1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5713 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5713
2、METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 1/10 ISSUED DATE: 2000. 05. 18 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 It is Superceded for all future projects and repla
3、ced by GMW3172. 1. PURPOSE This standard aims at specifying the method of verifying whether the metal stamped type fuse and relay box (hereinafter called “fuse box”) in the engine room used for vehicles manufactured by GMDAT is appropriate. 2. SCOPE This standard applies to verifying appropriateness
4、 of the fuse box at new model development or change of the fuse box for the production models. 3. TEST EQUIPMENT 3.1. Power supply - 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 spray 3.9. Vernier calip
5、ers, projector 4. TEST ITEMS 4.1. Basic performance test 4.1.1. Appearance check (1) Test method: Visual inspection (2) Evaluation standard: No deformation, flaws affecting commercial value, dents, shrinkage, weld run marks, discoloration. 4.1.2. Outer dimensions (1) Test method: Measure dimensions
6、of each portion with vernier calipers or projector. (2) Evaluation standard: To meet drawing requirements EDS-T-5713METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 2/10 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 4.1.3. Connector
7、 insertion feel (1) Test method: With the lead wire assembled, evaluate feel while inserting the connector with a hand (2) Evaluation standard 1) To be inserted smoothly. 2) When the connector is inserted, there shall be clacking to confirm insertion. 4.1.4. Abnormal noise (1) Test method 1) Shake r
8、ight/left with hands 2) Perform test after inserting the connector with a lead wire and the spare fuse connected. (2) Evaluation standard 1) No abnormal noise in the box or loosening. 2) No harmful noise between the box and cap. 4.1.5. Voltage drop (1) Test method 1) With the designated components (
9、harness, fuse and dummy terminal in place of fuse) assembled to the fuse box, apply a current of 1A to the individual circuit and measure the voltage drop. The measuring point is 100mm from the conductor-depressed portion of the terminal. In measuring, the voltage drop in the fuse and cable is exclu
10、ded. The cable used shall be the same size as in the vehicle. After measurement for each circuit, divide the voltage drop by the number of contact points to have it the voltage drop per contact point. 2) Measuring point (See Fig 1) (2) Evaluation standard: Voltage drop, which varies according to the
11、 vehicle model and fuse box type, shall be specified in the drawing. In test, the value specified in the drawing shall be followed. Unless specified in the drawing, it shall not be larger than 3mV/A for each connected contact before durability test and not be larger than 10mV/A after durability test
12、. 64&$“#-&5&3.*/“-N7“NN4.1.6. Temperature change EDS-T-5713METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 3/10 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (1) Test method 1) After installing the cable and fuse to the fuse box, a
13、pply current equivalent to the actual load. 2) Record the measured temperature minus the ambient temperature when the temperature of each conducting part has been stabilized. 3) No. of measuring points shall not be less than 10 and their positions shall be selected from where the preliminary test te
14、mperature was high. The measuring points shall be selected following an agreement among related departments prior to test. 4) The ambient temperature of engine room components shall basically be 90 and components shall be attached in the vehicle condition. 5) In temperature measuring, attach the the
15、rmocouple for temperature measuring to the point. (by soldering) 6) The thermocouple shall be attached around the cathode connector neck (See Fig2) and separately agreed upon when required. 7) Change of measuringpoints and the actual loading conditions shall be agreed upon among related departments
16、prior to test. The test is conducted under the changed conditions. (2) Evaluation standard 1) Temperature rise : Max 50 2) No deformation of the fuse box. 3) Voltage drop : To meet 4.1.5.(2). .&“463*/(10*/55&3.*/“-4#-0864&-*/&#-“%&64&3&-“:$“#-&5&3.*/“-.&“463*/(10*/54.2. Mechanical performance test 4
17、.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 terminal 5 times at a speed of 20200X per minute. The result of each measurement shall meet the evaluation standard. (2) Evaluation
18、standard EDS-T-5713METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 4/10 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 1) Mini/auto fuse: Max 9.2Kgf, maxi/slow blow fuse: Max 10Kgf. 2) When the fuse other than these are used, its in
19、sertion force shall be separately specified on the drawing and shall be met in test. 4.2.2. Fuse detachment 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 20200X /min. Measure the force 5 times when the terminal sep
20、arates from the box. The result of each measurement shall meet the evaluation standard. (2) Evaluation standard 1) Vertical: 1.5Kgf 10Kgf 2) 30inclination: No separation of the terminal at 8Kgf. (In case the fuse housing is used, the 30inclination test may be omitted.) 4.2.3. Box fixing part strengt
21、h (1) Test method: Immediately after taking the fuse box out of thermostatic chamber following exposure to 03 for 12 hours, evaluate as follows: 1) Formally fasten with a fastener. 2) Fasten the bolt or nut in the following conditions: - Bolt, nut : M6 - Fastening torque : M6 : 46 N 3) Under the set
22、 conditions, pull it with a force of 10Kgf in the direction perpendicular to the fixing part. 4) The withstanding force of the mounting hole in the vehicle condition shall be MIN 6N. 5) In the event of any changes in the size of bolts and nuts and fastening torque stated in clause 2), the size of bo
23、lts and nuts shall be specified in the drawing, which shall be followed in test. (2) Evaluation standard: No damage 4.2.4. Relay insertion force/ detachment force (1) Test method: After aligning the relay and its insertion part on a straight line, fix the relay to the tension tester, and insert it t
24、o the terminal 5 times at a speed of 20200X per minute. The result of each measurement shall meet the evaluation standard. (2) Evaluation standard : 1) 280 micro relay : insertion force 12Kgf Max, detachment force 3.0 15.0Kgf 2) 280 mini relay : insertion force 12Kgf Max, detachment force 3.0 15.0Kg
25、f 3) When the relay other than these are used, its spec and evaluation standards shall be separately specified on the drawing and shall be met in test. 4.2.5. Connector insertion force (1) Test method: Measure the force 5 times when inserting mating parts of the housing combined with a negative term
26、inal and fuse box at a speed of 20200mm/min with the locking part locked. The result of each measurement shall meet the evaluation standard. (2) Evaluation standard : according to Table 1. When the connector and relay other than those specified in the following table are used, it shall be specified
27、in EDS-T-5713METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 5/10 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology the drawing. In evaluation, requirements specified in the drawing shall be met. No of terminal Terminal size Insertion
28、force Max. 6P 070, 090,090II 250,312Min. Max. 0.8Kgf.cm a point Max. 3.2Kgf.cm a point 7P 12P 070, 090,090II 250,312Min. Max. 1P 0.8Kgf.cm a point Max. 1P 3.2Kgf.cm a point 13P Min. 070,090,090II Max. 1P 0.8Kgf.cm a point RELAY ISO MINI 280 MINI Max. 12Kgf.cm Max. 10Kgf.cm 4.2.6. Connector detachmen
29、t force (1) Test method: Measure the force 5 times when pulling mating parts of the housing combined with a negative terminal and fuse box at a speed of 20200mm. The result of each measurement shall meet the evaluation standard. (The housing, etc. shall not be locked.) (2) Evaluation standard : acco
30、rding to Table 2. When the connector and relay other than those specified in the following table are used, it shall be specified in the drawing. In evaluation, requirements specified in the drawing shall be met: No of terminal Terminal size Detachment force Max. 6P 070, 090,090II 250,312Min. 0.2Kgf.
31、cm 0.8Kgf.cm a point 0.2Kgf.cm 4.5Kgf.cm a point 7P 12P 070, 090,090II 250,312Min. 0.2Kgf.cm 0.8Kgf.cm a point 0.2Kgf.cm 4.5Kgf.cm a point 13P Min. 070,090,090II 0.2Kgf.cm 0.8Kgf.cm a point BUSS terminal 1Kgf.cm 14Kgf.cm 4.2.7. Drop test (1) Test method: Immediately after taking the fuse box out of
32、thermostatic chamber following exposure to 03 for 12 hours, evaluate as follows: Drop the fuse box with specified harness fastened from a height of 0.5m onto the concrete floor coated with 10mm thick epoxy. (2) Evaluation standard 1) No breakage 2) No separation of the fuse, spare fuse, cover, fuse
33、puller. 4.2.8. Fastening torque of mounting portion (1) Test method: After fastening the mounting portion to the body-side bracket in the vehicle condition with bolts/nuts using a torque wrench, measure the torque under which cracks start to develop in the mounting portion of the junction box. The m
34、easuring temperature shall be the normal temperature and nuts (bolts) used in the vehicle shall be used. (Test shall be performed after placing the junction box into the 0 thermostatic EDS-T-5713METHOD OF TEST FOR ENGINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 6/10 ISSUED DATE: 2000. 05. 18 REV
35、ISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology chamber for 12 hours.) (2) Evaluation standard 1) M5 : No crack under the force up to 70Kgf. 2) M6 : No crack under the force up to 110Kgf. 4.2.9. Connector twisting durability (1) Test method: Grip the junction box with a hand and inser
36、t the connector perpendicularly to the axial direction along the longitudinal and lateral axes 10 times respectively by twisting its tip. (2) Evaluation standard 1) Appearance : No harmful crack, corrosion, flaw, deformation, discoloration. 2) Voltage drop : to meet 4.1.5, (2). 4.3. Electric perform
37、ance test 4.3.1. Insulation resistance (1) Test method: Apply DC 500 V to the fuse 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: 100 Mi
38、n. 4.3.2. Voltage resistance (1) Test method: Apply AC 1000 V for 1 minute to the fuse 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. Overcurrent (1) Test method: To the
39、 circuit to be measured of the fuse box furnished with wire and fuse, apply current equivalent to 135% of the rated fuse value until short circuit takes place. (Perform test with 200% of the rated fuse value for reference.) (2) Evaluation standard 1) No ignition and deformation and discoloration of
40、the box. 2) Voltage drop : to meet 4.1.5, (2) 4.3.4. Actual load and rated capacity temperature rise test (1) Test method 1) With the cable, fuse, etc assembled into the fuse box, apply the actual load and the load equivalent to 100% of the fuse value to each circuit individually and simultaneously.
41、 (The reason of applying 100% load is to check the possibility of ignition.) 2) Some of measuring points for this test shall be selected among the points that have exhibited high temperature in the temperature change test. (Measuring points are usually selected in the order of recorded temperature f
42、rom the top down following a separate agreement.) 3) Conditions for this test shall be based on 4,4,10, (1), 2). Test shall be performed only up to the point where the temperature rise for the load equivalent to 100% of the rated capacity reaches the saturation point. EDS-T-5713METHOD OF TEST FOR EN
43、GINE ROOM JUNCTION BOX (METAL STAMPED TYPE) PAGE: 7/10 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (2) Evaluation standard: No harmful defects (ignition, short, thermal damage etc.) in the fuse box. 4.4. Environmental performance test 4.4.1. Cold resis
44、tance test (1) Test method 1) Cold resistance test is conducted after fuse 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 temperature reaches ambient temperature (2) Evaluation standard 1) Appear
45、ance : No harmful deformation. 2) Abnormal noise : No abnormal noise or excessive playing in the fuse box. 3) Voltage drop : to meet 4.1.5, (2). 4.4.2. Heat resistance test (1) Test method 1) Heat resistance test is conducted after fuse box, with the cable and fuse equipped, is installed to the brac
46、ket in the vehicle condition. 2) After exposure to 125 for 120 hours, leave it until its temperature reaches ambient temperature. (2) Evaluation standard 1) Appearance : No harmful deformation. Check if the cover is not loosened and detached. 2) Abnormal noise : No abnormal noise or excessive playin
47、g in the fuse box. 3) Voltage drop : to meet 4.1.5, (2). 4.4.3. Humidity resistance test (1) Test method 1) With the designated wiring assembled to the fuse box, hang it for 96 hours in such a way as not to be touched by water drops at temperature of +40 and humidity of 90 95% RH. 2) During test, ap
48、ply DC 13.5 V between a terminal and the adjacent terminal every 24 hours to measure leakage current. (2) Evaluation standard Leakage current : To drawing spec. Max. 1mA unless specified otherwise in drawing. 4.4.4. Thermal shock test (1) Test method 1) Thermal shock test is conducted after the fuse
49、 box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) Conduct the following 125 cycles: exposure to 1253 for 30 min and subsequently to -403 for 30 min. Temperature change interval shall not exceed 5 minutes. (2) Evaluation standard 1) Appearance : No harmful deformation. 2) Abnormal noise : No abnormal noise or excessive playing in the fuse box. EDS-T-5713METHOD O
