1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards ENGINE ROOM FUSE BOX Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5710 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 1/10 ISSUED DATE:
2、 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW3172. 1. PURPOSE This standard aims at specifying the standard based on which
3、to verify whether the engine room fuse box (hereinafter called “F/box“) used for vehicles manufactured by GMDAT is appropriate. 2. SCOPE This standard applies to verifying appropriateness of F/box at new model development or change of F/box of the production models. 3. TEST EQUIPMENT 3.1. Power supp
4、ly - DC 24V/200A) 3.2. Oscilloscope 3.3. Recorder 3.4. Electric load 3.5. Digital multimeter 3.6. Tension tester 3.7. Thermostatic chamber 3.8. Salt spay 3.9. Slide calipers, projector 4. TEST ITEMS 4.1. Basic performance test 4.1.1. Appearance inspection (1) Test method: Visual inspection (2) Evalu
5、ation standard: No deformation, flaws, dents, contraction, weld run or discoloration. 4.1.2. Dimension check (1) Test method: Measure dimensions of each portion with slide calipers or projector. (2) Evaluation standard: To meet drawing requirements. EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 2/10 ISSUED D
6、ATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 4.1.3. Connector insertion (1) Test method: Evaluate while inserting the connector with hands. (2) Evaluation standard 1) To be inserted smoothly. 2) When the connector is inserted, there shall be clacking to confirm
7、 insertion. 4.1.4. Abnormal noise (1) Test method 1) Shake right/left with hands. 2) Conduct test with a through type connector and spare fuse provided. (2) Evaluation standard 1) No abnormal noise in the box or loosening. 2) No harmful noise between the box and cap. 4.2. Mechanical performance test
8、 4.2.1. Fuse insertion force (1) Test method: After aligning the fuse and its insertion part on a straight line, fix the fuse to the tension tester, and insert it to the holder 10 times at a speed of 20TT per minute to get the value. (2) Evaluation standard 1) Mini/auto fuse : max 9.2Kgf 2) Maxi/slo
9、w blow fuse : max 18.4Kgf 4.2.2. Fuse separation force (1) Test method: With the fuse and its insertion part combined, fix the fuse to the tension tester, and pull it at a speed of 20 mm/min. Measure the force 10 times when the terminal separates from the box to get the value. (2) Evaluation standar
10、d : 1.5Kgf 8Kgf 4.2.3. Terminal fixing force (1) Test method: After putting to the box the terminal with min 0.85SQ cable attached to connect it, pull it vertically at a speed of 20mm/min with a push-pull gage or tension tester. Measure the force when the terminal separates from the box. After insta
11、lling the terminal as described above, apply a force of 8Kgf in the direction 30from the horizontal plane, and check if the terminal is not detached from the box. (2) Evaluation method 1) Vertical: minimum 8Kgf 2) 30inclination: No separation of the terminal at 8Kgf. 4.2.4. Box fixing part strength
12、(1) Test method: Immediately after taking the F/box out of thermostatic chamber following exposure to 0 for 12 hours, evaluate as follows: EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 3/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 1) Formally fasten with a f
13、astener. 2) Fasten the bolt or nut in the following conditions: - Bolt : M6 - Nut : M5 - Fastening torque : M5 - 65Kgf.cm / M6 - 110Kgf.cm 3) Under the set conditions, pull it with a force of 10Kgf in the direction perpendicular to the fixing part. (2) Evaluation standard : No breakage. 4.2.5. Conne
14、ctor insertion force (1) Test method: Measure the force when inserting mating parts of the housing combined with a negative terminal and F/box at a speed of 205mm/min. (2) Evaluation standard : To Table 1. No. of terminals Terminal size Insertion force Max. 6P 070, 090 Min. 250 Max. 6Kgf58.8N Max. 1
15、0Kgf98N 7P 12P 070, 090 Min. 250 Max. 10Kgf98N Max. 15Kgf137.2N Min. 13P - Max. 15Kgf137.2N Relay ISO MINI 280 MINI Max. 12Kgf117.6N Max. 10Kgf98N 4.2.6. Connector separation force (1) Test method: Measure the force when pulling mating parts of the housing combined with a negative terminal and F/box
16、 at a speed of 205mm/min. (2) Evaluation standard : To Table 2. No. of terminals Terminal size Insertion force Max. 6P 070, 090 Min. 250 1Kgf9.8N 5Kgf49N 1Kgf9.8N 10Kgf98N 7P 12P 070, 090 Min. 250 1Kgf9.8N 9Kgf88.2N 1Kgf9.8N 14Kgf137.2N Bus terminal 1Kgf9.8N 14Kgf137.2N 4.2.7. Connector locking part
17、 strength (1) Test method: While having the connector in junction without a terminal, pull the connector in the direction 30from the horizontal plane at a speed of 20 200mm/min. Measure the force when the locking mechanism gets unlocked or broken. (2) Evaluation method EDS-T-5710ENGINE ROOM FUSE BOX
18、 PAGE: 4/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 1) Axial: minimum 10Kgf98N 2) 30inclined direction: No separation or breakage of locking system. 4.2.8. Impact resistance (1) Test method: Immediately after taking the F/box out of thermostatic ch
19、amber following exposure to 0 for 12 hours, evaluate as follows: Drop a F/box with specified harness fastened from a height of 0.5m onto a asphalt or concrete floor. (2) Evaluation standard 1) No breakage. 2) No separation of the fuse, spare fuse, cover, fuse puller. 4.3. Electric performance test 4
20、.3.1. Insulation resistance (1) Test method: Apply DC 500 V to the F/box, to which the specified fuse and relay are assembled, to measure resistance between adjacent terminals, between adjacent buses and between a terminal or distributing panel and case. (2) Evaluation standard: Minimum 100 4.3.2. V
21、oltage resistance (1) Test method: Apply DC 1000 V for 1 minute to the F/box, to which the specified fuse is attached, to check dielectric breakdown between adjacent holes and adjacent patterns. (2) Evaluation standard: No dielectric breakdown. 4.3.3. Actual loading temperature rise test (1) Test me
22、thod 1) After installing the cable and fuse to the F/box, apply current equivalent to the actual load. 2) Loads operating condition a. Continuous loads with loading time 10 seconds or more (stop lamp, wiper, head lamp, tail, IG, blower): 45min ON, 15min OFF b. Intermittent loads with loading time be
23、tween 5 and 10 seconds (horn, turn signal lamp, power window, cigar lighter): 30sec ON, 30sec OFF c. Loads with loading time less than 5 seconds (door lock/unlock, ): 5sec ON, 55sec OFF 3) Temperature measuring point : As shown in Fig 1, attach a temperature measuring sensor (thermocouple) around th
24、e negative connector neck. EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 5/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology JH.QPJOU.QPJOU5FSN 5FSN4#-0864&-*/&#-“%&64&3&-“:$BCMF4) The thermocouple for temperature measuring shall be attached with epoxy. 5) Tempera
25、ture measuring shall be conducted when the conducting part temperature is stabilized after loading. Ambient temperature is deducted from the measured temperature. 6) No. of measuring points shall not be less than 10 and their positions shall be selected where the preliminary test temperature was hig
26、h through consultation between the test engineer and design engineer. 7) Ambient temperature shall be +90, and parts shall be attached similar to the vehicle condition. 8) Before loading, be sure to remove the existing fuse and replace it with a shunt. Then check appropriateness of the current to ap
27、ply before individual loading. (2) Evaluation standard 1) Temperature rise : maximum temperature change +55 2) To meet requirements in 4.1.1(Appearance), 4.3.4(Voltage drop). 4.3.4. Actual load and rated capacity temperature rise test (1) Test method 1) The following test is individually conducted a
28、t the same time for each circuit with the cable and fuse assembled to F/box under the actual load and the load equivalent to 100% of the fuse rated capacity. 2) Some items of rated capacity temperature rise test are selected at the portion that registered high temperature at test to 4.3.3. (Usually
29、select 4 measuring points in decreasing order from the highest temperature.) 3) For actual load temperature rise test, conduct test again for items excluded from the above 2). 4) Loads in actual load temperature rise test shall be based on 4.3.3.1, 2). 5) Loads in rated capacity temperature rise tes
30、t shall be applied for continuous 24 hours. 6) Temperature measuring point and setting to follow 4.3.3.1 3), 4), 7) and 8). 7) For temperature measuring, record measuring temperature minus ambient temperature. (2) Evaluation standard 1) Temperature rise : maximum temperature change +55 EDS-T-5710ENG
31、INE ROOM FUSE BOX PAGE: 6/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 2) To meet requirements in 4.1.1(Appearance) and 4.3.4(Voltage drop). 4.3.5. Voltage drop (1) Test method 1) With the designated components (harness, relay, fuse, etc.) assembled
32、to F/box, apply current of 1A to the constructed circuit. 2) Voltage drop is measured at 100mm point of the cable as shown in Fig 2. 3) Voltage drop at fuse ends and cable 100mm point are excluded. JHVTF$BCMF5FSNJOBMN7“NN(2) Evaluation method: Maximum 15mV/A ( inter connection : maximum 1mV/A) 4.3.6
33、. Overcurrent (1) Test method 1) To the circuit to be measured of the fuse box furnished with cable and fuse, apply current equivalent to 135% of fuse rated value. 2) Current is applied simultaneously and individually after the existing fuse is replaced with a shunt and appropriateness of current to
34、 be applied is confirmed. 3) Fuses to measure and temperature measuring points are selected following consultation between the test engineer and design engineer. 4) Overcurrent is applied until fuse short. (2) Evaluation method: To meet requirements in 4.1.1(Appearance) and 4.3.4(Voltage drop). 4.3.
35、7. Instantaneous short test (1) Test method 1) Test is conducted at the fuse box with the cable and fuse attached under the following conditions: 2) Vibrating conditions . Frequency : 11.7 200Hz . Period : 20 minutes/cycle (11.2Hz 200Hz 11.7Hz) . Acceleration : 2.2G(21.57m/s2) EDS-T-5710ENGINE ROOM
36、FUSE BOX PAGE: 7/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 3) Loading conditions : DC 5V, 1mA current 4) Test time : min. 5 minutes (2) Evaluation method: Continuation of voltage less then 3.5V for 10 sec or more measured at the measuring instrume
37、nt is considered short. 4.4. Environmental performance test 4.4.1. Cold resistance test (1) Test method 1) Cold resistance test is conducted after F/box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) After exposure to -40 for 120 hours, leave it until its
38、 temperature reaches ambient temperature. (2) Evaluation method: To meet requirements in 4.1.1(Appearance), 4.1.4(Abnormal noise) and 4.3.4(Voltage drop). 4.4.2. Thermal resistance test (1) Test method 1) Thermal resistance test is conducted after F/box, with the cable and fuse equipped, is installe
39、d to the bracket in the vehicle condition. 2) After exposure to 125 for 120 hours, leave it until its temperature reaches ambient temperature. (2) Evaluation method: To meet requirements in 4.1.1(Appearance), 4.1.4(Abnormal noise) and 4.3.4(Voltage drop). 4.4.3. Humidity resistance test (1) Test met
40、hod 1) With the designated wiring assembled to F/box, hang it for 96 hours not to be touched by water drops at temperature of +80 and humidity of 90 95%. 2) During test, apply DC 16 V between the terminal and adjacent terminal case every 24 hours to measure leakage current. (2) Evaluation standard:
41、Leakage current maximum 1mA 4.4.4. Thermal shock test (1) Test method 1) Thermal shock test is conducted after F/box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) Conditions a. 1 cycle . 30 minute +125 . 30 minute -40 b. Temperature change not to exceed
42、5 minutes. c. No. of test cycles : 125 cycles EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 8/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (2) Evaluation standard: To meet requirements in 4.1.1(Appearance), 4.1.4(Abnormal noise) and 4.3.4(Voltage drop). 4.4.5
43、. Temperature-humidity cycle test (1) Test method 1) Temperature-humidity cycle test is conducted after F/box, with the cable equipped, is installed to the bracket in the vehicle condition. 2) Conditions a. Humidity : 95 98% b. Temperature : -40 +80 c. 1 cycle : . 16 hours +40 . 2 hours - 40 . 2 hou
44、rs +80 . 4 hours 25 d. No. of cycles : 15 cycles (360 hours) (2) Evaluation standard: To meet requirements in 4.1.1(Appearance), 4.1.4(Abnormal noise), 4.3.1(Insulation resistance), 4.3.3 (Temperature rise) and 4.3.4(Voltage drop). 4.4.6. Salt spray test (1) Test method 1) Salt spray test is conduct
45、ed after F/box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) Conditions a. Temperature : 35, b. Humidity : 9095% c. Salt water concentration : 5% d. Impressed voltage : Apply DC 16 V between the terminal and adjacent terminal case every 24 hours. e. Spra
46、y time : 96 hours (2) Evaluation standard: Leakage current : maximum 1mA 4.4.7. Composite environment test (1) Test method 1) Composite environment test is conducted after F/box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) Test conditions a. Temperature
47、 : -40 +80 b. Humidity : 80 95% RH c. Vibration . Frequency : 11.7 200Hz EDS-T-5710ENGINE ROOM FUSE BOX PAGE: 9/10 ISSUED DATE: 1998. 06. 08 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology . Period : 20 minutes/cycles(11.2Hz 200Hz 11.7Hz) . Acceleration : 2.2G(21.57m/s2) d. Loading
48、 : Actual loads to conditions in 4.3.3.1, 2). e. 1 cycle . 16 hours +80 . 2 hours +80 -40 . 2 hours -40 . 4 hours -40 +80 _) )$:$-&f. No. of test cycles : 15 cycles (350 hours) (2) Evaluation standard: To meet requirements in 4.1.1(Appearance), 4.1.4(Abnormal noise), 4.3.1(Insulation resistance), 4.3.3(Temperature rise), 4.3.4(Voltage drop), 4.3.6(Instantaneous short) 5. EVALUATION 5.1. In all test, evaluation standards specified for each individual test shall be met. 5.2. Also, during and after durability test, no malfunction of the sample sha
