1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW14036 Global Generator Specification Copyright 2011 General Motors Company All Rights Reserved June 2011 Originating Department: North American Engineering Standards Page 1 of 22 1 Introduction. 3 1.1 Scope. 3 1.2 Mission/Theme. . 3 1.3 Class
2、ification. 3 2 References . 3 2.1 External Standards/Specifications. 3 2.2 GM Standards/Specifications. . 3 2.3 Additional References. 3 3 Requirements . 3 3.1 System/Subsystem/Component/Part Definition. . 3 3.1.1 Appearance. 3 3.1.2 Content. 3 3.1.3 Ambient Environment 3 3.1.4 Interfaces. . 3 3.1.5
3、 Usage Definition. . 4 3.2 Product Characteristics. 4 3.2.1 Generator Control. 4 3.2.2 Generator Output Voltage. 6 3.2.3 Load Response Control (LRC). 6 3.2.4 Operating Speeds. 6 3.2.5 Operating Temperatures. 6 3.2.6 Generator Subcomponent Operating Temperatures. . 6 3.2.7 Generator Efficiency. 7 3.2
4、.8 Rotational Inertia. 7 3.2.9 Regulator Assembly. . 8 3.3 Generator Performance Requirements. 8 3.3.1 Generator Output Current. 8 3.3.2 Generator Parasitic Current. . 8 3.3.3 Generator Output Voltage Ripple and Transients. . 8 3.3.4 Generator Output Voltage with Disconnected Battery. . 8 3.3.5 Gene
5、rator Noise. . 8 3.3.6 Electromagnetic Compatibility (EMC). 9 3.3.7 Over-voltage Protection. . 9 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STAND
6、ARDS GMW14036 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 2 of 22 3.3.8 Reverse Voltage Protection. . 9 3.4 Product Assurance Requirements. 9 3.4.1 Quality Assurance Requirements. 9 3.4.2 Reliability Requirements. 9 3.4.3 Durability Requirements. 9 3.5 Generator Material
7、 Requirements. 9 3.5.1 Generator Insulation Material. 9 3.5.2 Generator Isolation Material. 10 3.5.3 Materials to Avoid. 10 3.5.4 Recycling/Recovery. . 10 4 Validation 10 4.1 General. . 10 4.1.1 Record Retention. . 10 4.1.2 Sample Documentation. . 11 4.1.3 Sample Size. . 11 4.1.4 Power Supplies. 11
8、4.1.5 Equipment Tolerances. . 11 4.1.6 Measurement Accuracy. . 11 4.1.7 Test Repeatability. 11 4.1.8 Test Default Conditions. . 11 4.1.9 Failure Determination 11 4.1.10 Disposition of Samples. 12 4.2 Validation Cross Reference Index. 12 4.3 Validation Test Procedures. 13 4.3.1 Generator Output Curre
9、nt Test. 13 4.3.2 Generator Parasitic Current Test. . 14 4.3.3 Generator Output Voltage Ripple and Transients Test. . 14 4.3.4 Generator Output Voltage with Disconnected Battery Test. . 14 4.3.5 Durability Test. 14 4.3.7 Generator Thermal Cycle Life Validation. . 17 4.3.8 Generator Noise. . 18 4.3.9
10、 Electromagnetic Compatibility. . 18 4.3.10 Over-Voltage Protection. 19 4.3.11 Reverse Voltage Protection. . 19 5 Provisions for Shipping 19 6 Notes 19 6.1 Glossary. 19 6.2 Acronyms, Abbreviations, and Symbols. . 19 7 Additional Paragraphs 20 8 Coding System . 20 Copyright General Motors Company Pro
11、vided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14036 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 3 of 22 9 Release and Revisions 20 Appendix A
12、- Generator Drive Torque 21 Appendix B 22 1 Introduction Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This specification defines the electric
13、al, mechanical, environmental, reliability and durability performance and validation requirements for generators used in all GM Global common passenger car and light duty truck applications worldwide. 1.2 Mission/Theme. Generators are used in vehicles to supply the electrical system with electric en
14、ergy and to recharge the battery. 1.3 Classification. This specification is applicable to all future Global common generators used in GM passenger car and light duty truck vehicles and is intended to promote uniformity of application across all future GM passenger car and light duty truck vehicles.
15、2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM 4804 ISO 1043-2 ISO 11469 ISO/TS 16949 ISO 1043-1 ISO 1629 ISO/DIS 18064 SAE J726b 2.2 GM Standards/Specifications. GMW3044 GMW3097 GMW3172 GMW14480 GMW3059 GM
16、W3103 GMW3200 GMW16266 GMW3091 GMW3116 GMW8778 GMW16290 2.3 Additional References. Generator Outline Drawing Generator Statement of Requirements (SOR) Packard Electric Part Number 90563303 (ZFW-2-83) 3 Requirements 3.1 System/Subsystem/Component/Part Definition. 3.1.1 Appearance. The generator appea
17、rance shall reflect quality design and the casting and visible protrusions shall be free of dents, nicks, scratches, blowholes, and any other abnormalities reflecting poor workmanship. 3.1.2 Content. 3.1.2.1 Physical Content. Refer to Generator SOR. 3.1.2.2 Functional Content. Refer to Generator SOR
18、. 3.1.3 Ambient Environment. The generator shall be capable of meeting all performance specifications with inlet air temperatures ranging from -40 C to +125 C. The generator must also be capable of withstanding non-operating storage over the temperature range of -48 C to +125 C, and non-operating st
19、orage temperature of 150 C for 30 minutes, without impairing its ability to subsequently meet all specifications. 3.1.4 Interfaces. 3.1.4.1 Generator Output and Mechanical Interfaces. Generator output power shall be provided via the output terminal connection that shall be an M8 1.25 threaded stud.
20、The stud hardness shall be of grade 8.8 and be tin zinc plated as specified in GMW3200. In addition, the outside end of the threaded stud shall have a dog or P point to ease nut engagement. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo rep
21、roduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14036 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 4 of 22 The stud assembly shall be designed to withstand an applied torque value up to 16 Nm, and shall not lose its str
22、uctural integrity due to repeated loosening and tightening of the terminal nut. To ensure tight output connections, the output terminal may be designed to include a captive bushing that permits the stud to stretch and maintain a significant clamping force on the output ring terminal. The ratio of st
23、retch length to stud diameter shall be 2.5:1. An anti-rotation feature shall be provided to ensure protection against cable rotation. The generator housing and mounting attachments also serve as the generator current return path. This path from chassis ground must be designed for low contact resista
24、nce and exhibit a voltage drop of less than 0.1 V at the maximum generator output current. 3.1.4.2 Generator Control Interfaces. Generator control shall interface using a Packard Electric 2-way sealed harness connector, part number 90563303 (ZFW 2-83). The mating regulator connector shall have the c
25、ontrol functions arranged from left to right in the order (F, L) when viewing the generator with the connector latch tang up. Table 1: Generator Control Interfaces Control Function PE Connector L = Control and Fault Cavity A F = Field Monitor Cavity B The control functions “F“ and “L“ shall be molde
26、d into the generator connector body. If the F-terminal is not required, a threaded stud/ring terminal interface for the L-terminal is optional (upon application requirement). 3.1.4.3 Generator Mounting Interfaces. The mounting bolt pattern for the generator must match that shown in the SOR or outlin
27、e drawing for the appropriate vehicle/powertrain configuration. M10 1.5 or M8 1.25 mounting hardware conforming to metric standards for a class 8.8 or 10.9 bolt, plated according to GMW3044, will be used to mount the generator. All tapped holes in the generator housing shall conform to metric standa
28、rds and shall withstand a minimum applied torque of 48 Nm when using M10 bolts (40 Nm with threaded captive bushing), or 22 Nm when using M8 bolts, without stripping the threads. All through holes shall be able to withstand the forces of fasteners with 67 Nm of applied torque. 3.1.4.4 Generator Cool
29、ing. Air-cooled generators shall employ internal fans. Intake and exhaust ports shall have grills to inhibit the entry of foreign matter. The positive rectifier heatsink of air-cooled generators shall utilize forced convection cooling and not conductive heat transfer for cooling. The minimum insulat
30、ion thickness between the positive heatsink and generator ground shall be 2 mm and the minimum surface leakage distance shall be 5 mm. The generator is required to operate with air inlet ambient temperatures up to 125 C and provide the reliability performance specified herein. 3.1.4.5 Drive Pulley a
31、nd Drive Torque. The generator pulley shall be steel and must comply with GMW16290 or as specified in the SOR or outline drawing. The effective pulley diameter must be as specified for the application. If the SOR specifies a de-coupler type pulley it shall conform to GMW16266. The generator and pull
32、ey shall be capable of supporting a drive belt load, resolved into a single equivalent pulley load, of 1067 N (240 lb) continuous and 1373 N (350 lb) for 0.1% of usage time. The generator supplier shall provide data on generator input torque at 4 different temperatures as a function of generator spe
33、ed and field monitor duty cycle into 14 V, as shown in Appendix A. 3.1.5 Usage Definition. The generator shall convert input shaft mechanical power to output electrical power having a positive voltage with respect to generator housing ground. 3.2 Product Characteristics. 3.2.1 Generator Control. Gen
34、erator control is achieved by using one of the following two control strategies: Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14036 Co
35、pyright 2011 General Motors Company All Rights Reserved June 2011 Page 5 of 22 1. Regulated Voltage Control (RVC), where the generator regulated set-point voltage is controlled remotely. 2. Conventional (non-RVC) Regulation, where the generator regulated set-point voltage is determined by the genera
36、tor internal regulator. Both control strategies employ two terminals: L-Terminal. F-Terminal. In some applications, conventional regulation may not require an F-terminal. 3.2.1.1 L-Terminal. With an RVC regulator, a multifunction control terminal (L-terminal) shall be provided that can be used to: T
37、urn generator output power on or off. Indicate when the generator is insufficiently rotating or operating improperly. The L-terminal is used for set-point voltage control where the regulator voltage is programmed by a 128 Hz 5% Pulse Width Modulated (PWM) voltage waveform applied to the L-terminal.
38、With conventional (non-RVC) regulation, the L-terminal is used to: Turn generator output power on. Indicate when the generator is insufficiently rotating or operating improperly. 3.2.1.1.1 L-Terminal Control Function. Generators with RVC regulators shall have the capability to be turned on or off. G
39、enerator turn-on is normally initiated by pulse-width modulating the L-terminal to a duty cycle that corresponds to the desired regulated set-point voltage. Generator turn-off is accomplished by pulse-width modulating the L-terminal to a low duty cycle that corresponds to a voltage set point below b
40、attery voltage. If the L-terminal remains low after starting engine, the generator will self-start once a nominal operating speed, 3100 15% rpm, is detected. With conventional (non-RVC) regulation, generator turn-on is initiated when a positive voltage (5 V to 12 V) is applied to the L-terminal. The
41、 generator shall also have a self-start capability once a nominal operating speed, 3100 15% rpm, is detected. However, a 2 second time delay is required after initial start-up. After this delay, the generator field must be ramped at the Load Response Control (LRC) rate (5 s) until stable regulation
42、is achieved regardless of engine speed. The generator shall not be damaged with a fully charged 12 V battery continuously connected to the L-terminal even with zero generator shaft speed. The generator regulator shall not return 12 V or battery voltage on the L-terminal control line. For more electr
43、ical characteristics of the L-terminal, refer to GMW8778. 3.2.1.1.2 L-Terminal Monitor Function. The L-terminal shall also function as a fault indicator by pulling the applied voltage low. With RVC, the regulator shall pull the L-terminal low if any of the following conditions occur: Insufficient ge
44、nerator rotation. Field control failure. With conventional regulation, the generator shall pull the L-terminal low when the L-terminal is enabled and any of the following conditions occur: Insufficient generator rotation. High Output Voltage: Generator output voltage is 1.25 0.25 V above the regulat
45、or set point voltage. Low Output Voltage: Generator output voltage is less than 11.35 0.25 V and generator shaft speed greater than 3100 15% rpm. When indicating a fault condition due to insufficient generator rotation, the L-terminal shall be pulled low at a generator speed between 500 rpm and 1000
46、 rpm, with a maximum time delay of 1.5 seconds. 3.2.1.2 F-Terminal. The F-terminal is used to monitor the PWM field voltage. With the generator field referenced to ground, the F-terminal shall be connected to the high side of the field with a provision to limit fault current. When the field switch i
47、s conducting, essentially battery voltage appears at the F-terminal, and, thus, the average F-terminal voltage is proportional to field strength. Generators using a low side field switch Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reprod
48、uction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14036 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 6 of 22 must correct for the field polarity inversion and provide the required PWM field voltage. The PWM field voltage fre
49、quency shall operate between 60 Hz and 460 Hz, and have a duty cycle between 5% and 100%. For more electrical characteristics of the F-terminal, refer to GMW8778. 3.2.2 Generator Output Voltage. The generator output voltage shall be direct current (DC) derived from full wave rectified multi-phase voltages and shall be regulated. Diodes shall not be used to rectify the mid-point of a Wye
