1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW14551 Electronic Throttle Control Pedal Lab Durability Test Copyright 2011 General Motors Company All Rights Reserved December 2011 Originating Department: North American Engineering Standards Page 1 of 19 1 Scope Note: Nothing in this standard supe
2、rcedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. Not applicable. 1.2 Foreword. This procedure is to evaluate the durability characteristics of the Electronic Throttle Control (ET
3、C) Accelerator Pedal Mechanism (APM) as a component. This procedure is a descendant of test procedure GMW15855 Throttle Systems Lab Durability test. 1.3 Applicability. All passenger vehicles, light and medium duty trucks with ETC. 2 References Note: Only the latest approved standards are applicable
4、unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GMW15008 GMW15855 2.3 Additional References. Component Technical Specification (CTS) Data Sheets available from the GM Pedal Engineer National Instruments LabVIEW 3 Resources 3.1 Facilities. GM,
5、Supplier, or contracted test facilities. 3.2 Equipment. 3.2.1 Test Machines. 3.2.1.1 Humidity chamber capable of exposing APMs to 100% humidity at laboratory ambient temperature for 48 continuous hours. 3.2.1.2 Permanent or temporary fabricated environmental chamber capable of maintaining APMs at an
6、y specified uniform temperature between -40 C to 85 C 5 C. This chamber must allow application of simulated foot operated loads and resulting pedal motion. 3.2.1.3 A dry contaminant spray system capable of automatically or manually dispensing a specified quantity or duration of dry contaminant mixtu
7、re specified in Section 3.3.1 to portions of the APM. Unless otherwise specified by GM Engineering, the spray shall be aimed at the pedal pivot, sensor and other vulnerable areas to simulate likely contamination entering the APM. 3.2.1.4 Programmable controller and data logger capable of monitoring
8、the APMs and controlling the load actuator during the three (3) modes for cycling the APM, 3.2.1.4.1 through 3.2.1.4.3 (Reference National Instruments - LabVIEW). 3.2.1.4.1 Actuate from idle to 95% 2% of full travel for 999 cycles at a cycle rate of 1 Hz to 2 Hz, then apply and hold for at least 0.5
9、 second normal 100% full travel load plus twice the load tolerance specified by the 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 GMW14551
10、 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 2 of 19 Component Technical Specification (CTS) for the one thousandth cycle as specified in Appendix A Test Schedules. 3.2.1.4.2 Actuate from idle to full travel with load increased to 334 N 20 N as specified by the Appen
11、dix A Test Schedules at a cycle rate of at 1 Hz to 2 Hz. After the APM has reached the travel or load specified, the actuator must pull back and let the pedal retract by means of its own return mechanism. 3.2.1.4.3 Drive cycle per Appendix G. 3.2.1.4.4 Controller shall provide supply voltage(s) of 5
12、.0 V 0.1 V to each sensor, ground voltage of 0.0 V 0.1 V to each sensor, and control the test environment as specified. The test controller/data recorder shall also be capable of monitoring sensor outputs, applied forces, temperature, humidity, other parameters as specified by GM Engineering, and pe
13、rform continuous near real time sensor diagnostic checks as required per Section 3.5.1 and GM Engineering. See Appendix C for the minimum sensor parameters to be continuously monitored during test. 3.2.1.5 Test fixture that can accurately position a portion of an actual or simulated front of dash (F
14、OD) including deflections, load actuators, environmental chamber and full travel floor stop (if part of the design). GM shall decide if a simulated or actual floor pad, carpeting, floor mat, insulation, pedal stop, and/or other interior vehicle components shall be used in the test based on if or how
15、 the design that is being tested interfaces with these components. Pedal packaging information math data shall be provided by GM. 3.2.1.6 Load actuator capable of applying loads specified in 3.2.1.4. Loads shall be applied to the accelerator pedal pad as specified by GM Engineering. Note: (Reference
16、) 203 mm from the heel point as shown on the design layout (ball of foot position for the 50% male) and the angle of application, shall be 15 degrees left to right in the horizontal plane (Figure 1) for 50% of parts tested each phase, 0 degrees for at least 25% parts tested in each phase, and 15 deg
17、rees right to left in the horizontal plane, for up to 25% of parts tested each phase. Figure 1: Plan View Pedal Apply Angle 3.2.2 Instrumentation. 3.2.2.1 Test controller/data recorder capable of controlling and recording environments, forces, displacements and voltages as specified within. 3.2.2.2
18、Force plot load transducers capable of measuring 0 N to 50 N 0.5 N. 3.2.2.3 Cycling load transducers capable of measuring 0 N to 450 N 3 N. 3.2.2.4 Electronic temperature and humidity sensors. 3.2.2.5 Heating and cooling sources (i.e., heat gun, nitrogen, carbon dioxide (CO2). 3.3 Test Vehicle/Test
19、Piece. Number of samples to be tested per CTS. 3.3.1 Contaminant mixture consisting of the following: 0.14 kg (5 oz) Coarse Air Cleaner Test Dust 0.14 kg (5 oz) 400 grit Alumdum 0.07 kg (2.5 oz) 150 grit Alumdum Copyright General Motors Company Provided by IHS under license with General Motors Compa
20、nyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14551 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 3 of 19 0.14 kg (5 oz) Rock Salt 3.3.2 Miscellaneous Equipment. Wire harnesses with appropriat
21、e connectors for links between connectors and controllers. 3.4 Test Time. Calendar time: 45 to 75 days Test hours: 30 to 60 hours Coordination hours: 32 hours (4 days) 3.5 Test Required Information. 3.5.1 Validation Performance Requirements. Each sensor must be continuously monitored during all test
22、ing as specified in this section. Also, before, during and after testing, each sample must conform to requirements stated in the CTS which may include, but is not limited to: return response, apply load, return load, hysteresis, travel, sensor outputs, etc. See Appendices B and C for minimum paramet
23、ers to be recorded. The sensor parameters shall be checked at least every 1 ms and, in order for proper correlation computations while the pedal is moving, sensor output shall be sampled within 40 s of each other. All errors detected shall be recorded and reported to GM Engineering at regular interv
24、als and in the final test report. A fault or failure is considered to have occurred if during testing, four (4) errors were detected on each of four (4) continuous scans, or 20 errors during any 1 second interval. If a fault is detected, the data logger shall record 10 seconds of all monitored param
25、eter data before and after the fault, the sample shall stop testing, and GM Engineering contacted within 48 hours. Data collection manner shall be reviewed and agreed on by GM and the test facility prior to start of test. 3.5.2 Reliability and Durability goals as defined by the CTS shall be achieved
26、. 3.5.3 Test Reports. Interim and final test reports shall contain actual values, plots of parameters specified in the Data Check List, and total number of errors recorded and when for each sample. Interim and final test reports shall also contain an example of at least one second of typical perform
27、ing data of sensor outputs. 3.6 Personnel/Skills. Technician shall be competent and experienced at performing component tests on electronic systems with applied environments. 4 Procedure 4.1 Preparation. 4.1.1 Inspect all test hardware for damage. If any hardware is damaged, report damage to test en
28、gineer. Do not install on test. 4.1.2 Install test hardware in test buck or equivalent per applicable design layout and Master Process Document (MPD) to simulate in-car position. 4.1.3 Perform Schedule I, II, III, and IV per Appendix A. 4.1.4 Repeat Schedule IV until reliability goals stated in CTS
29、are achieved. 4.1.5 Perform Schedule V. 4.1.6 Before, during, and after: cycling, force and sensor plots, and slow/fast/side load returnability evaluations at environmental extremes, Inspect APMs for cracks, distress, squeaks, rattles, and sticking. 4.2 Conditions. 4.2.1 Environmental Conditions. No
30、t applicable. 4.2.2 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. 4.3 Instructions. 4.3.1 Guidelines. After test APMs can be evaluated on applicable vehicles
31、, or an ETC system simulator for ETC system validation. 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 GMW14551 Copyright 2011 General Moto
32、rs Company All Rights Reserved December 2011 Page 4 of 19 5 Data 5.1 Calculations. Not applicable. 5.2 Interpretation of Results. Not applicable. 5.3 Test Documentation. Report using the Data Sheets available from the GM Pedal Engineer. 6 Safety This standard may involve hazardous materials, operati
33、ons, 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 applicability of regulatory limitations prior to use. 7 Notes 7.
34、1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. APM Accelerator Pedal Mechanism CO2 Carbon Dioxide CTS Component Technical Specification d Displacement ETC Electronic Throttle Control F Force FOD Front of Dash MPD Master Process Document PPS Pedal Position Sensor S Sensor Outpu
35、ts 8 Coding System This standard shall be referenced in other documents, drawings, etc., as follows: Test to GMW14551 9 Release and Revisions This standard was originated in October 2005. It was first approved by the Global Chassis Powertrain Integration Center Team in March 2006. It was first publi
36、shed in June 2006. Issue Publication Date Description (Organization) 1 JUN 2006 Initial publication. 2 DEC 2011 Revised to current template. (Pedal GSSLT) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted w
37、ithout license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14551 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 5 of 19 Appendix A: Test Schedules Table A1: Schedule I Thermal Shocks Force and Sensor Plots per Appendices B,C, D and E, and Sensor Resistance Measur
38、ements at ambient per Appendix I Soak at -40 C for 30 minutes, transition to +80 C within 30 seconds, hold for 30 minutes, transition to -40 C within 30 seconds. Repeat sequence seven (7) times. Table A2: Schedule II Start of Test Side Steps Cycle Count Temperature (C) Travel (% Pedal Position Senso
39、r (PPS) Peak Load (N) 10 Laboratory ambient Release from full travel As required Force and Sensor Plots per Appendices B, C, D, and E, and Sensor Resistance Measurements at ambient per Appendix I Laboratory ambient Idle Full travel As required Table A3: Schedule III 24 Hour Soak at 80 C and 95% Humi
40、dity Event Cycle Count Temperature (C) Travel (%PPS) Peak Load (N) 24 hour soak at 80 C and 95 to 100% humidity 80 5 Begin Schedule IV cold soak within one hour -40 5 Table A4: Schedule IV Cycling Event Cycle Count Temperature (C) Travel (%PPS) Peak Force (N) 2 hour soak at -40 C. Cycle pedal once;
41、pedal shall return on its own to within Ignition Cycle, idle output tolerances within 150 ms. Force and Sensor Plots per Appendices B, C, D, and E. Sensor Resistance Measurements at cold per Appendix I. Apply Force Consistency (stick-slip) evaluation at cold per Appendix F. Noise/Squeak evaluation b
42、eginning at cold per Appendix H. Within Ignition Cycle evaluation at cold per Appendix G. -40 5 As specified As required Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WOR
43、LDWIDE ENGINEERING STANDARDS GMW14551 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 6 of 19 Event Cycle Count Temperature (C) Travel (%PPS) Peak Force (N) 2 hour soak at +80 C. Force and Sensor Plots. Sensor Resistance Measurements at hot. Apply Force Consistency (stic
44、k-slip) evaluation at hot. Noise/Squeak evaluation beginning at hot. Within Ignition Cycle evaluation at hot. 80 5 As specified As required Once every 1000 cycles As required for 95% travel, and CTS specified full travel +2 times tolerance Force and Sensor Plots (This evaluation not required after 1
45、 M cycles.) Lab ambient As specified As required Cycle 1001 to 10 000 Lab ambient Idle to 95%, full travel once every 1000 cycles As required for 95% travel, and CTS specified full travel +2 times tolerance Force and Sensor Plots (This evaluation not required after 1 M cycles.) Lab ambient As specif
46、ied As required Cycle 10 001 to 100 000 Lab ambient Idle - 95%, full travel once every 1000 cycles As required for 95% travel, and CTS specified full travel +2 times tolerance Force and Sensor Plots (This evaluation not required after 1 M cycles.) Lab ambient As specified As required Cycle 100 001 t
47、o 150 000 -40 5 Idle - 95%, full travel once every 1000 cycles As required for 95% travel, and CTS specified full travel +2 times tolerance Force and Sensor versus Displacement Plots at cold, Force consistency evaluation at cold, and Noise/Squeak evaluation at cold. -40 5 As specified As required Co
48、pyright 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 GMW14551 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 7 of 19
49、Event Cycle Count Temperature (C) Travel (%PPS) Peak Force (N) Cycle 150 001 to 200 000 80 5 Idle to 95%, full travel once every 1000 cycles As required for 95% travel, and CTS specified full travel +2 times tolerance 2 hour soak at -40 C. Cycle pedal once. Pedal shall return on its own to within ignition cycle, idle output tole
