1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5714 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5
2、714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 1/9 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 It is Superceded for all future projects and
3、replaced by GMW3172. 1. PURPOSE This standard aims at specifying the method of verifying whether the conventional box 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 appropr
4、iateness 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. Verni
5、er calipers, 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 dim
6、ensions of each portion with vernier calipers or projector. EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 2/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (2) Evaluation standard: To meet drawing requirements 4.1.3.
7、 Abnormal noise (1) Test method 1) Shake right/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. 4.1.4. Voltage drop (1) Test
8、method 1) With the designated components (harness, relay, 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 cable tip. In measuring, the voltage drop in the fuse and cable is excluded. 2) Measuring poi
9、nt (See Fig 1) (2) Evaluation standard: Voltage drop, which varies according to the 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
10、 contact before durability test and not be larger than 10mV/A after durability test. 64&$“#-&5&3.*/“-N7“NN4.1.5. Temperature change (1) Test method 1) After installing the cable and fuse to the fuse box, apply current equivalent to the actual load. 2) Record the measured temperature minus the ambien
11、t temperature when the temperature of each conducting part has been stabilized. EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 3/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 3) No. of measuring points shall not be
12、less than 10 and their positions shall be selected from where the preliminary test temperature was high. The measuring points shall be selected following an agreement among related departments prior to test. 4) The ambient temperature of engine room components shall basically be 90 and components sh
13、all be attached in the vehicle condition. 5) In temperature measuring, attach the thermocouple for temperature measuring to the point. (by soldering) 6) The thermocouple shall be attached around the cathode connector neck (See Fig2) and separately agreed upon when required. 7) Change of measuringpoi
14、nts and the actual loading conditions shall be agreed upon among related departments prior to test. The test is conducted under the changed conditions. (2) Evaluation standard 1) Temperature rise : Max 55 2) No deformation of the fuse box. 3) Voltage drop : To meet 4.1.4.(2). .&“463*/(10*/55&3.*/“-4
15、#-0864&-*/&#-“%&64&3&-“:$“#-&5&3.*/“-.&“463*/(10*/54.2. Mechanical performance test 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 terminal 5 times at a speed of 20200X per minut
16、e. The result of each measurement shall meet the evaluation standard. (2) Evaluation standard 1) Mini/auto fuse: Max 9.2Kgf, maxi/slow blow fuse: Max 18.4Kgf. 2) When the fuse other than these are used, its insertion force shall be separately specified on the drawing and shall be met in test. EDS-T-
17、5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 4/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 4.2.2. Fuse detachment force (1) Test method: With the fuse and its insertion part combined, fix the fuse to the tension teste
18、r, and pull it at a speed of 20200X /min. Measure the force 5 times when the terminal separates from the box. The result of each measurement shall meet the evaluation standard. (2) Evaluation standard 1) Vertical: 1.5Kgf 8Kgf 2) 30inclination: No separation of the terminal at 8Kgf. 4.2.3. Box fixing
19、 part strength (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)
20、Under the set 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), t
21、he size of bolts 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, an
22、d 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 standard : 1) 280 micro relay : insertion force 3.5Kgf Max per pin, detachment force 0.8Kgf Min per pin 2) 280 mini relay : insertion force 3.5Kgf Ma
23、x per pin, detachment force 0.8Kgf Min per pin 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. Terminal fastening force (1) Test method: After putting the terminal with a wire into the box an
24、d having it connected, pull it in the vertical direction at a rate of 20200X per minute with a push-pull gage or tensile strength tester and measure the load at the moment when the terminal comes out of the box. The measured load shall meet the evaluation standard. Then , apply the 6Kgf in the direc
25、tion of 30with respect to the horizontal plane and confirm if the terminal does not come out of the box. (2) Evaluation standard 1) 280 MINI FUSE REC. : detachment force 6Kgf Min, applicable wire diameter 0.3 3.0SQ 2) 250 TAB TERMINAL : detachment force 6Kgf Min, applicable wire diameter 0.85 5.0SQ
26、EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 5/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 3) When the relay other than these are used, its spec and evaluation standards shall be separately specified on the draw
27、ing and shall be met in test. 4.2.6. Drop test (1) Test method: Immediately after taking the fuse box out of 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 10
28、mm thick epoxy. (2) Evaluation standard 1) No breakage 2) No separation of the fuse, spare fuse, cover, fuse puller. 4.3. Electric performance 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
29、 between adjacent terminals, between adjacent buses and between a terminal or distributing panel and case. (2) Evaluation standard: 100 Min. 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
30、 between adjacent holes and adjacent patterns. (2) Evaluation standard: No dielectric breakdown 4.3.3. Overcurrent (1) Test method: To the 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. (2
31、) Evaluation standard 1) No ignition and deformation and discoloration of the box. 2) Voltage drop : to meet 4.1.4, (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
32、to 100% of the fuse value to each circuit individually and simultaneously. (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. (Me
33、asuring points are usually selected in the order of recorded temperature from the top down following a separate agreement.) 3) Conditions for this test shall be based on 4.4.7, (1), 2). Test shall be performed only up to the point where the temperature rise for the load equivalent to 100% of the rat
34、ed capacity reaches the saturation point. EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 6/9 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 e
35、tc.) in the fuse box. 4.4. Environmental performance test 4.4.1. Cold resistance 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 -403 for 120 hours, leave it until
36、its temperature reaches ambient temperature (2) Evaluation standard 1) Appearance : No harmful deformation. 2) Abnormal noise : No abnormal noise or excessive playing in the fuse box. 3) Voltage drop : to meet 4.1.4, (2). 4.4.2. Heat resistance test (1) Test method 1) Heat resistance test is conduct
37、ed after fuse box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) After exposure to 1253 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 lo
38、osened and detached. 2) Abnormal noise : No abnormal noise or excessive playing in the fuse box. 3) Voltage drop : to meet 4.1.4, (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 w
39、ater drops at temperature of +403 and humidity of 90 95% RH. 2) During test, apply DC 14.5 V between a terminal and the adjacent terminal every 24 hours to measure leakage current. (2) Evaluation standard: Leakage current : To drawing spec. Max. 3mA unless specified otherwise in drawing. 4.4.4. Ther
40、mal shock test (1) Test method 1) Thermal shock test is conducted after the fuse 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 -403for 30 min. Temperature change interv
41、al shall not exceed 5 minutes. (2) Evaluation standard 1) Appearance : No harmful deformation. EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 7/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 2) Abnormal noise : No ab
42、normal noise or excessive playing in the fuse box. 3) Voltage drop : to meet 4.1.4, (2). 4.4.5. Temperature and humidity test (1) Test method 1) After mounting the harness to the fuse box, install it to the bracket in the vehicle condition and perform the test. 2) Conditions a. Humidity : 90 95% RH
43、b. Temperature : -403 903 c. 1 Cycle : . +403 for 16hrs . -403 for 2hrs . +903 for 2hrs . +253 for 4hrs d. Time : 120Hr e. The time required for temperature change shall be 1 hour. (2) Evaluation standard 1) Appearance : No harmful deformation. 2) Abnormal noise : No abnormal noise or excessive play
44、ing in the fuse box. 3) Voltage drop : to meet 4.1.4, (2). 4) Insulation resistance : Min 100 4.4.6. Salt spray test (1) Test method 1) After mounting the harness and fuse to the fuse box, install it to the bracket in the vehicle condition and perform the test. 2) Conditions a. Temperature : 35 b. S
45、pray : 23Hrs On 1Hr Off (compressive air pressure: 10.2bar) c. Salt concentration : 5% d. Total time : 96 hours (total cycle : 4cycles) e. Applied voltage : DC 14.5V (2) Evaluation standard 1) Appearance : No harmful deformation 2) Abnormal noise : No abnormal noise or excessive playing in the fuse
46、box. 3) Voltage drop : to meet 4.1.4, (2). 4) Insulation resistance : Min 100 5) Leakage current : Max 3mA (DC 14.5V) EDS-T-5714METHOD OF TEST FOR ENGINE ROOM FUSE & RELAY BOX (CONVENTIONAL TYPE) PAGE: 8/9 ISSUED DATE: 2000. 05. 18 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 4.
47、4.7. Composite environment test (1) Test method 1) Composite environment test is conducted after the fuse box, with the cable and fuse equipped, is installed to the bracket in the vehicle condition. 2) Test conditions a. Temperature : -40 90 b. Humidity : 90 95% RH c. Vibration . Frequency : 11.7 20
48、0Hz . Duration : 20 min/cycle (11.2Hz 200Hz 11.7Hz) . Acceleration: 2.2G(21.57m/s2)d. Mounting condition : actual vehicle condition e. Load : Apply agreed-on load condition 45 min ON, 15 min OFF (Loading conditions are to be separately agreed upon.) f. 1 cycle . +903 for 16 hrs . +903 -403 for 2 hrs
49、 . -403 for 4 hrs . -403 +903 for 2 hrs g. Duration : 12.5 Cycle (300 hrs) (2) Evaluation standard 1) Appearance : No harmful deformation 2) Abnormal noise : No abnormal noise or excessive playing in the fuse box. 3) Voltage drop : to meet 4.1.4, (2). 4) Temperature rise range : Max. 55 5) Dielectric force : Min 100 6) Momentary sho
