voltage must not exceed 300 mV peak to peak. Power supplies used for photometric measurements must conform to SAE J1330. 5.4 Equipment Tolerances Supplier must use test setups and equipment capable of measuring test parameters (expressed in nominals) within the limits found in Equi
31、pment Tolerance Table. SAE/USCAR-14 Revision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 7 - Equipment Tolerance Table Test Chamber Temperaturenominal 3CTime nominal 0.5% Forces nominal 0.01 N Distances nominal 0.01 mm Voltages nominal 0.01 V for photometricsnominal 0
32、.1 V for all other tests MSCD nominal 2.0% NOTE: This table is not to be used for performance dependent variable (refer tosection Measurement Accuracy). 5.5 Measurement Accuracy Meters and gages used to assess the performance dependent variable, as defined by the basic function of the test sample, m
33、ust have a smallest unit of measure one order of magnitude less than the least significant digit specified. For example, even though a 0.6 mm and 0.60 mm wire 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 reso
34、lution is needed for the second wire. 5.6 Test Repeatability and Calibration 5.6.1 Equipment Repeatability All measurement equipment used for product evaluation must be repeatable to within 10% of the part tolerance according to DaimlerChrysler, Ford, and General Motors Measurement Systems Analysis
35、Reference Manual. 5.6.2 Equipment Calibration Equipment re-calibration/re-certification timing is to be calculated based on the capability of any individual instrument to retain its “Manufacture Stated Accuracy“ between recall periods. However, this time shall not exceed one year. SAE/USCAR-14 Revis
36、ion 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 8 - 5.6.3 Laboratory Masters (Photometry Only) Lamps which are traceable to known standards are laboratory masters. Each supplier must use laboratory masters for comparison measurements, calibration of test equipment, an
37、d for evaluating long-term drift in test equipment. 5.7 Test Default Conditions When specific test conditions are not given, the following basic conditions apply: 1. Test the bulb in its normal operating orientation. 2. Perform tests or measurements at the following ambient conditions:Room Temperatu
38、re23C +/- 5C3. Season the bulbs for 1% of the laboratory life, 10 hours maximum at 14VDC. 4. When testing dual filament bulbs, each filament can be tested in the same capsule or in separate capsules, unless otherwise specified. When testing both filaments in the same capsule, the sequence of testing
39、 must be recorded . Both filaments should never be lit at the same time during any test. 5.8 Test Sharing Within Bulb Families The results of tests performed on one bulb type may, in some cases, be used to indicate the capability of another bulb type within the same bulb family. For example, a crush
40、 test performed on a clear, 800 series bulb type may be used as a demonstration of the glass strength of all clear, 800 series bulb types made by the same process from the same glass from the same source. Sound judgment must guide this practice. Bulbs within the same bulb family that share component
41、s such as glass envelopes, lead wires, filaments, bases, fill gases, etc., may be able to share test results. The customer will be the final authority on whether this surrogate data may be used. 5.9 Test Failure Procedure Should a test failure occur, the customer (Quality, Purchasing, and Design/Rel
42、ease Engineer) shall be notified immediately. When contact cannot be immediately made, stop the test until the requesting party can be contacted. SAE/USCAR-14 Revision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 9 - 5.10 Control Plans Supplier must maintain a control
43、plan, consistent with the AIAG, for each bulb type (or bulb family), that contains appropriate controls to ensure that all the significant/critical characteristics covered by the tests in sections Physical Performance, and Durability.5.11 Reliability Programs and Methods 5.11.1 Reliability Growth an
44、d Ongoing Quality Improvements Suppliers must establish and implement a plan to improve demonstrated product quality and reliability. They must establish procedures for analyzing and correcting end-of-line defects and predominant failure modes identified by the field return program. True reliability
45、 growth occurs when design changes to the bulb or manufacturing process are made to eliminate the failure modes. 5.11.1.1 Notification of Process Changes Suppliers must notify the customer of manufacturing process, material, or design changes to determine if resubmission for PPAP approval is require
46、d. 5.11.2 Quality/Reliability Improvement Tools Suppliers must use appropriate methods to improve the quality and reliability of their products in accordance with QS-9000. Examples of such methods are Field Return Programs, Design Failure Mode Effects Analysis (DFMEA), Process Failure Mode Effects A
47、nalysis (PFMEA), and Fault Tree Analysis (FTA) or Fishbone Diagrams.Further information on these methods is available from the Automotive Industry Action Group (AIAG). 5.12 Hazardous Material Restriction Any regulated substance that is identified by any federal, state, provincial, or local governmen
48、t unit or automotive manufacturer, shall not be used in the manufacturing process of any socket. Any socket manufacturer that is currently supplying hazardous material in a component will submit a timeline to General Motors, Ford, and DaimlerChrysler for the removal of said product. SAE/USCAR-14 Rev
49、ision 2 January 2006 SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES - 10 - 6 PHYSICAL PERFORMANCE These tests are intended to measure the innate characteristics of the bulbs. All data must be recorded according to section: Record Retention. 6.1 Physical Dimensions The purpose of this examination is to verify that all of the physical dimensions of the bulb are in agreement with the drawing. 6.1.1 Measurement Apparatus Equipment capable of determining the actual dimensions specified in the bulb drawing within the tolerance li
