1、 Initiator Technical Requirements and Validation 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 (USCAR) certifie
2、s 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 their purposes
3、. Copyright 2005, USCAR All rights reserved. Printed in U.S.A. Issued June 2005 SAE/USCAR-28 QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8518 FAX (724) 776-3036 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SUMMARY OF CONTENTS 1. INTRODUCTION5 1.1 Scope 5 1.2 Preface Definitions 5 2.
4、 APPLICABLE DOCUMENTS 5 3. REQUIREMENTS 6 3.1. General Requirements 6 3.1.1 General6 3.1.2 Reliability .6 3.1.3 Tolerances for Testing & Environmental Conditioning 6 3.2. Functional Requirements 6 3.2.1 Electrical6 3.2.1.1 Bridge Circuit Resistance 6 3.2.1.2 Insulation Resistance 7 3.2.1.3 All Fire
5、Constant Current.7 3.2.1.4 All Fire Constant Voltage All Fire Constant Resistance 7 3.2.1.5 No Fire.7 3.2.1.6 High Current 7 3.2.1.7 Monitor Current .7 3.2.1.7.1 Continuous 7 3.2.1.7.2 Pulsed .8 3.2.1.8 Electrostatic Discharge (ESD).8 3.2.1.8.1 Standard ESD .8 3.2.1.8.2 SAE J1113-13 ESD.8 3.2.1.9 El
6、ectromagnetic Interference (EMI).8 3.2.1.10 Transient Pulse .9 3.2.2 Mechanical 9 3.2.2.1 Overall Dimensions .9 3.2.2.2 Assembly.9 3.2.2.2.1 Pin-Type Initiator .9 SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 2 - 3.2.2.2.2 Leadwire Initiator .9 3.2.2.2.3 Herm
7、etic Seal9 3.2.2.3 Initiator Pins.9 3.2.2.3.1 Dimensions9 3.2.2.3.2 Durability of Plating .9 3.2.2.4 Leadwire10 3.2.2.4.1 Size .10 3.2.2.4.2 Strength.10 3.2.2.4.3 Colors 10 3.2.2.4.3.1 Inert Initiators.10 3.2.2.4.3.2 Live Initiators .10 3.2.2.5 Structural Integrity .10 3.2.3 Ballistic 10 3.2.3.1 Bal
8、listic Function Time 10 3.2.3.2 Ballistic Output 10 4. VALIDATION .11 4.1 Characterization of New Initiator Technologies.11 4.2 Radio Frequency Interference (RFI) Suppression Device Presence .11 4.3 Design Verification/Prodution Validation Report Format .11 4.4 Deviations from Test Procedure12 4.5 D
9、esign Verification Process 12 4.5.1 DV Program Sequence12 4.5.2 DV Test Plan .12 4.6 Production Validation Process 13 4.6.1 PV Program Sequence13 4.7 Validation Tests & Environments 13 4.7.1 General Requirements 13 4.7.1.1 Ballistic Test Device 13 4.7.1.2 Allowable Time Period for Ballistic Test 13
10、4.7.1.3 Pass/Fail Criteria .13 4.7.2 Tests14 4.7.2.1 Electrical Resistance & Low Temperature Baseline Test14 4.7.2.2 Electrical Resistance & Room Temperature Baseline Test.14 4.7.2.3 Electrical Resistance & High Temperature Baseline Test.14 4.7.3 Environments 14 4.7.3.1 Mechanical Shock .14 4.7.3.2
11、Thermal Shock Cycle 14 4.7.3.3 Random Vibration/Thermal Profile .15 4.7.3.4 Acceleration.16 4.7.3.5 High Temperature Accelerated Aging .16 4.7.3.6 Temperature/Altitude Cycle.16 4.7.3.7 Temperature/Humidity cycle17 4.7.3.8 Moisture Resistance Cycle17 4.7.3.9 Salt Spray18 SAE/USCAR-28 Issued June 2005
12、 TITLE: Initiator Technical Requirements and Validation - 3 - 4.7.3.10 Long Term Aging.18 4.7.3.11 Continuous Monitor Current 18 4.7.3.12 Pulsed Monitor Current .18 4.7.3.13 Transient Pulse .18 APPENDICES APPENDIX A CONSTANT CURRENT AND CONSTANT VOLTAGE FIRING CIRCUIT AND TRANSIENT PULSE DIAGRAM17 A
13、PPENDIX B REQUIREMENTS FOR CHARACTERIZATION OF NEW INITIATOR TECHNOLOGIES .20 APPENDIX C VALIDATION TEST MATRIX.24 APPENDIX D BRUCETON METHOD26 APPENDIX E NEYER D OPTIMAL, 1994 TEST METHOD .30 APPENDIX F COMMON INTERFACE DRAWING 32 APPENDIX G EMI TEST PROCEDURE 34 APPENDIX H GLOSSARY.45 SAE/USCAR-28
14、 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 4 - Change Log This Change Log lists all approved changes implemented in this document since the last published version. For the original release of the document the Change Log is empty. Paragraph Affected Description of Chan
15、ge Date Requester 4.7.3.5 thru 4.7.3.9 Move Salt Spray Exposure to end of Sequential Environments. (Done to avoid inadvertent extension of Salt exposure by carrying salt solution into subsequent tests.) (Change to Baseline Draft of 11/30/99) 3/15/2005 L. Knowlden (GM) S Stram (DC) M Quade (Ford) 4.7
16、.3.3.4 Revise initiator vibration profile to the equivalent vibration/thermal cycle of the inflator. (Inflator vibration is more severe) 3/15/2005 L. Knowlden (GM) S Stram (DC) M Quade (Ford) SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 5 - USCAR INITIATOR T
17、ECHNICAL REQUIREMENTS AND VALIDATION (DRIVER, PASSENGER, & SIDE SYSTEMS) 1. INTRODUCTION 1.1. Scope This specification establishes the design, performance, and validation requirements for the initiator assembly used in airbag modules, seatbelt pretensioners and/or any other Electro-Explosive Devices
18、 (EED). 1.2. Preface Definitions Initiator: For the purposes of this specification an initiator shall include an electro-explosive device (including electro-ignited micro gas generators of single charge container design). Specific design elements are not limited except by the performance and reliabi
19、lity requirements contained herein. Degradation (following environmental conditioning): The term “degraded“ refers to dudding, change in bridge circuit resistance out side of tolerance range, change in electrical sensitivity out side of tolerance range or an increase in average Time To First Pressur
20、e (TTFP ) and/or a change in average peak pressure (as measured in a closed bomb) greater than 20% of the average of a virgin control group (i.e. DV/PV baseline group) when deployed using the all fire pulses detailed in Sections 3.2.1.3 and 3.2.1.4 of this document. Shall Requirements: The initiator
21、 is required to meet all shall requirements without exceptions. Should Requirements: Should requirements are to provide preferred requirements where absolute compliance is not possible within current technology limitations. For additional definitions see Appendix H Glossary. 2. APPLICABLE DOCUMENTS
22、MIL-STD-202 Method 213B Mechanical Shock MIL-STD-202F Method 101D Salt Spray MIL-STD-202F Method 106E Moisture Resistance Cycle MIL-STD-131A Test 105.1 Temperature/Humidity Cycle MIL-STD-833D Method 1003 Insulation Resistance MIL-STD-1576 Method 2201 Bridge Circuit Resistance MIL-STD-1576 Method 220
23、5 ESD SAE J1113-13 ESD SAE/USCAR-2 Standard for Automotive Electrical Connection Systems PPAP QS9000 SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 6 - 3. REQUIREMENTS 3.1. General Requirements 3.1.1. General The initiator supplied under this specification sha
24、ll meet all of the functional requirements outlined for a fifteen year vehicle life. The initiator shall meet these requirements both before and after the environmental conditioning specified and over the temperature range of -40C to +85C. 3.1.2. Reliability All structural and performance related fe
25、atures shall be manufactured and/or processed in accordance with automotive industry accepted quality requirements for purchased materials and shall be done with the concurrence of the intended vehicle manufacturers Supplier Quality Assurance group(s). 3.1.3. Tolerances for Testing & Environmental C
26、onditioning Unless otherwise specified, the tolerances to be used shall be as follows: Time 1% (except where minimums are stated) Temperature 3C Relative Humidity (R.H.) 10 % Force 4 Newtons Acceleration 2% Vacuum 10 mm Hg Frequency 4% or 2 Hz (which ever is greater) Current 0.01 amps Voltage 5% Res
27、istance 1% Note: Unless otherwise specified all test temperatures shall be at ambient (23C). 3.2. Functional Requirements 3.2.1. Electrical 3.2.1.1 Bridge Circuit Resistance The bridge circuit resistance shall be 2.00 0.30 ohms over the temperature range of -40C to +85C (per MIL-STD 1576 (USAF) Meth
28、od 2201 or equivalent). SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 7 - 3.2.1.2 Insulation Resistance The insulation resistance shall be a minimum of 1 megohm when tested using 500 volts DC for 2 seconds (per MIL-STD 833D Method 1003, Condition E (500 VDC)
29、or equivalent). 3.2.1.3 All Fire Constant Current The initiator shall demonstrate an all fire current value with 0.99999 reliability and 95% confidence (as determined by the Bruceton Method Appendix D and/or Neyer D-Optimal per Neyer, 1994 Appendix E ) of no greater than 1.20 amperes DC at -40C and
30、+23C. The current level shall be determined by varying the current in the firing circuit shown in Figure 1 of Appendix A of this document. Delivery of energy from the constant current power source to the initiator shall be terminated 2 milliseconds after initializing the discharge. The ballistic fun
31、ction time shall meet the requirements of 3.2.3.1 Ballistic Function Time. 3.2.1.4 All Fire Constant Voltage All Fire Constant Resistance The initiator shall demonstrate an all fire current value with 0.99999 reliability and 95% confidence (as determined by the Bruceton Method, Appendix D and/or Ney
32、er D-Optimal per Neyer, 1994 Appendix E ) of no greater than 6 Volts at -40C and +23C. The current level shall be determined by varying voltage and holding the resistance of the total circuit to 4.0 ohms as shown in Figure 2 of Appendix A of this document. Delivery of energy from the power source to
33、 the initiator shall be terminated 2 milliseconds after initializing the discharge. The ballistic function time shall meet the requirements of 3.2.3.1 Ballistic Function Time. 3.2.1.5 No Fire The initiator shall demonstrate a no fire current value with 0.999 reliability and 95% confidence (as determ
34、ined by the Bruceton Method Appendix D and/or Neyer D-Optimal per Neyer, 1994 Appendix E) of no less than 0.400 amperes constant current DC pulse at +23C and +85C. Delivery of energy from the constant current power source to the initiator shall be terminated 10 seconds after initializing the dischar
35、ge. 3.2.1.6 High Current The initiator shall deploy when subjected to 40 amperes 5 % , nominal of DC current for a duration of 2 milliseconds at -40 C and +85 C per the matrix in appendix C. 3.2.1.7 Monitor Current 3.2.1.7.1 Continuous The initiator shall not degrade and shall not deploy when subjec
36、ted to a 160 milliampere DC continuous current at +85C for 42 days (1008 hours). SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 8 - 3.2.1.7.2 Pulsed The initiator shall not degrade and shall not deploy when subjected to 60,000 cycles of a periodic current puls
37、e of 50 milliseconds on duration, 160 milliamperes amplitude, 1 second off duration. 3.2.1.8 Electrostatic Discharge (ESD) 3.2.1.8.1 Standard ESD The initiator shall not degrade and shall not deploy when subjected to the following capacitive discharge test. Charge a 500 picofarad capacitor (+/- 10 %
38、) to 25,000 volts (+/- 250 V) and then discharge through a 5000 ohm resistor (+/- 10%) connected in series to the initiator. Subject the initiator to 5 discharges with a minimum of 5 seconds between discharges (per MIL-STD-1576, Method 2205) via each of the following connections: 1) pin to pin or le
39、ad to lead 2) pin A or lead A to body 3) pin B or lead B to body 4) shorted pins or leads to case 3.2.1.8.2 SAE J1113-13 ESD The initiator shall not degrade and shall not deploy during testing. Each unit shall be subjected to five positive and five negative polarity discharges at each voltage level
40、using direct contact discharge for a total of 200 pulses. There shall be a minimum of 5 seconds between discharges as detailed in SAE procedure J1113-13 using a 150 picofarad capacitor through a 500 ohm resistor at 4, 8, 15, 20, 25 Kilovolt levels, via each of the following connections: 1) pin to pi
41、n or lead to lead 2) pin A or lead A to body 3) pin B or lead B to body 4) shorted pins or leads to case 3.2.1.9 Electromagnetic Interference (EMI) The initiator shall not degrade and shall not deploy when exposed to large-signal RF energy over 10 to 1500 Megahertz. RF Absorbed Power Withstand shall
42、 be 3 watts for a duration of 60 seconds. Pin type initiator shall be tested with a standard RF filtered connector as specified by the Vehicle Engineering Organization and intended for production. The type and part number of the connector shall be reported as part of the test configuration. Note: Se
43、e Appendix G for detailed procedure. SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 9 - 3.2.1.10 Transient Pulse The initiator shall not degrade and shall not deploy when subjected to the transient pulse (see detail in Appendix A Figure 3 of this specification
44、) at 250 Hz for 24 hours. 3.2.2. Mechanical 3.2.2.1 Overall Dimensions The initiators overall dimensions and external configuration shall conform to the requirements set forth in the standard interface drawing (Appendix F) or by the applicable airbag inflator or pretensioner manufacturer. 3.2.2.2 As
45、sembly 3.2.2.2.1 Pin-Type Initiator The initiator assembly shall include an EED and pins to provide an interface for an integral electrical connector containing an EMI suppression device in accordance with SAE/USCAR-2 “Standard for Automotive Electrical Connection Systems“. 3.2.2.2.2 Leadwire Initia
46、tor The initiator assembly shall include an EED and EMI suppression device and leadwires. 3.2.2.2.3 Hermetic Seal The initiator pyrotechnic chamber assembly shall pass a gross and fine Helium leak (or equivalent test) check at A3B C13C2 D E F G H Section Test Title Quantity 320 90 180 10 60 30 20 10
47、 60 III. POST CONDITIONING INSPECTIONS - Visual Inspection (Post Conditioning) 180 10 60 30 20 10 60 3.2.1.1 Bridge circuit Resistance 180 10 60 30 20 10 60 3.2.1.2 Insulation Resistance 180 10 60 30 20 10 60 - Thermal Transient (Initiator Suppliers Test) 180 10 60 30 20 10 60 - Radiographic Inspect
48、ion (Suppliers Test) 180 10 60 30 20 10 60 3.2.2.4.2 2Lead Strength 90 180 10 60 4.7.1 IV. DEPLOYMENT TESTS -40C 30 20 10 20 10 5 3 20 +23C 30 20 20 10 10 4 20 3.2.3 & 4.7.2 Function Time, Ballistic Output +85C 30 20 20 10 5 3 20 -40C 50 33.2.1.3 All Fire (2ms Constant Current Bruceton Tests) +23C 5
49、0 50 -40C 50 33.2.1.4 All Fire (2ms Constant Current Bruceton Tests) +23C 50 50 +23C 50 33.2.1.5 No Fire +85C 50 -40C 10 10 3.2.1.6 High Current (40 amp) +85C 10 10 3.2.2.5 Visual Inspection (post deployment) 320 90 180 10 60 30 20 10 60 SAE/USCAR-28 Issued June 2005 TITLE: Initiator Technical Requirements and Validation - 28 - APPENDIX D BRUCETON METHOD Introduction A prerequisite to valid reliability estimation of an electro-explosive device (EED) is a sensitivity test program carefully chosen a
