1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW14106 Specification for Integrated Fuel Tank Assembly Copyright 2012 General Motors Company All Rights Reserved January 2012 Originating Department: North American Engineering Standards Page 1 of 30 1 Introduction Note: Nothing in this standa
2、rd 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 document provides the standard technical requirements for the Integrated Fuel Tank Assembly. This document shall only b
3、e used when invoked by a program specific technical specification. References to the program specific technical specification are included in this document where program specific requirements are expected to exist. The program specific technical specification may include additional program specific
4、requirements that are not referenced in this document and may supercede any requirements included in this document. In the case of any conflicts between this document and the program specific technical specification, the program specific technical specification takes precedence. This specification e
5、stablishes the Integrated Fuel Tank Assembly requirements for General Motors (GM) gasoline, gasoline blend, and diesel fueled vehicles. The functions, performance, design constraints, and validation required of the Integrated Fuel Tank Assembly are directly defined in this document or a reference is
6、 made to another document. Refer to the Fuel Pump Module (FPM) Component Technical Specification (CTS) for requirements specific to the module. This document contains component technical specifications common to all programs. Reference the program/vehicle specific document for additional requirement
7、s unique to the application. 1.2 Mission/Theme. The Integrated Fuel Tank Assembly is a functional vehicle component for receiving and storing fuel; sensing and signaling fuel quantity; supplying fuel to the engine; and (for gasoline only) managing both refueling vapor and fuel vapor generated during
8、 use of the vehicle by the vehicle operator. The integrated fuel tank assembly is to carry out these functions while meeting specific requirements of the customer, the Powertrain, other interfaces, mandated safety and emission standards, and corporate objectives. 1.3 Classification. This specificati
9、on applies only to gasoline, gasoline blend and diesel fueled vehicles. It includes requirements for both complete and incomplete vehicles, and for specific applications, such as police and taxi use. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1
10、 External Standards/Specifications. 40 CFR, Part 86 DIN EN 228 FMCSR 393.65 SAE J2587 70/220/EEC DIN EN 590 FMCSR 393.67 ASTM A463M DIN V 51606B GB18296-2001 ASTM D4169 E/ECE/324 SAE J1645 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo repr
11、oduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14106 Copyright 2012 General Motors Company All Rights Reserved January 2012 Page 2 of 30 2.2 GM Standards/Specifications. 9984120 GMW14291 GMW14846 GMW15017 9984123 GMW14475 GMW14847 GMW15200 GM6295M
12、 GMW14507 GMW14848 GMW15272 GM9322P GMW14508 GMW14849 GMW15311 GMW3032 GMW14547 GMW14850 GMW15357 GMW3059 GMW14555 GMW14851 GMW15359 GMW3086 GMW14573 GMW14852 GMW15449 GMW3116 GMW14638 GMW14853 GMW15450 GMW8518 GMW14671 GMW14854 GMW15451 GMW14057 GMW14681 GMW14860 GMW15646 GMW14081 GMW14800 GMW14872
13、 GMW15862 GMW14085 GMW14801 GMW14889 GMW15986 GMW14170 GMW14802 GMW14992 GMW16434 GMW14234 GMW14842 GMW15010 2.3 Additional References. 10325851 Embedded Ring (Plastic Tanks) 10325852 Lock Ring 10336924 Weld Ring (Steel Tanks) 15224665 Tank Groove 15256371 Modular Reservoir Assembly (MRA) Flange 157
14、76431 Lock Ring 15776432 Embedded Ring (Plastic Tanks) 15776433 Seal (Fluorocarbon) 15776434 MRA Flange 15776438 Tank Groove 22682111 Seal (Fluorocarbon) CG1130 Integrated Fuel Tank Assembly Program Specific Document CG1752 Hydrocarbon Permeation Measurement Process CG2015 Integrated Fuel Tank Assem
15、bly SSTS Section 4.2 Validation Cross Reference Index (VCRI) CG2309 Process Control exhaust system, body and suspension components according to the design guidelines identified in Fuel Tank Clearances Best Practices. The Exhaust and Body Groups shall agree on the packaging for the specific applicati
16、on, to ensure clearances are maintained. 3.2.5.3 Fuel Tank Assembly Interface. The major interfaces within the integrated fuel tank assembly are defined in the following paragraphs. 3.2.5.3.1 Inlet Check Valve (ICV) Assembly Interface. The major interfaces of the inlet check valve assembly are defin
17、ed in the following paragraphs. 3.2.5.3.1.1 ICV Electrical Grounding. Reference the Inlet Check Valve Component Technical Specification for Electrical Grounding. 3.2.5.3.1.2 ICV to Tank Shell Connection. The inlet check valve assembly shall have a leak-free mechanical connection (weld) to the fuel t
18、ank. 3.2.5.3.1.3 Fill Pipe Assembly to ICV Pull Off Force. The Inlet Check Valve to Fuel Fill Pipe Hose joint must satisfy the Fuel Fill Hose Pull-Off Test per GMW14291. 3.2.5.3.1.4 ICV to Fill Pipe Hose Connection. The Inlet Check Valve to Fuel Fill Pipe Hose joint must satisfy the Fuel Fill Hose S
19、ealing Test per GMW14681. 3.2.5.3.1.5 Fill Pipe Hose to ICV Insertion Force. The maximum insertion force of a Fuel Fill Pipe hose over an Inlet Check Valve shall be less than or equal to 67 N or satisfy the Fuel Fill Hose Push-On Test per Copyright General Motors Company Provided by IHS under licens
20、e with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14106 Copyright 2012 General Motors Company All Rights Reserved January 2012 Page 15 of 30 GMW14291. Only new hoses not previously assembled shall be
21、used to establish a push on force, repeated assembly of the same hose shall not be allowed. 3.2.5.3.2 Modular Reservoir Assembly. The MRA to fuel tank mounting shall provide a leak free interface when assembled. 3.2.5.3.2.1 Fuel Tank Assembly Natural Frequency. The fuel tank assembly, when mounted i
22、n the vehicle, shall not have a natural frequency less than 30 Hz, as measured in an area directly below the MRA reservoir, or at the cover. 3.2.5.3.3 Fuel Level Sensor Clearance. The reservoir as assembled in the tank shall have a minimum clearance of 25 mm from the fuel level sensor float arm and
23、float in its entire range of movement. Clearance to the tank top and bottom (vertical directions only) may be less than 25 mm to achieve the desired fuel indication levels, however, clearance shall be considered for build variation to avoid noise or float damage. (Reference Fuel Pump Module CTS GMW1
24、4081.) 3.2.5.3.4 Shutoff and/or Vent Valve Assembly. The shutoff valve assembly shall provide a leak free interface when assembled to the tank. 3.2.5.3.4.1 Fill Pipe Assembly and/or Fill Pipe Vent Line to Shutoff and or Vent Valve POA of Tank Shell. The Shutoff and/or Vent Valve Assembly to Fuel Fil
25、l Pipe Hose joint must satisfy the Fuel Fill Hose Pull-Off Test per GMW14291. 3.2.5.3.4.2 Shutoff and/or Vent Valve Assembly to Fill Pipe Vent Hose Connection. The Shutoff and/or Vent Valve Assembly to Fuel Fill Pipe Vent Hose joint must satisfy the Fuel Fill Hose Sealing Test per GMW14681. 3.3 Desi
26、gn and Construction. Requirements and constraints applicable to design and construction characteristics of the Integrated Fuel Tank Assembly are identified in the following paragraphs. 3.3.1 Materials, Processes, and Parts Selection Guidelines. Constraints and guidelines that apply to the materials,
27、 processes, and parts to be used in the integrated fuel tank assembly follow. 3.3.1.1 Material Guidelines. Materials specific to the integrated fuel tank assembly are to satisfy the following (reference Fuel Storage and Handling SSTS for complete material listing): 3.3.1.1.1 GM Engineering Materials
28、 and Processes Standards. Materials shall be selected in accordance with the GM Engineering Materials and Processes Standards unless superceded by specific requirements identified in this document. 3.3.1.1.1.1 Tank Material. Material specified for Plastic Fuel Tanks is GMW3086, and GM6295M or Type 1
29、 ASTM A463M, Coating Designation T1M 120 for steel tanks. Deviations require approval from Materials Engineering. 3.3.1.1.2 Material Selection. Materials that would create a disposal concern, e.g., lead, should not be selected. 3.3.1.1.3 Corrosion Testing. Test for Cosmetic Corrosion per GMW14872, t
30、he fuel tank assembly shall meet the requirements GMW15272 (see Appendix A), based on rating per GMW15357 and GMW15359. 3.3.1.1.4 Functional Corrosion. Test per GMW14872 duration D. 3.3.1.1.4.1 Fuel Tank Assembly shall have no loss of function or leak fuel per Leak Detection section 3.3.1.1.14. 3.3.
31、1.1.4.2 Be rated 6 or better per GMW15357 and GMW15359. 3.3.1.1.4.3 Not have parent metal loss (pitting) exceeding 10% of the original material thickness. Use a mild media blast process or a non-damaging cleaning solution to remove corrosion by product before taking metal loss measurement. 3.3.1.1.5
32、 Recycling Guidelines. The fuel tank assembly shall be identified for recycling in accordance with GMW3116. 3.3.1.1.6 Polymer Parting Line/Pinch. Plastic fuel tank parting lines shall not extend beyond the tank wall greater than 2 mm, and pinch flanges shall not exceed 6 mm. 3.3.1.1.7 Fuel Tank Drop
33、 Test GMW14853 Non-Metallic Fuel Tank, -40 C Six Meter Drop Test. Used by tank suppliers to develop tank designs and for quality control during production. The drop test shall be conducted in accordance with GMW14853. Testing to this section shall be done during development and a specified frequency
34、 shall be agreed upon within the control plan. Polymer Fuel Tank Shell drop test supercedes GMW3086 requirements. The fuel tank shall be dropped from a height that is 6 m above the floor it Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo rep
35、roduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14106 Copyright 2012 General Motors Company All Rights Reserved January 2012 Page 16 of 30 is striking during a freefall or a height that applies an impact energy of 4000 J when the fuel tank strikes
36、 the floor. The shell drop test is to include the encapsulated MRA ring. All test data to be reviewed with GM Engineering for disposition. 3.3.1.1.8 Fuel Tank Shell Burst Test. GMW15449 (Pressure Testing of Nonmetallic Fuel Tanks) for the Fuel Tank Shell Burst test supercedes GMW3086 requirement. Th
37、e tank shell pressure during the test shall meet a burst test requirement of 345 kPa (50 psi). 3.3.1.1.8.1 Polymer Tank Shell Hardware for Burst Test. The test shall be conducted in accordance with GMW15449 for polymer tank shells. The burst test is to include the encapsulated FPM ring (E ring) for
38、polymer tanks. 3.3.1.1.8.2 Steel Tank Hardware for Shell Burst Test. Testing shall be conducted in accordance with GMW15449 for steel tank shells in the region of the Corporate Common Component (CCC) FPM interface to the tank shell. The components shall include E, L and O rings, FPM flange and the s
39、teel shell O ring groove. The intent is to test the burst integrity of the seal interface components; it is not intended to test a steel tank shell or integrated tank assembly. The tank shell and O ring groove shall be Light duty steel per GM6295M, or Type 1 ASTM A463M, Coating Designation T1M 120.
40、3.3.1.1.9 Fuel Tank Assembly Burst Test for Polymer Tank Shell and Integrated Components. GMW15449 (Pressure Testing of Nonmetallic Fuel Tanks) The integrated fuel tank assembly burst test supercedes GMW3086 requirement. Test shall be conducted in accordance with GMW15449. The tank pressure during t
41、he test shall meet a burst test requirement of 275 kPa (40 psi). This test is to be conducted in vehicle assembly or a fixture to simulate this condition. 3.3.1.1.10 Lubricant specified per Chassis Fuel Subsystem Technical Specification Section 3.3.1.1. 3.3.1.1.11 Recyclable Recovery Guidelines. The
42、 integrated fuel tank assembly shall support the system requirements for Recyclable Recovery guidelines per GMW3116, reference the Fuel Storage and Handling Subsystem Technical Specification. 3.3.1.1.12 Lock Ring Assembly Torque. The lock ring assembly torque shall be greater than 135 Nm and less th
43、an 406 Nm, and shall be 100% inspected per SAE J2587. 3.3.1.1.13 Refer to the preferred material web site for material callouts (URL link in Tech Memory, Chassis Fuel Best Practices). Deviations require approval from Materials Engineering. 3.3.1.1.14 Leak Detection. Leak test procedures must ensure
44、that the MRA and baffles are not displaced inside the fuel tank during leak check procedure. 3.3.1.1.14.1 Leak Testing of Nonmetallic Fuel Tank (Air Under Water). Tests shall be conducted in accordance with GM9322P. Every tank manufactured shall be leak tested. No permanent deformation or leakage is
45、 allowed. Programs using OBD are not required to run this test. 3.3.1.1.14.2 Leak Testing of (OBD) On Board Diagnostics Tank (Helium or Equivalent). The Integrated Fuel Tank Assembly shall support the subsystem leak detection and vapor flow monitoring to meet the on-board diagnostic requirements, an
46、d maximum allowable 15 m leak to atmosphere. Reference the Fuel Storage and Handling Subsystem Technical Specification (in regions where applicable). The integrated fuel tank assembly shall be designed to avoid bottoming out or over extending the fuel pump module during onboard leak diagnostic testi
47、ng. Every OBD tank assembly manufactured shall be leak tested with helium or equivalent to 15 m. Details regarding the leak testing procedure (conditions, media, and test procedure) must be agreed upon between supplier and GM Procuring Division. 3.3.1.1.15 Heat Cycle. Subject a fully assembled empty
48、 tank to 15 heat cycles, where one cycle consists of: -40 C 3 C for 7.5 h, followed by +23 C 3 C for 0.5 h, followed by +80 C 3 C for 15.5 h, followed by +23 C 3 C for 0.5 h. After the heat cycle is complete, perform leak test per Leak Detection section 3.3.1.1.14. 3.3.1.1.16 Fuel Level Sensors Full
49、 and Empty Stop Check. After the production assembly of all Fuel Level Sensors (FLS) into the integrated fuel tank assembly a 100% check on each (FLS) resistance shall be conducted. The resistance shall be checked at the “full” and “empty” stop positions. The resistance level shall be within the parameters identified in GMW14081 Fuel Pump Module Specification, Sensor Accuracy (reference section 3.2.1.78 Table 25). Copyright General Motors Comp
