1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW14278 Static and Dynamic Test of Cover Spare Wheel/Tool Compartment and Shelves in the Vehicle Load Compartment Copyright 2011 General Motors Company All Rights Reserved November 2011 Originating Department: GME Specification Center Page 1 of
2、 12 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. The purpose of this test procedure is to determine deflection and durability
3、of the spare wheel/tool compartment cover and other shelves under static and dynamic loads. 1.2 Mission/Theme. This specification is applicable to all covers, load floors, and shelves in installed condition. The test shall be performed with all released installation components. 1.3 Classification. N
4、ot applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GMW3059 GMW15992 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 Calibration. The test facilities and eq
5、uipment shall be in good working order and shall have a valid calibration label. 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with respect to their physical definition. 3.1
6、.3 Facilities. Short-wave Belgian Block Track (e.g., on the Dudenhofen PG). 3.1.4 Equipment. 3.1.4.1 Adjustable measuring linkage. 3.1.4.2 Base plate/load application plate 300 mm x 300 mm. 3.1.4.3 Base plate/load application plate with a diameter of 80 mm. Rubber stamp (diameter 20 mm attached in t
7、he center of the 80 mm plate) 3.1.4.4 Measuring tape. 3.1.4.5 Straight rod (e.g., made of aluminum or wood) 600 mm x 30 mm x 4 mm. 3.1.4.6 The test weight should be the max. authorized vehicle payload (rear axle load). 3.1.4.7 Tie down ropes/belts. 3.1.4.8 Sand bags preferably 20 kg each. 3.1.5 Test
8、 Vehicle/Test Piece. 3.1.5.1 Load Surface and Measuring Points. The load application plate/base will be placed centrally with reference to the supporting distance 400 mm. Deflection is measured in the center of the loaded surface. Copyright General Motors Company Provided by IHS under license with G
9、eneral Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14278 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 2 of 12 With supporting distances 400 mm an edge of the base plate is place
10、d 50 mm from a supporting edge. Deformation is measured at this edge. 3.1.6 Test Time. Not applicable. 3.1.7 Test Required Information. 3.1.7.1 Maximum Loads. If not otherwise defined within the scope of the project, the basic assumption is that the load floors and shelves are capable of the max. au
11、thorized payload. Consequently the Fmax. is defined as the maximum allowed payload on the rear axle. Thus, Fmax=Max axle load Curb mass rear axle Otherwise, the program Mass Engineer and/or Chassis DRE/SVE shall be able to provide the payload rear axle data. 3.1.7.2 If the load compartment is provid
12、ed with tie-down rings for securing the cargo, load floor stress will be increased if the tie-down rings are used. In such case force Fmax. shall be multiplied by factor 0.2 and considered for testing with tie-down rings. Refer to Static Abuse Test according to paragraph 4.3.1. 3.1.8 Personnel/Skill
13、s. Not applicable. 3.2 Preparation. The test sample shall be allowed to soak at the appropriate inspection temperature for 2 h prior to the test. 3.2.1 The test temperatures for static tests are: -30 C, +20 C, and +80 C. 3.2.2 The maximum allowed deviation is 3 C. 3.3 Conditions. 3.3.1 Environmental
14、 Conditions. See paragraph 3.2. 3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.4 Instructions. Not applicable. 3.5 Data. Not applicable. 3.6 Safety. T
15、his standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicabili
16、ty of regulatory limitations prior to use. 3.7 Documentation. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and approved by the responsible GM Department prior to the start of delivery of production level components
17、or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation of any change
18、or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed to between the
19、responsible GM department and the supplier. 3.7.1 Test Results. The test results shall be documented in Appendix A, Data Sheet A1. 4 Requirements and Procedure 4.1 Static Test. The purpose of this test is to determine the deflection under static load. The static load is of the maximum authorized pay
20、load (axle load). F stat = F max 4.1.1 Static Test Performance. For this test, the 300 mm x 300 mm base plate will be used. The test sample shall be placed in the original body, or an appropriate underbody in installed position. The base plate shall be placed as described in paragraph 3.1.5. 4.1.1.1
21、 The deformation zero-measurement is made with a load of 100 N applied to the base plate. 4.1.1.2 Immediately after this the total weight Fstat is applied to the sample (on the squared plate as shown at Figure 1), 100 N is included in the total weight. Copyright General Motors Company Provided by IH
22、S under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14278 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 3 of 12 Figure 1: Load Application using a Test Buck
23、4.1.1.3 After 15 minutes of load application the deflection (elastic deformation) shall be measured at the points defined above. 4.1.1.4 The weight is now removed except for the basic load. 4.1.1.5 After further 15 minutes the permanent (plastic) deformation shall be measured. 4.2 Dynamic Test. The
24、purpose of this test is to determine the deflection under dynamic load conditions. The dynamic test shall be made at the maximum authorized load Fdyn. For this the 20 kg sandbags shall be evenly placed on the sample to be tested. F dyn = F max The number of sandbags is limited by the requirement tha
25、t it shall be possible to close all doors and the tailgate (in the case of SUVs, from the load floor to the headliner). If the specified load cannot be applied, the load applied shall be documented as the test load. 4.2.1 Test on the Belgian Block Track. Before the test, check the test sample evenne
26、ss using a straight rod. Uneven areas shall be recorded. The test load shall be placed and secured with tie down belts. Subsequently, the following tracks shall be used: x Torture Track (20 times) x Belgian Block 0.3 km with speed 30 km/h x Chuckholes 0.3 km with speed 35 km/h x Hump track 0.3 km wi
27、th speed 35 km/h (e.g., on the Dudenhofen Proving Ground, Milford Proving Ground). 4.2.1.1 The total weight Fmax. shall be removed. 4.2.1.2 After a recovery time of 15 minutes, the straight rod shall be placed diagonally in the obviously most unfavorable location for measurement of the permanent set
28、. 4.2.2 Curb Test. Before the test, check the test sample evenness using a straight rod. Uneven areas shall be recorded. The test ballast shall be placed and secured with tie down belts. Subsequently, drive off a 100 mm high curb (i.e. sidewalk) at a right angle in forward direction 10 times as show
29、n in Figure 2. The test shall be performed at a vehicle speed of 5 km/h maximum. Figure 2: Curb Test Diagram 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 ENGIN
30、EERING STANDARDS GMW14278 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 4 of 12 4.2.2.1 Remove total weight. 4.2.2.2 After a recovery time of 15 minutes, the straight rod shall be placed diagonally in the obviously most unfavorable location for measurement of permanent
31、 set. 4.3 Abuse Test. The purpose of the abuse test is to check whether the parts are capable of carrying the specified loads. When driving the vehicle, vertical accelerations of up to 5G will occur. For the calculation of the max. load, accelerations of up to 2.5G shall be considered. Failure of th
32、e parts as a result of the test is not allowed. Failure is defined as cracks and buckles jeopardizing full function of the parts. Even without destruction, no obvious permanent deformation is allowed after removal of the load. The 20 kg sandbags shall be evenly placed on the sample to be tested. 4.3
33、.1 Static Abuse Test (Distributed Load test). The static abuse test is defined as follows: FMstat.= (Fdyn x 0.2 (if tie downs available) + (Fdyn x 2.5) In some cases, when using a test buck or vehicle, FMstat calculation may be affected or limited by the volume capacity in the rear compartment. If t
34、his is the case, test the load floor separately with all its supporting components. A picture using a test buck is shown at Figure 3. Figure 3: Distributed Load Test example 4.3.1.1 A 5 minute load application must not result in failure of the test sample. 4.3.1.2 After the test, no cracking is allo
35、wed. Permanent deformation is allowed as long as it does not compromise the perceived quality of the customer eyes. Full function of the part shall not be compromised. 4.3.1.3 This test can be performed instead of the Dynamic Test described in paragraph 4.2. This static abuse test is performed only
36、if the dynamic test is not run. It is one or the other. 4.3.2 Dynamic Abuse Test. The dynamic abuse test is defined as follows: FMdyn = Fdyn x 1.2 Dynamic abuse test is performed in the road tracks described in paragraph 4.2.1. The factor 1.2 in the formula above is used when having tie downs. If no
37、t available, this test is not applicable 4.3.2.1 The test shall not result in failure of the test sample. No cracking is allowed. Permanent deformation is allowed as long as it does not compromise the perceived quality of the customer eyes. Full function of the part shall not be compromised. 4.3.2.2
38、 The evaluation shall be made immediately after the test according to the criteria described in the Dynamic Test according to paragraph 4.2. 4.3.2.3 This test is required only when the Dynamic Test according to paragraph 4.2 is performed. Copyright General Motors Company Provided by IHS under licens
39、e with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14278 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 5 of 12 4.4 Static Abuse Test Point Loading (Knee/Palm Test). Place
40、 the base plate with a diameter of 80 mm in the weakest place (e.g., in the center of an unsupported area, or over a cavity). Subsequently, a body style specific weight shall be applied. An example is shown in Figure 4. 4.4.1 A 5 minute load application must not result in failure of the test sample.
41、 No cracking is allowed. Permanent deformation is allowed as long as it does not compromise the perceived quality of the customer eyes. Full function of the part shall not be compromised. 4.4.2 Weight. 4.4.2.1 Hatch Backs and Wagons or similar body styles the weight is 1000 N. 4.4.2.2 Notch Backs an
42、d other Vehicles with enclosed trunks the weight is 500 N. Figure 4: Knee/Palm Test Load Application 4.5 Sand Bag Drop. This test can run with a full vehicle, Buck or fixtured. Place the load floor in designed position, including the design supporting areas. A 20 kg sandbag shall drop from a height
43、of 300 mm from the load floor. Test environment at ambient, +80 C and -30 C. Load shall be dropped in the weakest load floor area. No cracking or permanent damage to the load floor is permissible. 4.6 Sill Plate with and without Flipper Door. 4.6.1 Static Abuse Test (Point Loading). The tests shall
44、be performed either fixed or in a vehicle/buck. The 80 mm base plate shall be used. Place the base plate in the weakest location (e.g., in the center of an unsupported area, over a cavity, or between two attachment points). Subsequently, the load is applied. 4.6.1.1 A 15 minute load application must
45、 not result in failure of the test sample. 4.6.1.2 On each side of the flipper door mechanism a vertical load of 500 N shall be applied at the same time as shown in Figure 5. Measurement of the deformation is not required. After the test, visible signs of objectionable permanent damage, breakage or
46、cracking is not allowed. The Sill Plate must remain attached to the Body. The sealing shall be in the intended position. No loss of function. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without licens
47、e from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14278 Copyright 2011 General Motors Company All Rights Reserved November 2011 Page 6 of 12 Figure 5: Static Abuse Test (Point Loading) 4.6.2 Static Abuse Load Flipper Door Area (Z Load). Test to be performed either fixed or in a vehicle/buck. For
48、this test a tensile/compression gauge with a 80 mm base plate and 20 mm diameter rubber stamp shall be used to simulate a punctual load. A force F = 100 N and 200 N shall be pushed vertically in the rear flange surface of the sill plate/flipper door as shown in Figure 6. The load shall be applied co
49、nstantly until the load is reached. The test should run 5 times (cycles) per load. Neither the axis or bracket should imply any signs of loss of retention to sill plate, nor the sill plate imply any signs of cracking. Deformation and/or detachment of the rod from the sill plate hooks retainers is not permissible. Figure 6: Z Load Application Point 4.7 Durability 4.7.1 Durability Test Load Floor. 4.7.1.1 Rel
