1、STANDARD FOR D.C. BRUSH MOTOR HVAC BLOWERSThe 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 c
2、ompliance 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.Copyri
3、ght 1999, USCARAll rights reserved. Printed in U.S.A.Issued February 1999SAE/USCAR-6QUESTIONS 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 SCOPE2.0 REFERENCE DOCUMENTS AN
4、DDEFINITIONS2.1 Applicable Drawings/Specifications2.2 Application Specific Requirements2.3 Test Categories3.0 OUTLINE4.0 GENERAL REQUIREMENTS4.1 Record Retention4.2 Sample Documentation4.3 Hazardous Material Control4.4 Materials and ProcessStandards4.5 Default Test Conditions4.6 Equipment4.7 Measure
5、ment Resolution4.8 Equipment Calibration4.9 Customer Notification of Non-conformance4.10 General Endurance Objective4.11 Design Verification4.12 Production Validation4.13 Failure Mode and Effect Analysis (FMEA)4.14 Quality Control4.15 Jury Evaluation5.0 PERFORMANCE REQUIREMENTS/TESTS5.1 Motor Perfor
6、mance5.2 Noise5.3 Demagnetization5.4 Axial Force5.5 Electromagnetic Compatibility6.0 ENVIRONMENTAL REQUIREMENTS/TESTS6.1 Random Vibration6.2 High Temperature Soak6.3 Salt Spray6.4 Dust7.0 DURABILITY REQUIREMENTS/TESTS7.1 Endurance8.0 RELIABILITY REQUIREMENTS/TESTS8.1 Production Validation TestingReq
7、uirements8.2 In-Process Validation TestingRequirements9.0 ELECTRICAL CONNECTORREQUIREMENTSAPPENDICESA DESIGN VERIFICATION TESTSB NEW AND CARRY-OVER PRODUCTIONVALIDATION TESTSC IN-PROCESS VALID ATION TESTSD LESSONS LEARNEDE GLOSSARY OF TERMSSAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTO
8、R - HVAC BLOWERS-2-1.0 SCOPEThis standard sets forth the performance and durability requirements for 12-volt, D.C. brush-typeelectric motors used for automobile Heating, Ventilation, and Air Conditioning (HVAC) blowersand outlines Production Validation and Continuing Conformance testing.2.0 REFERENC
9、E DOCUMENTS AND DEFINITIONSRequirement Hierarchy In the event there is a conflict between this standard, and any drawings/specifications, prioritize requirements as follows:1st - Applicable drawing(s)2nd - Application Specific Requirements3rd - USCAR standard4th - Other related standards or specific
10、ations2.1 Applicable Drawings/SpecificationsThe applicable drawings/specifications for the HVAC motor shall contain or reference the following:All dimensional requirementsPerformance requirements/conditionsSupplier part numberDirection of RotationPositive terminal identificationReference to applicab
11、le portions of this and other standardsThe typical mating connector and terminalsFederal Motor Vehicle Safety Standard (FMVSS) RequirementsWherever possible the applicable electrical connector should be used in conducting the test sequences contained in this document to simulate actual in-vehicle co
12、nditions.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.2.2 Application Specific RequirementsThe application specific requirements shall identify the para
13、meters that differ from the general specifications in this document. The application specific requirements may or may not be an integral part of the applicable drawings.SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-3-2.3 Test Categories2.3.1 Design Verification TestsDe
14、sign Verification tests are frequently used to evaluate specific areas of the design. They are a tool for evaluating design alternatives, proposed improvements, cost reduction proposals, or determining root causes of field problems.2.3.2 Production Validation TestsProduction Validation tests are the
15、 acceptance tests for production part approval.2.3.3 In-Process Validation (Continuing Conformance)TestsIn-process Validation tests are tests to ensure continuing conformance of production samples to the specified requirements.3.0 OUTLINEThis engineering standard is a supplement to the released moto
16、r drawings/specifications and any applicable HVAC subsystem drawings/specifications. Details of test procedures are provided where necessary. Tests in each section shall be performed in the stated sequence. A glossary of terms and details for selected test fixtures and equipment are provided in this
17、 standard.4.0 GENERAL REQUIREMENTS4.1 Record RetentionRecord retention shall comply with PPAP and QS-9000.4.2 Sample DocumentationEngineering test samples shall be identified by part number, serial number, and motor build dateunless otherwise noted.4.2.1 Required Data PackageThe required data packag
18、e for the appropriate level of submission is to be included with the sample submission to the customer. The data package shall include the applicable test data for each performance parameter, and the serial number of each part in the submission.4.2.2 Design Verification SamplesDesign Verification sa
19、mples are prototype motors representing the production intent design.Sample sizes are given in Appendix A.SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-4-4.2.3 Production Validation SamplesProduction Validation samples are defined as motors taken from a 300-unit minimu
20、m production run generated from production tools and processed before the first volume shipment. Sample sizes are given in Appendix B.4.2.4 In-Process Validation (Continuing Conformance) SamplesIn-Process Validation samples are motors randomly selected for inspection from lots that have been subject
21、ed to all normal high volume production processing, including final packaging.An inspection lot is defined as the total number of motors of a given basic design produced in one shift. An inspection lot may be divided into two or four sublots at the suppliers option.Each sublot shall be inspected in
22、accordance with the Continuing Conformance tests described in Appendix C.If variations of a basic motor design (termination, finish, etc.) are produced in a lot (or sublot), the sample size will remain the same but shall include as many of the variations as possible.In-Process Validation samples are
23、 also subject to certain reliability tests. See Appendix C.4.3 Safety/Environmental RequirementsWhen required, products and processes used by suppliers to manufacture products shall conform to employee and consumer health, employee safety, and environmental requirements contained in the customers dr
24、awings/specification.4.4 Materials and Process StandardsSuppliers are expected to subscribe to appropriate Materials and Process Standards that are called out by the customer. The supplier shall not change any material or process requirements subsequent to Design Verification approval without the wr
25、itten consent of the customers releasing department.Suppliers shall use the most recent versions of any applicable reference documents or standards.4.5 Default Test ConditionsWhen specific test conditions are not given either in the product design specification or elsewhere in this standard, the fol
26、lowing basic conditions shall apply:a) Room Temperature = 23 2C (73 4F)b) Atmospheric Pressure = 650 - 800 mm Mercuryc) Voltage = 13.5 0.1 vdcSAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-5-4.6 EquipmentUnless otherwise specified, Table 1 represents recommended equipme
27、nt.TABLE 1 - Equipment4.7 Measurement ResolutionMeters and gages used in measurements of the test sample shall be capable of measuring to one tenth of the specified resolution. For example, even though a 0.1 mm and 0.10 mm might be the same dimension, calipers capable of 0.01 mm resolution may be us
28、ed to measure the first dimension but a micrometer with 0.001 mm resolution is required to measure the second dimension.4.8 Equipment CalibrationInstrumentation shall be calibrated according to QS-9000.SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-6-4.9 Customer Notifi
29、cation of NonconformanceShould a test nonconformance occur, notify the customer to determine what further actions are required.4.10 General Endurance ObjectiveThe objective of the design and construction of the blower motor is to be capable of operating in its intended environment and application, w
30、ithout malfunction, for at least 4000 hours on the agreed cyclic speed schedule.4.11 Design VerificationThe supplier shall conduct Design Verification tests on samples during each phase of motor development (as defined by the customer) according to Appendix A.4.12 Production ValidationThe supplier s
31、hall conduct Production Validation testing on production samples according to Appendix B before the first volume shipment.4.13 Failure Mode and Effect Analysis (FMEA)Within 90 days of source selection, the supplier shall prepare a preliminary design FMEA and review it with the customer. A customer-a
32、pproved design FMEA shall be required before program tooling release. The supplier shall complete a Process FMEA and review it with the customer before the start of Production Validation testing.4.14 Quality ControlA supplier who furnishes finished parts is responsible for the quality of all compone
33、nts of the shipped assembly, 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. If required by the customer, an itemized list of important characteristics shall be submitted w
34、ith motor approval samples.Any change to the components, processes, materials, or subcontracted suppliers requires prior customer approval.100 Percent Production Testsa) Functionally test blower motors at room temperature at conditions which meet or correlate to those shown on the applicable drawing
35、/specification.b) Subjectively evaluate the blower motors for noise. The minimum evaluation condition shall be a voltage sweep of the motor at no load throughout its low speed/high speed range; the sweep shall have a minimum duration of 6 seconds. A suitable listening environment is required. The mo
36、tor shall not be noisier than a noise master motor or equivalent recording.SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-7-4.14 (Continued):c) Observe the commutation wave form and confirm that the wave form is characteristic of a population of motors known to be in go
37、od working order.4.15 Jury EvaluationIf a jury evaluation is conducted for specific or overall noise characteristics, the following rating scale, Table 2, is recommended with a minimum acceptable level specified by the customer.TABLE 2 - Noise Rating Scale5.0 PERFORMANCE REQUIREMENTS/TESTS5.1 Motor
38、Performance5.1.1 Procedure1. Mount the motor on a dynamometer capable of absorbing the output power of the motor on a continual basis, as well as being able to exceed its stall torque.2. Perform the following as indicated on the applicable drawing/specification:a) Adjust the cooling air flow (5 CFM,
39、 unless otherwise specified).b) Apply regulated voltage to motor terminals.c) Adjust load for proper torque.NOTE: The tolerances for the values used in step 2 are as follows:Air Flow 0.50 CFM, Voltage 0.05 vdc, Torque 0.5 oz. in. (.0035 Nm)SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTO
40、R - HVAC BLOWERS-8-5.1.1 (Continued):3. Record the motor terminal voltage, current, speed, and torque after thirty (30) minutes of operation or longer, if necessary, to achieve temperature stabilization.5.1.2 Acceptance CriteriaEach motor shall be capable of meeting the current, speed, and torque re
41、quirements at the operating conditions shown on the applicable drawing/specification when tested according to section 5.1.5.2 Noise Tests5.2.1 Quantitative Measurement (Room Ambient)5.2.1.1 Procedure1. Test the motor in a quiet room, with ambient noise level less than 30 dB(A).2. Suspend the motor f
42、rom the mounting plate by nonmetalic strings or mount on a suitably designed fixture. Ensure that the motor is oriented to simulate in-vehicle position.Achieve a motor no-load speed of 1500 rpm 10 rpm by applying the necessary voltage to the motor terminals. The total running time for each motor sha
43、ll not be longer than10 minutes.3. Measure the average sound pressure level in dB(A) at each of the following three locations: 10 cm axially from the shaft extension end of the motor, 10 cm radially to the side centered on the frame of the motor and 90 from any cooling hole, and 10 cm axially to the
44、 rear of the motor.4. Ensure that the free space around the motor is not less than 61 cm (24 in.), except for the noise meter and its stand.5.2.1.2 Acceptance CriteriaRefer to applicable drawing/specification for the maximum allowable motor noise. If no maximum is specified, the limit shall be 48 dB
45、(A) for the shaft extension end of the motor, and 45 dB(A) for each of the other two locations.5.2.2 Subjective Noise Evaluation Room Ambient Test5.2.2.1 Procedure1. Test the motor in a quiet room with ambient noise level less than 30 dB(A).2. Suspend the motor from the mounting plate by nonmetalic
46、strings or mount on a suitably designed fixture. Ensure that the motor is oriented to simulate in-vehicle position.3. Subjectively evaluate the noise of the motor under no load throughout its speed range.SAE/USCAR-6 ISSUED FEBRUARY 1999STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS-9-5.2.2.2 Acceptanc
47、e CriteriaThere shall be no objectionable noises such as ticks, howls, chirps, squeals, etc.5.2.3 Subjective Noise Evaluation Low-Temperature Test5.2.3.1 Procedure1. Place the motor in an environmental chamber at -40C 2C (-40F 4F) and allow it to stabilize for a minimum of 4 hours.2. Conduct a subje
48、ctive noise evaluation by applying 12 to 14 volts to the motor terminals; subsequently, reduce the voltage to sweep through the entire operating speed range over a period of one minute. Subjective evaluation may be conducted by either direct or correlated instrumented methods.5.2.3.2 Acceptance Crit
49、eria Low-Temperature TestThere shall be no objectionable noises, such as bearing squeal, at start-up or during the remainder of the test.5.2.4 Chirp Test (Room Ambient)5.2.4.1 ProcedureNote: The fixture for this test may be a simple rack or stand that supports the motor.1. Install the proper blower wheel for the application and mount the motor and wheel on a fixture representative of the in-vehicle orientation.2. Run motor continuously for 1000 hours at 1000 rpm 200 rpm.3. Subjectively evaluate each motor for 30 seconds for the presence of chirp at l
