1、GM DAEWOO Auto Electrical Devices to be Tested 3.2. ESD (Electrostatic Discharge); Movement of electrostatic charge that is generated before two objects of different levels come into contact. 3.3. ESD SIMULATOR; Equipment that is used to simulate an ESD model from a passenger in a car 3.4. GROUND PL
2、ANE; A piece of metal plate (without aluminum material) used for a reference point common to a test sample, ESD simulator, and other auxiliary devices 3.5. ESD Model from Passenger; A model composed of capacitance and resistor that is modeled on a passenger at the point of riding 3.6. IEC 801-2; ESD
3、 standard issued by International Electric/Electronic Technology Association (not limited to cars) 4. TEST EQUIPMENT 4.1. Specification of ESD simulator MODE INSIDE VEHICLE MODE(Fig 1) OUTSIDE VEHICLE MODE (Fig 2) 1) Voltage -15KV +15KV -25KV +25KV 2) Capacitance 33010% pF 15010%pF 3) Resistance 200
4、010% 200010% 4) Rise Time (up to coaxial target) (1) Direct Contact (8KV ) 0.7(tr)1ns (2) Spatial Discharge 5ns (1) Direct Contact (15KV) : 5ns (2) Spatial Discharge (% 15KV): No Limitation 5) Tip IEC 801-2 (See Fig 3.) IEC 801-2 (See Fig 3.) 4.2. ESD simulator must be designed for the inside discha
5、rge capacitor to be fully charged before energy transfer to the test sample. . EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 2/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology 4.3. ESD simulator must structurally be separated electrically into
6、 hightension ground and chassis ground. 4.4. ESD simulator must be the one that is commercialized. 4.5. Ground Plate Ground plate must be made of conductive metal such as copper, brass, or steel plated with copper or brass, except aluminum. Its thickness must be above 1mm at least and its area must
7、above 1m2at least. The size depends on that of the test sample. The size of a plate must be fabricated under the condition that the plate should have a margin of 0.1 m at minimum from the test sample on every side. The plate must be connected to the building ground point through a possible shortcut
8、with a piece of thick ground strap. (Ground Strap Spec : Length 1m, Thickness 50mm, Inductance 2 ) 4.6. Static Dissipative Material) : 10M /unit length2 Static Dissipative Material Surface Resistance1G /unit length24.7. Coaxial Target) Detector to be used to verify a waveform generated in ESD genera
9、tor. Detailed specifications of currently used 50 coaxial target show a target is used according to IEC801-2 and based on ESD Verification using ESD Simulator described in Chapter 8 and 9. (See Fig 4.) 4.8. 20dB WIDEBAND ATTENUATOR : used to verify an ESD waveform from simulator. Attenuation of 50 ,
10、 20dB is necessary. (bandwidth : 1GHz, 2KW peak power) 4.9. Measuring Equipment : Oscilloscope to be used to monitor a waveform that is detected must cover a bandwidth of 500MHz or higher and be available for 1GIGA samplings per second. Input impedance must be 50 . 4.10. Probe : Electrometer probe i
11、s used to verify a charging voltage on ESD simulator. Input impedance must be 100G . 5. Test Plan Make a plan before each testing. Caution : test car specifications, test conditions, ESD conditions, IDLE, other restrictions 6. Test Preparations and Procedures 6.1. ESD points are at least fixed to ar
12、eas covering passenger-controlled electrical switches and controllers. Knob, handle, and leveler essential for access to riding are included. 6.2. A series of steps for a test are performed under the condition the engine is DRIVE MODE. 6.3. Perform the procedure of verification of ESD simulator wave
13、form and apply a discharge voltage to a test car. EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 3/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology 6.4. Ground the ESD simulator to the body part of the car inside using ground wire. (See Fig 5.)
14、 For the body part, steel seat, seat moving rail, or other chassis part are suitable. 6.5. The simulation of Causing ESD at the specified point is simulated as if real ESD was caused. Put a fully charged ESD simulator near to the point at a speed of 0.5cm/s or slower until ESD is caused. 6.6. Apply
15、electricity at the level of 4KV, 8KV, and 15KV All ESD-possible points inside of a car using 330pF/2 pack. Use 150pF/2 pack for items like headlight switch, ignition switch, etc easily controllable when making an approach from car outside to inside. 6.7. When applying a voltage at a specified level
16、to the specified point, use the positive and negative poles three times at least, respectively. An interval of ESD tests must be above 5 seconds at least. Note) Apply a specified voltage to all the points per level by rotate polarity one after the other. 6.8. Enter in the test report data on all the
17、 phenomena like VISIBLE, AUDIBLE, FAILURES, etc caused during the ESD application. Monitor periodically all the devices running in various modes such as heater control, air-conditioner control, radio control, digital display, etc whether they are normally running during the test. 7. PROCEDURE OF VER
18、IFICATION OF ESD SIMULATOR WAVEFORM IN INSIDE AND OUTSIDE MODES (150pF, 330pF) (QUARTERLY) 7.1. Testing Setup 7.1.1. Setup testing equipment as shown in Fig 6. Fig 7 shows an equivalent circuit diagram for the testing setup. The need of 20dB attenuator shown in Fig 6 depends on the vertical sensitiv
19、ity of the oscilloscope. 7.1.2. The coaxial target must be grounded to the center of the ground plate. The output end of the coaxial target must be connected to the waveform measuring device (oscilloscope side) by its 50 double-shielded flexible cable of 1 m or shorter in length. This cable does not
20、 have to form a closed loop, but insulated from the plate. The high-tension voltage ground of the ESD simulator must be directly grounded using a grounding strap. (Grounding strap spec : Length 1m, Inductance 2 ) 7.1.3. To adjust the display voltage of ESD simulator, match the ESD simulator voltage
21、to its desirable level and polarity using an electrometer. Use each probe head of 330pF and 150pF simulators to check the settings of the voltages of 2KV, 4KV, 6KV, 8KV, 15KV, and 25KV. Under the condition of “Voltage of Discharge Waveform 5KV”, the voltage measured with an electrometer must be with
22、in the range of 500V. In case of “5KVVoltage of Discharge Waveform25KV”, it must be within 10% of the range. 7.2. Procedure of Choosing ESD simulator Rise Time 7.2.1. On the oscilloscope, time value along the horizontal axis and amplitude level value along the vertical axis must be set enough to vie
23、w the rise time of ESD waveform. The sweep rate of a waveform along the horizontal axis EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 4/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology must be set based on how many times to trigger a waveform.
24、 7.2.2. Procedure of Verification of ESD by Contact (See 6.) : Perform an ESD test using parameters of test level, polarity, rise time, and the first peak current according to Table 1. Fig 8 shows a typical waveform. Table 1. Parameters for Verification of ESD by Contact LEVEL INDICATED VOLTAGE (KV)
25、 FIRST PEAK CURRENT (A) RISETIME WITH DISCHAGE SWITCH (ns)1 20.5 7.5+2.25/-0 0.7-1 2 40.5 15+4.5/-0 0.7-1 3 60.6 22.5+6.75/-0 0.7-1 4 80.8 30+9.0/-0 0.7-10.7-1 7.2.3. Procedure of Verification of Spatial ESD (See 6.) : Place an ESD simulator 15 mm away from the coaxial target. Put the ESD simulator
26、with a spatial ESD probe built in perpendicular to the target within a tolerance of 15. From this position, move the probe slowly near to the target until the first spatial ESD gets caused. (5mm/s). In this case, only one ESD waveform is needed. The test voltage level for the rise time of spatial ES
27、D is 15KV. For this test, use each probe head of 330pF and 150pF. Fig 8 shows a typical waveform. Note) Moving the probe head slowly maximizes various ESD phenomena, ESD at a low level, resonance on testing equipment. 7.2.4. Record the waveform and parameters. 7.2.5. Check that the rise time is 5ns
28、at each polarity. 7.2.6. A proper ESD waveform is the one that is generated more than 6 timers repeatedly when each action of spatial ESD and contact ESD is performed 10 times. 7.3. ESD simulator RC Time Constant Procedure 7.3.1. On the oscilloscope, time value along the horizontal axis and amplitud
29、e level value along the vertical axis must be set enough to view the rise time of ESD waveform. The sweep rate of a waveform along the horizontal axis must be set based on how many times to trigger a waveform 7.3.2. Verification of RC Time Constant on ESD 330pF and 150pF probe heads must be performe
30、d at a level of 15KV (only for spatial ESD). 7.3.3. Cause ESD slowly by moving a simulator slowly to the target. (5mm/s). 7.3.4. Take a photo of a waveform once generated by ESD. 7.3.5. Record the waveform and parameters. 7.3.6. When the second peak of the waveform is reduced by 63%, define the RC t
31、ime constant based on the ESD curve at the peak point. 7.3.7. Verify if the RC time constant is 660130ns for 330pF model and 30060ns for 150pF model. EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 5/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technol
32、ogy 7.3.8. A proper ESD waveform is the one that is generated more than 6 timers repeatedly when each action of spatial ESD and contact ESD is performed 10 times. 8. PROCEDURE OF VERIFICATION OF ESD SIMULATOR WAVEFORM IN INSIDE AND OUTSIDE MODES (150pF, 330pF) (DAILY) 8.1. Verify ESD simulator charg
33、ing everyday before ESD test. 8.2. To adjust the display voltage of ESD simulator, match the ESD simulator voltage to its desirable level and polarity using an electrometer. Use each probe head of 330pF and 150pF simulators to check the settings of the voltages of 2KV, 4KV, 6KV, 8KV, 15KV, and 25KV.
34、 Under the condition of “Voltage of Discharge Waveform 5KV”, the voltage measured with an electrometer must be within the range of 500V. In case of “5KVVoltage of Discharge Waveform25KV”, it must be within 10% of the range. 9. Test result decision standard INSIDE VEH. OUTSIDE VEH. CLASS A CLASS B CL
35、ASS C 15KV 25KV REGION III REGION II 14KV 15KV REGION II 8KV 8KV REGION II 4KV 4KV REGION I 9.1. FUNCTIONAL STATUS CLASSIFICATION) 9.1.1. CLASS A : CONVENIENCE FUNCTION 9.1.2. CLASS B : CRITICAL FUNCTION 9.1.3. CLASS C : SAFETY-CRITICAL FUNCTION 9.2. REGION OF PERFORMANCE 9.2.1. REGION I: There is n
36、o malfunction in the simulator during/after the application of power. 9.2.2. REGION II : There is a malfunction in the simulator during the application of power, but the simulator returns to the normal state after the application. 9.2.3. REGION III: There is a malfunction in the simulator during/aft
37、er the application of power, but the simulator returns to the normal state by an operator pressing the “RESET” button. 9.2.4. REGION IV: There is a malfunction in the simulator during/after the application of power and the simulator is not recoverable. 10. RELATED STANDARDS EDS-T-5516ELECTROSTATIC D
38、ISCHARGE TEST FOR VEHICLES PAGE: 6/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology 10.1. SAE J551/15 ISSUED MAY 95 : Vehicle Electromagnetic Immunity -ESD 10.2. GM EMC-34 : Electrostatic Discharge 11. ATTACHMENT Fig. 1. Inside Vehicle Parameters Fig. 2.
39、Outside Vehicle Parameters Fig 3. ESD Simulator Probe Tips EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 7/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology Fig. 4 IEC 801-2 ESD Coaxial Target EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES
40、 PAGE: 8/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology Fig. 5. Vehicle ESD Test Setup Fig. 6. ESD Simulator Verification Test Setup Configuration EDS-T-5516ELECTROSTATIC DISCHARGE TEST FOR VEHICLES PAGE: 9/9 ISSUED DATE: 1994. 11. 11 REVISED DATE: 2008. 11. 04 VERSION: 4 GM DAEWOO Auto & Technology Fig. 7. Equivalent Schematic Fig. 8. Typical Waveform Shape
