1、Comments, suggestions, or questions on this document should be addressed to: U.S. Army Tank-automotive and Armaments Command, ATTN: AMSRD-TAR-E/268, MS-268, Warren, MI 48397-5000 or emailed to dami_standardizationconus.army.mil. Since contact information can change, you may want to verify the curren
2、cy of this address information using the ASSIST Online database at http:/assist.daps.dla.mil AMSC N/A FSC 6220 INCH-POUND MIL-PRF-32243 12 March 2009 PERFORMANCE SPECIFICATION LIGHT EMITTING DIODE (LED) MILITARY DRIVING HEADLAMP This specification is approved for use by all Departments and Agencies
3、of the Department of Defense. 1. SCOPE 1.1 Scope. This standard establishes, unless otherwise specified, the minimum requirements for engineering acceptance for the operation, performance, and reliability of what is commonly termed as the seven (7) inch round Forward Lighting Driving Headlamp, for m
4、ilitary vehicles, with Light Emitting Diodes (LED) as the base of their technology for illumination and compliance with applicable SAE, United States FMVSS, Canadian CMVSS, MIL Standards and Military Performance Specifications. The lamps will be designed to conform to the photometry, mechanical, ele
5、ctrical and special performance requirements referenced within this document where applicable. Each production part need not be tested to the specified validation tests as proof of compliance. The headlamp may be supplied as a replacement part or as a component in a finished assembly. 1.2 Classifica
6、tion. The LED Military Driving Headlamp will be the following types and styles. Type I Lamp with Bucket Style 1- Lamp w/ Green Bucket (Short Mount 3/8” Mounting Stud Length) Style 2 - Lamp w/ Tan Bucket (Short Mount 3/8” Mounting Stud Length) Style 3 - Lamp w/ Black Bucket (Short Mount 3/8” Mounting
7、 Stud Length) Style 4- Lamp w/ Green Bucket (Long Mount 3/4” Mounting Stud Length) Style 5 - Lamp w/ Tan Bucket (Long Mount 3/4” Mounting Stud Length) Style 6 - Lamp w/ Black Bucket (Long Mount 3/4” Mounting Stud Length) Type 2 Lamp Only Provided by IHSNot for ResaleNo reproduction or networking per
8、mitted without license from IHS-,-,-MIL-PRF-32243 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents in other sections of this specification or recommended for additional informa
9、tion or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they will meet all specified requirement documents cited in sections 3 and 4 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifi
10、cations, standards, and handbooks. The following specifications, standards, and handbooks form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and
11、 Standards (DoDISS) and supplement thereto, cited in the solicitation (see 6.2). DEPARTMENT OF DEFENSE STANDARDS MIL-STD-461 - Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment FEDERAL STANDARDS FED-STD-595/34083 Green, Flat or Lusterless FED-ST
12、D-595/33446 Yellow, Flat or Lusterless FED-STD-595/37030 Miscellaneous, Flat or Lusterless (Copies of these documents are available online at http:/assist.daps.dla.mil/quicksearch/, or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) FEDERA
13、L MOTOR VEHICLE SAFETY STANDARDS FMVSS 571.108 - Code of Federal Regulations (CFR), Title 49, Chapter V National Highway Traffic Safety Administration (NHTSA), Department of Transportation (DOT), Part 571 Federal Motor Vehicle Safety Standards (FMVSS) Standard No. 108: Lamps, reflective devices, and
14、 associated equipment FMVSS 571.7 - Code of Federal Regulations (CFR), Title 49, Chapter V National Highway Traffic Safety Administration Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32243 3 (NHTSA), Department of Transportation (DOT), Par
15、t 571 Federal Motor Vehicle Safety Standards (FMVSS) (Copies of the above document is available from the Code of Federal Regulations from their website. http:/www.access.gpo.gov/nara/cfr/waisidx_06/49cfr571_06.html). 2.2.2 Other Government documents, drawings, and publications. The following other G
16、overnment documents, drawings, and publications form a part of this specification to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation. DRAWINGS 12480561 - WATERPROOFNESS REQUIREMENT FOR AUTOMOTIVE ELECTRICAL COMPONENTS LED HEADLAMP, 24 V, HIGH i
17、ncluding the electrical plug connection, when immersed in a 5% salt water solution for 120 hours minimum. 3.8.5 (5%) Salt Water Injection. The integrity of the lamps functionality shall be maintained against severe corrosion and moisture due to cracked or broken casings (lenses, housings, etc.) when
18、 a 5% salt water solution is injected inside an energized lamp for 18 hours. 3.8.6 Installation Harness Shock. Shall be tested according to SAE J1455. 3.9 Operating Voltage. The LED Headlamp shall meet the following requirements. 3.9.1 Variable Voltage Lamp. Operational DC Voltage: The LED external
19、lamps shall have an operational design voltage range of 10.0 VDC to 30.0 VDC. Lamps may be operational outside the stated design voltage range. 3.9.2 Single Voltage Lamp. Lamp components may be designed for a specific operational vehicle voltage range, such as 10V - 14 VDC for 12 V systems applicati
20、on or 22V - 30 VDC for 24 V systems applications. Lamps may be operational outside the stated design voltage range. 3.9.3 Reverse Polarity. Individual Lamp functions shall meet SAE J2139 voltage regulation for 12 volt or 24 volt lamps, or both for variable voltage lamps. 3.9.4 Jumper Start. Individu
21、al Lamp functions shall meet SAE J2139 jumper start test for 12 volt or 24 volt lamps, or both for variable voltage lamps 3.10 Additional SAE Electrical Tests. The LED Headlamp shall comply with the following SAE Electrical tests, on the high and low beam functions. 3.10.1 Electrostatic Discharge (E
22、SD). The LED Headlamp shall comply with +/- 4 kV level in both the operational mode, with 28.0 volts or 12.8 volts applied for single voltage lamps or both for variable voltage lamps and the non-operational (no voltage applied) handling mode. 3.11 Recommended Field Testing. Lamps to be durability fi
23、eld tested per the table below without failure or deterioration: Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32243 10 TABLE I: Recommended Field Testing Environment Location Duration Cold Cold Regions Test Center - Alaska 3 months minimum
24、 during extreme cold period of year Desert Yuma Proving Grounds - Arizona 3 months minimum during extreme hot period of year Temperate Aberdeen Proving Grounds Maryland 3 months minimum Tropical Tropic Regions Test Center - Panama 3 months minimum * Recommended vehicle-specific field testing in each
25、 extreme environment is very effective in finding weaknesses in the design not otherwise revealed by laboratory or bench testing. 4. VERIFICATION 4.1 Classification of inspection. Verification of meeting the requirements shall be in a documented form and the format may be of the choosing of the LED
26、Military Driving Headlamp manufacturer IAW lighting industries practices. All lamps used to perform testing qualifications and verification shall be kept by the respective lamp manufacturer for a minimum period of six months after completing all required testing parameters. Any and all failures that
27、 may arise from any required testing shall be recorded in the documentation and summarized in a separate test failure document called “Failed Test Item Parameter”. 4.1.1 First article inspection. First article inspection of the LED Military Driving Headlamp shall be produced prior to the manufacturi
28、ng of the item in production quantities. A quantity of fifty (50) production representative LED Headlamps shall be used for both destructive and non-destructive testing requirements. Thereafter, random testing if required will be performed in the same manor. 4.2 Design, Materials and Manufacturing p
29、rocesses. The lamps shall meet the operating, interface, support and ownership and environmental requirements specified in solicitation. 4.2.1 Recycled, recovered or environmentally preferable materials. A bill of materials that meet or exceed the operational and maintenance requirements shall be pr
30、ovided with the verification documents. 4.2.2 Materials. A bill of materials that meet or exceed the operational and maintenance requirements shall be provided with the verification documents. Lens materials shall comply with SAE J576 as referenced in FMVSS 571.108 except for Luminous Transmittance.
31、 Evidence of fungus resistance shall be provided with verification documents. If radioactive materials are Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32243 11 used, evidence shall be provided that no item, part or assembly contains radio
32、active materials in which the specific activity is greater than 0.002 microcuries per gram or total activity per item exceeds 0.01 microcuries. 4.2.3 Materials and Military LED Lamp Operational Temperatures. Evidence that materials used in the LED lamp finished assemblies for operational temperature
33、 range, in degrees, of - 50 C to 70 C, + or - 5 C, without any adverse physical or dimensional properties shall be provided. 4.3 Design and Construction. Evidence shall be provided demonstrating form, fit, function and backward compatibility with previously produced vehicle lamps. 4.3.1 Dimensional
34、Requirements. Evidence shall be provided demonstrating compliance that the LED Headlamp and all electronics necessary for operation shall be contained within the dimensions specified in SAE J1383 as specified by FMVSS 571.108. 4.4 Identification Codes, Markings and Notices. Evidence shall be provide
35、d demonstrating compliance with the marking requirements IAW SAE J759 for the functions specified by FMVSS 571.108 in the production year of original certification. Also evidence shall be provided demonstrating permanent marking of the normal operating voltage on any component of the lamp. 4.5 FMVSS
36、 571.108 Requirements. The Military LED Headlamp shall meet the SAE Recommended practices and other requirements specified by FMVSS 571.108 in the production of the original certification. 4.5.1 Photometry. (10) production level parts shall comply with Figure 27-1 or Figure 17-1 Photometric Test Poi
37、nt Values for Mechanical Aim Headlighting Systems for Upper and Lower Beams as specified by FMVSS 571.108. The test lamp shall be warmed up for 30 minutes or to photometric stability (+/- 3% within any 15 minute period) at room temperature (75 F). Test voltages shall be 12.8 VDC and 28 VDC +/- 1 VDC
38、 for variable voltage lamps and 12.8 VDC or 28 VDC +/- 1 VDC for single voltage lamps. Evidence demonstrating compliance shall be provided. 4.5.1.1 Photometry. (2) production level parts shall comply with section 4.5.1 above. Evidence demonstrating compliance from an A2LA certified independent ( thi
39、rd party) test facility shall be provided. 4.5.2 Color. (10) production level parts shall comply with SAE J578c as specified by FMVSS 571.108. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32243 12 4.5.3 Abrasion. The LED Headlamp exterior
40、lens shall comply with abrasion testing section as specified by FMVSS 571.108. (1) production level part shall comply with the photometry requirements of FMVSS 571.108 Figure 27-1 or Figure 17-1 for High and Low Beams after abrasion. 4.5.4 Chemical Resistance. The LED Headlamp exterior lens shall co
41、mply with chemical resistance testing section 8.3 (and section 8.10.1 for replaceable lens headlamps) as specified by FMVSS 571.108. (1) production level part treated with all 5 chemicals or (5) production level part treated with 1 chemical each shall comply with the photometry requirements of FMVSS
42、 571.108 Figure 27-1 or Figure 17-1 for High and Low Beams after the chemical wipe procedure. 4.5.5 Temperature Cycle. The LED Headlamp shall comply with temperature cycle testing section specified by FMVSS 571.108. The lamp shall be energized at design voltage and at the maximum wattage dissipation
43、 for the lamps intended usage. A headlamp, mounted on a headlamp test fixture, shall be subjected to 10 complete consecutive cycles having the thermal cycle profile shown below. During the hot cycle, the lamp, shall be energized commencing at point “A” and de-energized at point “B”. Separate or sing
44、le test chambers may be used to generate the environment of Figure I. All drain holes, breathing devices or other openings or vents of the headlamps shall be in their normal operating positions. After a temperature cycle test is conducted, the headlamp shall show no evidence of delamination, fractur
45、es, entry of moisture or deterioration of bonding material, color bleeding, warpage or deformation visible without magnification or lens warpage greater than 0.118 in. (3 mm) when measured parallel to the optical axis at the point of intersection of the axis of each light source with the exterior su
46、rface of the lens, and it shall meet the photometric requirements applicable to the headlamp system under test. (1) production level part shall comply with the photometry requirements of FMVSS 571.108 Figure 27-1 or Figure 17-1 for High and Low Beams. (2) production level parts may be tested, one fo
47、r each beam and shall comply with the photometry requirements of FMVSS 571.108 Figure 27-1or Figure 17-1 for High or Low Beams as appropriate after the temperature cycle. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-32243 13 FIGURE I: Ther
48、mal Cycle Profile 4.5.6 Internal Heat Test. The LED Headlamp shall comply with Internal Heat Test testing section specified by FMVSS 571.108. The lamp shall be energized at design voltage and at the maximum wattage dissipation for the lamps intended usage. After an internal heat test conducted in ac
49、cordance with paragraph S8.6.2, there shall be no lens warpage greater than .118 in. After the internal heat test there shall be no lens warpage greater than 0.118 in. (3 mm) when measured parallel to the optical axis at the point of intersection of the axis of each light source with the exterior surface of the lens, and it shall meet the photometric requirements applicable to the
