1、GM DAEWOO Auto in the operating voltage of 9V16V, the operating temperature of -40+85(PASSENGER ROOM) and -40+105(UDHD), the storage temperature of -40+105(PASSENGER ROOM) and -40+125(UDHD). (2) If there are no special regulations, they shall be measured at the test voltage of over 4 points (9V, Nom
2、inal Voltage: 12V make free-fall of the fuse box with the stipulated harness connected to the concrete floor from 1M high in the both directions of X axis, and then in the both directions of Y axis and then Z axis. (2) Evaluation Criteria 1) No damage shall happen 2) Fuse, spare fuse, cover, and fus
3、e puller shall not be detached. 8.1.3.11. Torque of the attached Part (1) Test Method By screwing Nut(Bolt) up, connect the attached part onto the bracket of the body side of the real vehicle with Torque Lench. measure the Torque of the crack-creating installment part of the junction box. The measur
4、ement shall be made at room temperature, and the nuts (bolts) shall be the same used for the real vehicle. (After the junction box is stored in 0 constant temperature chamber for 12 hours, this test shall be taken). (2) Evaluation Criteria 1) M5: No Crack shall occur below the Torque noted on the dr
5、awing. 2) M6: No Crack shall occur below the Torque noted on the drawing. 8.1.3.12. Connector Distortion durability (1) Test Method Grab the junction box with hand, and turn the connector 10 times respectively in the direction crossing at the right angle, in back and forth direction, and in left and
6、 right direction, in order to insert it. (2) Evaluation Criteria 1) Appearance: No crack, corrosion, scratch, deformation, and discoloration shall occur. 2) Voltage Drop: follow 8.1.1(2). 8.1.3.13. Fixation Force of Terminal (1) Test Method Connect the electric codes-wired terminal to the box, and p
7、ull this at the speed of 20200X /min, using a push-pull gauge or a tension tester. Measure the load generated when the terminal is taken out from the box, and the measured values shall satisfy the evaluation criteria. And then, put 6Kgf load in the direction of 30from the horizontal and check whethe
8、r the terminal is taken out from the box or not. (2) Evaluation Criteria 280 MINI FUSE REC.: over 6Kgf of detachment force, 0.3 3.0SQ of diameter of the applied electric code 250 TAB TERMINAL: over 6Kgf of detachment force, 0.85 5.0SQ of diameter of the applied electric code When using non-above- st
9、ated specifications, record the specification and evaluation criteria on the drawing EDS-T-5718SPECIFICATION FOR SMART JUNCTION BOX TEST PROCEDURE PAGE: 17/21 ISSUED DATE: 2005. 07. 07 REVISED DATE: 2008. 10. 21 VERSION: 2 GM DAEWOO Auto & Technology which shall be used for the test. 8.2. Electrical
10、 Performance Test 8.2.1. Insulation resistance Test (1) Test Method Provide DC voltage (500V) to the fuse box with stipulated fuse and relays assembled for 1 minute and measure the case resistances between adjacent terminals, between adjacent codes, between terminals, or between the wiring plate. (2
11、) Evaluation Criteria Over 100 max. 8.2.2. Dielectric Resistance Test (1) Test Method After providing AC voltage (1000V) to the fuse box with the stipulated fuse assembled for 1 minute, measure if insulation destructions between adjacent holes, adjacent patterns happen. (2) Evaluation Criteria There
12、 shall be no insulation destruction. 8.2.3. Over-current Test (1) Test Method 1) Under the stabilized temperature condition of 40and +85(Passenger Room), and +105(UDHD), provide 135%, 200%, and 350% load currents of the fuse capacity to the circuit of the smart junction assembly whose wiring, fuse,
13、and relay connected, while using the rated voltage. Provide this load current until short-circuit. 2) Fuse Cut-out Test: provide 150% of currents for the real vehicle for 60 minutes. In case of the test, use the fuse whose capacity is higher than shunt or the rated capacity. 3) Over-Current Cycle Te
14、st: perform 720 cycles (1 Cycle means 135% of fuse capacity for 1 minute On and 9 minute OFF) by each circuit. In case of the test, use the fuse whose capacity is higher than the shunt or rated one. In case of the circuit without fuse, provide 150% of the current for the real vehicle. (2) Evaluation
15、 Criteria 1) Apparent crack, ignition, deformation of the box (sinking and contraction), discoloration, and the disconnection of PCB pattern shall not occur. 2) Voltage Drop: 8.1.1(2) shall be satisfied. 8.2.4. Real Load and Rated Capacity Temperature Increase Test (1) Test Method 1) For this test,
16、assemble electric codes, fuses, and relays in the smart junction box and provide the load as much as 100% of the rated capacity of the load current and fuse noted on the drawing (The reason of providing 100% current is to check the risk of ignition). 2) There shall be more than 10 measurement points
17、 which shall undergo PCB pattern soldering. EDS-T-5718SPECIFICATION FOR SMART JUNCTION BOX TEST PROCEDURE PAGE: 18/21 ISSUED DATE: 2005. 07. 07 REVISED DATE: 2008. 10. 21 VERSION: 2 GM DAEWOO Auto & Technology 3) Regarding test time, perform this test until the increased temperature of the load with
18、 100% rated capacity reaches the saturation. (2) Evaluation Criteria No deformation and defect (ignition and burning) shall occur in the smart junction box. PCB patterns shall not open the circuit. 8.3. Environmental Performance Test 8.3.1. Humidify Test (1) Test Method 1) Assemble the wiring in the
19、 fuse box according to the regulation, and set it under the condition of 852.5temperature and 90 95% RH humidity. After that, hang it for 96 hours without the reach of water drops. 2) During the test, provide DC voltage (14.5V) to the terminal and between the cases of adjacent terminals every 24 hou
20、r for short-circuit measurement. (2) Evaluation Criteria Leakage Current: The acceptable range of measurement shall be based on the drawing. If the drawing has no special regulations, the maximum current shall be 1mA. 8.3.2. Dust Test (1) Test Method Install the junction box assemble (relay excluded
21、) in the air-tight test chamber (the width, length, and height are 9001200mm), and ii) spray the pressured air to the 1.5kg of Portland cement (JIS Z-8901 8 types) for 10 seconds. While doing so, spread the air in an invariable way with a FAN. This process is 1Cycle, and 8Cycles shall be performed.
22、(2) Evaluation Criteria (the dust shall not affect the functions) 1) Voltage Drop: 8.1.1(2) shall be followed. 2) Leakage Current: Max 1mA (in case that DC 14.5V is provided) 3) Insulation resistance: Min. 100 8.3.3. Dew Test (1) Test Method Let the junction box assemble (relay excluded) in the cons
23、tant temperature chamber at the temperature of +852.5(Passenger Room), +1052.5(UDHD), and the humidity of 9095% RH for 30 minutes. After that, let the assemble in the constant temperature chamber with 0 for 10 minutes again. This process is 1 cycle, and perform 48 cycles (However, during the test, a
24、pply 14.5V in the IGN ON circuit). (2) Evaluation Criteria 1) Voltage Drop: 8.1.1(2) shall be followed. 2) Appearance: Crack, corrosion, defect, deformation, discoloration, and burning shall not take place. 8.3.4. Corrosion GAS Test (UDHD) EDS-T-5718SPECIFICATION FOR SMART JUNCTION BOX TEST PROCEDUR
25、E PAGE: 19/21 ISSUED DATE: 2005. 07. 07 REVISED DATE: 2008. 10. 21 VERSION: 2 GM DAEWOO Auto & Technology (1) Test Method Store the junction box assemble (relay excluded) in the test chamber filled with SO2 GAS at the concentration of 10ppm, the humidity of over 90%, and room temperature (This test
26、is taken only when terminals are newly developed). (2) Evaluation Criteria 1) Voltage Drop: 8.1.1(2) shall be followed. 2) Appearance: Cracks, corrosion, defect, deformation and discoloration shall not occur. 8.3.5. Oil Resistance Test (UDHD) (1) Test Method Mount the engine oil box (Qualified oil/2
27、0W) on the junction box assemble (relay excluded) and let it in the constant temperature chamber at 503. Two hours later, take it out and let it at room temperature. (However, this test shall be taken only when resin materials are newly developed.) Scrub the cover of the junction box (which the caut
28、ion note is printed on) with the cloths respectively smeared by anti-freezing fluid, tricorne oil, mission oil, engine oil, gear oil, gasoline, kerosene, and diesel. (2) Evaluation Criteria Appearance: Diffusion and erase of printed remarks shall not take place. There shall be no crack, corrosion, s
29、cratch, deformation, and discoloration. 8.3.6. Temperature/Humidity Test (1) Test Method. 1) Make wiring in the smart junction box, and install it on the bracket under the same condition of real vehicle. 2) Test Condition (a) Temperature: -402.5 +852.5(Passenger Room) -402.5 +1052.5(UDHD) (b) Humidi
30、ty: 90 95% RH (c) Installation Condition: The same condition with the real vehicle (d) 1Cycle 16h +852.5(Passenger Room), +1052.5(UDHD) 2h+802.5(Passenger Room), +1052.5(UDHD) -40 4h -402.5 2h -402.5 +852.5(Passenger Room), +1052.5(UDHD) (e) Time: 120 hours (f)Time needed for temperature to change i
31、s 1 hour. (2) Evaluation Criteria 1) Appearance: No deformation shall be made. PCB pattern shall not be open. 2) Abnormal Joint: There shall be no loose or abnormally-connected joints in the box. 3) Voltage Drop: 8.1.1(2) shall be satisfied. 4) Insulation resistance: minimum. 100 EDS-T-5718SPECIFICA
32、TION FOR SMART JUNCTION BOX TEST PROCEDURE PAGE: 20/21 ISSUED DATE: 2005. 07. 07 REVISED DATE: 2008. 10. 21 VERSION: 2 GM DAEWOO Auto & Technology 5) Leakage Current: It shall be less than 1mA. 8.3.7. Combined Environmental Test (1) Test Method 1) As for the combined environmental test, install elec
33、tric codes, fuses, and relays in the fuse box, and install the smart junction box on the bracket under the same condition with the real vehicle. 2) Test Condition (a) Temperature: -402.5 +852.5(Passenger Room), +1052.5(UDHD) (b) Humidity: 90 95% RH (c) Vibration: Frequency/Sweep Time = 20 200Hz / 3m
34、in . Vibration frequency to acceleration: 3.0G 20 200Hz (Passenger Room) 4.5G 20 50Hz, 3.0G 50 200Hz(UDHD) . Vibration direction: Up and Down (Z axis) (d) Installation Condition: the same condition with the real vehicle (e) Current Load: The condition stated on the drawing is 45-minute ON and 15-min
35、ute OFF. (f) 1Cycle 16h +852.5(Passenger Room), +1052.5(UDHD) 2h +852.5(Passenger Room), +1052.5(UDHD) -402.5 4h -402.5 2h -402.5 +852.5(Passenger Room), +1052.5(UDHD) (g) Time: 12.5 Cycle (300 hours) (2) Evaluation Criteria 1) Appearance: There shall be no deformation and open of PCB pattern. There
36、 shall be no discoloration, unclear labels, and stains affecting the product value. (In case that judgment is hard, check it with the registered samples) 2) Abnormal Joint: There shall be no loose or abnormally-connected joints. There shall be no loose joints between the box and the cover. In case o
37、f special connectors, they are acceptable under the condition that stipulated wiring is used. 3) Voltage Drop: 8.1.1(2) shall be satisfied. 4) Temperature Increase: less than max. 55 5) Insulation resistance: Min. 100 6) Short-circuit: connect the test-required circuits in the series, and continuous
38、ly provide DC 5V/1mA. During the test, the short-circuit more than 10k /3.5V shall not occur. However, as for the selected circuit, continuously provide the real load to DC 14.00.2V during the combined environmental test. During this test, short-circuit higher than 10k /7V shall not be generated. 7)
39、 After the combined environmental test, the functions stated by 5.3.1 shall be satisfied. The wave patterns of the signal lines of modules in the smart junction box (which is measured under the combined environmental condition) shall satisfy the wave patterns described on the drawing. EDS-T-5718SPEC
40、IFICATION FOR SMART JUNCTION BOX TEST PROCEDURE PAGE: 21/21 ISSUED DATE: 2005. 07. 07 REVISED DATE: 2008. 10. 21 VERSION: 2 GM DAEWOO Auto & Technology 8) Voltage Drop after Fuse Insert/take out repeat Insert/take out the fuse of the test piece (which already underwent the combined environmental tes
41、t) 10 times. The result of the voltage drop of the circuit shall be less than PCB Total 30mV/A. 9. TEST ITEM BY EACH BOX TEST PIECE Numbers of Test Pieces Test Item S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S308.1. Basic Function Test 8.1.1. Voltage Drop X X X X X X X X X X X X X X X 8
42、.1.2. Temperature Change Test X X X X X X X X X X X X X X X 8.1.3. Mechanic Performance Test 8.1.3.1. Fuse Insertion Force X X X X X X 8.1.3.2. Fuse Detachment Force X X X X X X 8.1.3.3. Space Fuse Insertion / Detachment Force X X X X X X 8.1.3.4. Cover Connection and Detachment Force X X X X X X 8.
43、1.3.5. Box-Fixed Part Intensity X X X 8.1.3.6. Relay I Insertion /Detachment Force X X X X X X 8.1.3.7. Connector Insertion Force X X X 8.1.3.8. Connector Detachment Force X X X 8.1.3.9. Connector Locking Intensity X X X 8.1.3.10. Drop Test X X X X X 8.1.3.11. Torque of Installment Part X X X 8.1.3.
44、12. Connector Distortion Durability X X X 8.1.3.13. Fixation Force of Terminal X X X 8.2. Electrical Performance Test 8.2.1. Insulation resistance Test X X X 8.2.2. Voltage drop Test X X X 8.2.3. Over-current Test X X X 8.2.4. Real Load and Temperature of Rated Capacity X X X 8.3. Environmental Perf
45、ormance Test 8.3.1. Humidity Test X X 8.32. Dust Test X X 8.3.3. Dew Condensation Test X X 8.3.4. Internal-typed GAS Test X X 8.3.5. Oil Resistance Test X X 8.3.6. Temperature/Humidity Test X X 8.3.7. Combined environmental Test X X X * The test items and quantity of samples on the above test matrix can change depending on the design and discussions of contractor.
