1、 Specification for Testing Automotive Lamp Assemblies SAE/USCAR-34 October 2009 ISBN: 978-0-7680-3551-9 _ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United States Council for
2、 Automotive Research (USCAR) 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 no
3、t it is applicable for their purposes. Copyright 2009 USCAR Printed in U.S.A. All rights reserved. QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP A
4、SSEMBLIES SUMMARY OF CONTENTS 1. SCOPE* 2 2. SAFETY PRECAUTIONS . 2 2.1 High Voltage Identification/Labeling . 2 3. REFERENCE STANDARDS . 3 4. DIAGRAMS AND DEFINITIONS 3 4.1 Appendices . 3 5. GENERAL REQUIREMENTS . 3 5.1 Record Retention 3 5.2 Sample Documentation and Retention . 4 5.3 Power Sources
5、 4 5.4 Equipment Tolerances 4 5.5 Measurement Accuracy 5 5.6 Test Repeatability and Calibration 5 5.7 Test Default Conditions . 5 5.8 Test Failure Procedure . 5 5.9 Control Plans . 5 5.10 Reliability Programs and Methods 5 5.11 Hazardous Material Restriction . 6 6. ENVIRONMENTAL TESTS 6 6.1 Internal
6、 Heat 6 6.2 Vibration with Temperature Cycling 7 6.3 Pressure Test (Lens Attachment Burst Test) 9 6.4 Pressure Test - Lamp In-Line Conformity . 10 6.5 Current Decay Light Up Test 11 6.6 Leakage Test (Dunk Test) 11 6.7 Resonant Frequencies 12 6.8 Fluid Compatibility . 12 6.9 Condensation 13 7. DURABI
7、LITY . 14 7.1 Salt Spray 14 7.2 30 Day Light-Up Test 15 7.3 Bi-Function High Beam Actuator Durability - Hot Ambient Temperature Transition Rates, Lamp Function Cycling. 5. Run vibration 10(L/A). 6.4 Pressure Test - Lamp In-Line Conformity This first half of this test is used to develop the minimum a
8、cceptance pressure value for the In-Line Conformity test. This test shall not be run on unsealed passenger compartment mounted lamps or sealed lamps that do not have designed openings. 6.4.1 Test and Measurement Apparatus Regulated Pressure source recommend orifice restrictor to limit air flow after
9、 failure occurs. Pressure Gage recommend gage that maintains max pressure attained for recording purposes. 6.4.2 Determining In-Line Pressure Test Value 1. Select 14 lamps of each unique part number representative of one shifts production. 2. Set lamps aside to allow lamp sealants to cure. 3. After
10、sealant is cured, install all lamp sockets and plug all vent holes except one. 4. Place lamp in enclosed chamber to protect test individuals. 5. Connect pressure source and gage to lamp using the unused vent hole. If the lamp does not have a vent hole, the socket opening may be used. 6. The lamp sha
11、ll not have any light sources illuminated during or 30 minutes prior to applying pressure. 7. Measure the total weld length (L) in inches. 8. Calculate the area (A) encased by the weld length in square inches. 9. Calculate the maximum test pressure (Pmax) in psi using the simplified formula Pmax=10(
12、L/A). 10. Increase pressure, starting at Pmin=2(L/A) in 20 equal steps, psi minimum step, to Pmax, dwelling for 10 seconds after each increment. 11. Stop test immediately if leak occurs or Pmaxis reached. 12. Turn off pressure. 13. Record pressure at the time leakage occurred. 14. Calculate and reco
13、rd the lower control limit to 3 sigma. 15. Inline conformity pressure shall be set to 80% of the 3 sigma lower control limit or 1 psi (6.9kPa), whichever is greater. 6.4.3 Determining Conformity Leak Rate Value 1. Select 30 lamps of the same part number representative of one shifts production. 2. Se
14、t lamps aside to allow lamp sealants to cure. 3. After sealant is cured, connect pressure source and gage to lamp. 4. The lamp shall not have any light sources illuminated during or 30 minutes prior to applying pressure. 5. Apply pressure defined in step 15 above to the lamp. 6. Turn off pressure. 7
15、. Monitor and record rate at which pressure decays in Standard cm3/min, over the same period as the 100% in-line conformity test. 8. Using the data recorded in step 7, calculate and record the upper control limit to 3 sigma. SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEM
16、BLIES - 11 - 6.4.4 Acceptance Criteria Pressure decay calculated in step 8 shall be used as the upper control limit for 100% In-line conformity testing. Pressure decay rate upper control limit used shall not exceed 35 Standard cm3/min. The lamp shall not have any light sources illuminated during 100
17、% In-line leak conformity testing. A known failure of the dunk test shall be put through this test to verify the integrity of this test and that a leak is detected If during production testing 6.5 Current Decay Light Up Test Current decay testing captures multiple values during the turn-on phase and
18、 compares the change, or rate of change, with expected norms. It can be a useful screening test to help find discrepant bulbs, “Leakers” that may be prone to early failures. This test is not to be run on Halogen bulbs. 6.5.1 Test and Measurement Apparatus Power Supply Current Measuring capability at
19、 each bulb function pin Strip Chart recorder 6.5.2 Procedure 1. Connect power, ground and signal functions to the lamp 2. Apply 12.8 Vdc to each non-halogen bulb function 3. Monitor current draw at each function using strip chart or equivalent recorder for 5 seconds +/-0.5 seconds 4. Take 4 measurem
20、ents after power is applied at 1.0 second, 1.5 seconds, 2.0 seconds and 3.0 seconds. 6.5.3 Acceptance Criteria Slope of decay shall be less than 20ma/sec averaged over the four readings 6.6 Leakage Test (Dunk Test) This is a water submersion test to visibly verify the lamp assembly does not leak. 6.
21、6.1 Test and Measurement Apparatus Water Tank filled with tap water Regulated Pressure source Pressure gage 6.6.2 Procedure 1. Install all mated vehicle connectors and install all lamp sockets, except one. Plug all vent holes. 2. Connect pressure source to lamp assembly through the one un-installed
22、lamp socket opening. 3. Increase pressure to 1 psi. (6.9 kPa) 4. Completely submerge lamp assembly in the water. 5. Move lamp under water to eliminate any trapped air due to lamp geometry. 6. Begin a 1 min inspection after exterior trapped bubbles are eliminated. 6.6.3 Acceptance Criteria There shal
23、l be no bubbles that emerge from the lamp while it is submerged. The lamp shall not allow water intrusion. SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEMBLIES - 12 - 6.7 Resonant Frequencies Resonant Frequency IEC 60068-2-64 Vibration, broad band random and guidance 6.7.
24、1 Measurement Apparatus Resonant Frequency Equipment Table Equipment Requirements Closed loop dynamic vibration equipment and auxiliary controller capable of vibrating in sinusoidal mode Variable from 10 - 2000 Hz with tolerance of 4.0 dB and min. of 5Gs Accelerometer one rigidly mounted to the fixt
25、ure base and one rigidly mounted to the mid point of the lamp lens Fixture to mount the lamp assembly to the vibration table The fixture resonance must be 1000Hz 6.7.2 Procedure 1. Mount the lamp to the fixture, using the lamp attachment points and appropriate fasteners. Mounting of the lamp is to b
26、e representative of in car position. 2. Mount the accelerometer to the lamp lens. 3. Sweep the range from 10 to 500 Hz and back to 10 Hz (Minimum 1 minute nominal each direction) with a 0.5 g vertical input. 4. Use a recorder to identify all the resonant frequency ranges and peaks. 5. Record the ran
27、ge, both the starting and stopping frequencies, of each resonant harmonic according to section Record Retention. For purposes of this test, resonance is defined when the accelerometers show a peak (Ratio of Lamp accelerometer to Fixture accelerometer 1.5). 6. A graph depicting the resonant frequenci
28、es is the preferred record format. 7. For AFS systems, test at nominal swivel position, most inboard swivel position, and most outboard swivel positions. 6.7.3 Acceptance Criteria Resonance of lamp must be greater than 50 Hz. 6.8 Fluid Compatibility The objective of this test is to evaluate the inte
29、raction between common under-hood chemicals and the lamp. SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEMBLIES - 13 - 6.8.1 Test and Measurement Apparatus* Each of the test fluids as itemized in MVSS108 Chemical Resistance and those listed below. Fluid Table FLUID TYPE FL
30、UID DESCRIPTION* STABLIZATION TEMPERATURE C Brake Fluid SAE RM66-XX* 50 5 Oil ISO 1817, Oil No. 2 50 5 Gasoline ISO 1817, liquid C 25 5 Engine Coolant 50% ethylene glycol + 50% distilled water 100 5 Automatic Transmission Fluid Dexron III 50 5 Windshield Washer Solvent 50% Isopropyl Alcohol + 50% Wa
31、ter 25 5 Power Steering Fluid ISO 1817, Oil No. 3 50 5 Diesel Fuel 90% ISO 1817, Oil No. 3+ 10% P-Xylene 25 5 E85 Ethanol Fuel 85% Ethanol + 15% ISO 1817 liquid C 25 5 Tar Remover 45% Xylene + 55% Petroleum base mineral spirits 25 5 Engine Cleaner Tital Bafal Parafin wax CH4, Ethylene Glycol, Benzen
32、e, detergent 25 5 Grease Petroleum base 25 5 *Solutions are determined as percent by volume *Use latest available SAE reference fluid See appendix F for suggested fluid source list6.8.2 Procedure Run procedure as described in FMVSS 108, Section S8.3 6.8.3 Acceptance Criteria* No delamination, fractu
33、res, deterioration of the lens or bonding materials, or distortion of the plastic, or color fading shall be exhibited after the test has been completed. The labeling must remain legible. 6.9 Condensation This test determines the resistance capability of the lamp to forming condensation on the interi
34、or surfaces of the lamp. 6.9.1 Test and Measurement Apparatus Environmental chamber capability to subject the lamp assembly to water spray and separate cold (20 C 4 C, 80% -0% / + 20% RH) and hot areas (80 C 4 C 20% 10% RH Ramp 2 C/minute) Baffle, sealed to lamp, separating front and rear of lamp at
35、 exterior interface. Water spray nozzle(s) to fully cover test lamp(s) with water using a GG-25 full cone nozzle 4.7gpm (40psi) More than one may be required to cover the entire forward facing lens surface. Power Supply 6.9.2 Procedure 1. Install lamp assembly in environmental chamber “in-car” posit
36、ion with lens side facing the water spray nozzle(s) Tenside (10 to 40)%, Complex builder (0 to 10)%, Meta silicate (0 to 1)%, Water (54 to 84)% Three samples or two pair of handed lamp samples. Lamps require production representative molding stress levels of the bonded materials and production repre
37、sentative bonding between the joints to be tested. Annealing shall also be representative of the production process. 7.7.2 Procedure 1. For polycarbonate lenses prepare a solution of 34% ethyl acetate in methanol. For acrylic lenses, prepare solutions of 50% ethyl alcohol in water and 50% methyl alc
38、ohol in water. 2. Apply solvent to weld joint with a cotton ball or cheesecloth and thoroughly saturate the joint and the lens 50 mm from the joint. Allow to evaporate. NOTE: Use a well ventilated area and personal protective equipment to apply solvent. 7.7.3 Acceptance Criteria The plastic surface
39、shall not be etched. No cracks may form within three minutes of application on polycarbonate lenses using methyl acetate in methanol and within 4 minutes of application on acrylic lenses using ethyl alcohol and methyl alcohol. SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASS
40、EMBLIES - 20 - 7.7.4 Procedure Isopropanol Resistance. 1. When installed in their vehicle position, the lamps shall be sprayed three times at intervals of 10 minutes, e.g., with a beaked bottle containing a 50% solution of isopropanol and water. Spray in such a way that all the non-sealed areas, in
41、particular welds and adhesive interfaces are moistened appropriately. 2. For lamps with PC lenses, run an additional test using a degreasing agent with the following composition: Saturated hydrocarbon (paraffin) 97 1%. Aromatic hydrocarbon 1%. Emulsifier 3 1%. NOTE: The degreasing agent shall be use
42、d as concentrate only (Dont add water). 7.7.5 Acceptance Criteria The test samples shall not show any visible changes or cracks after 24 h. 7.7.6 Procedure Lamps with Acrylonitrile Butadiene Styrene/Polycarbonate (ABS/PC) Housings. 1. Mount lamp assembly in a car like test rig or on a complete car i
43、n a temperature chamber. 2. Raise chamber temperature to +70 3C for a front lamp and to +50 3C for a rear lamp. 3. Allow lamp temperature to normalize with the chamber temperature. 4. Using an alkaline agent (auto shampoo), prepare the test fluid to a ratio of 10% of alkaline agent and 90% water. 5.
44、 Brush the test fluid on the lens, housing and weld joints five times at one-hour intervals. 6. One (1) hour after the last treatment, the lens shall be rinsed with 15 5C water. 7.7.7 Acceptance Criteria 1. No cracks, deformations or other defects allowed within 72 h after test. 7.8 Photometrics and
45、 Aim All photometric testing and Beam Aim shall be per FMVSS 108, appropriate ECE regulations, or relevant regulations of the target market. 7.9 Beam Aim over Temperature Run ECE R112, Annex 4 Tests. This test shall be run on all headlamp assemblies regardless of target market. 7.9.1 Test and Measur
46、ement Apparatus Power Supply Photometric Measuring Equipment 7.9.2 Procedure Test per ECE R112, Section 2 7.9.3 Acceptance Criteria Must meet the test results of Section 2.2 of ECE R112 SAE/USCAR-34 Issued 2009-10 SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEMBLIES - 21 - 8. QUALITY/RELIABILITY PRO
47、GRAMS 8.1 Reliability Growth 8.2 Ongoing Quality Improvements 8.3 Quality/Reliability Improvement Tools 9. FIELD RETURN PROGRAM Suppliers must establish and implement a procedure for analyzing and correcting field return defects. Suppliers and customers will establish the proper frequency of an anal
48、ysis. Suppliers must use Pareto charts to help develop the detailed plans that are required to correct the most frequently occurring problems. Actual analysis and corrective action plans must be available upon request by the customer. 9.1 Design Failure Mode Analysis (DFMA) The DFMA procedure analyz
49、es the design of each piece part and is used to develop Key Product Characteristics. Suppliers must create a DFMA for each lamp part number supplied to the customer. These analyses are “living“ documents that should be modified as knowledge about the product and process is accumulated. Once Product Part Approval Process (
