1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW14785 Coolant Joint Pressure Vibration Temperature (PVT) Cycle Test Copyright 2012 General Motors Company All Rights Reserved August 2012 Originating Department: North American Engineering Standards Page 1 of 19 1 Scope Note: Nothing in this standar
2、d 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 Purpose. The purpose of this test is to evaluate the sealing capability of engine coolant hose connections and evaluate individual c
3、omponents of the hose connections by subjecting coolant hoses and their attachments to a thermal aging process and a pressure and motion/vibration cycle. 1.2 Foreword. Not applicable. 1.3 Applicability. This test is applicable to all vehicles and trucks utilizing glycol/water cooled internal combust
4、ion engines. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GMW14870 2.3 Additional References. 9985809 P-V-T Users Manual 3 Resources 3.1 Facilities. 3.1.1 A complete Press
5、ure-Vibration-Temperature (P-V-T) facility to enclose the coolant joints and related fixturing. The facility will include but is not limited to: 3.1.1.1 An environmental chamber capable of maintaining operating temperatures ranging from (-40 2) C to (+121 2) C (-40 3) F to (+ 250 3) F). 3.1.1.2 A mo
6、tion/vibration inducing system capable of ( 1.27) cm ( 0.5 in) displacement at a frequency of 60 cycles per minute. Displacement capability of up to ( 2.54) cm ( 1.0 in) or more is suggested to support exploratory testing. See Appendix D, Figure D1. 3.1.1.3 A variable displacement coolant circulatio
7、n pump capable of flowing coolant through the hoses at a rate of 11.3 L/minute to 19.0 L/minute (5.0 gal/minute) at room temperature. 3.1.1.4 A pressurization system capable of pressurizing the coolant to 0 kPa, 105 kPa, and 210 kPa (0 psig, 15 psig, and 30 psig, 0.5 psig), at a rate of 8 kPa/s (1 p
8、sig/s) at ambient temperature. 3.1.1.5 A coolant heater capable of heating the coolant to a maximum of (+121 2) C (+250 3) F). 3.1.1.6 An operating system (automatic or manual), with instrumentation, to control the test parameters listed above. 3.2 Equipment. 3.2.1 Instrumentation. Provided by IHSNo
9、t for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14785 Copyright 2012 General Motors Company All Rights Reserved August 2012 Page 2 of 19 (Optional) A precision measuring device to determine air tool speed in rpm. (Optional) Press
10、ure transducer, strip chart recorder, digital data logger, direct current (DC) amplifier, DC power supply to monitor pressurization ramp rate. No additional instrumentation required unless specified/indicated on Test Work Order (TWO), Activity Request (AR) or Test Plan. Note: Instrumentation is to b
11、e calibrated per laboratory standard practice. 3.2.2 Test Equipment. 3.2.2.1 Torquing Device. A pneumatic or electric torquing tool with microprocessor-based torque/angle controller monitor, having a power rating of 0.25 kW (1/3 hp) or less, with free speed not to exceed 350 rpm. Optional: A digital
12、 hand torque wrench. 3.2.3 Fixturing. Miscellaneous fixturing, fasteners, manifolds, and other mounting provisions to accommodate the test material. 3.3 Test Piece. Test material includes all hoses and attachments required to recreate/simulate in-vehicle installation. 3.3.1 Hoses/Assemblies. Complet
13、e hoses or hose assemblies including clamps and/or quick connects. For Validation testing, these should be certified hoses provided by the hose supplier, unless otherwise specified by the Requesting Engineer. For Development testing, the Requesting Engineer should specify hose conditions required/al
14、lowed. 3.3.2 Attachments. All attaching hardware, including retaining clips, brackets, etc., which constrain hose movement. 3.3.3 Fittings. One set of fittings for each hose/assembly to be tested simultaneously in the chamber, plus one additional set for installation force measurement. A set of fitt
15、ings is comprised of one production fitting (or production representative fitting for each free end of the hose/assembly). 3.3.4 Coolant. To reduce the formation of steam, coolant mixture shall be 85% ethylene glycol per 9985809 and 15% distilled water by volume. 3.3.5 Lubricant. Some fittings may r
16、equire lubrication, per direction from test requestor. If required, apply lubricant specified by test requestor, approximately six (6) ml per fitting. Record lubricant part number in test log. 3.4 Test Time. Times are dependent on the number of samples which can be tested simultaneously. The followi
17、ng estimates are for a minimum of two samples and maximum of six (6) samples. Calendar time: 10 days to 15 days (typical) Test hours: 6 hours to 20 hours Coordination hours: 10 hours to 20 hours 3.5 Test Required Information. 3.5.1 Test Work Order, Activity Request (AR), or equivalent local authoriz
18、ing documentation. 3.5.2 Test Log Data, both manual and digital. (Appendix B) 3.5.3 Validation Test and Vehicle Review form. (Appendix B) 3.5.4 Hose assembly part numbers and installation layouts clearly describing the X, Y, Z mounting locations of all fittings, hoses, clips and brackets, as require
19、d. (Appendix C) 3.5.5 Test Plan. Provide a plan, including purpose/scope of test, material availability date, required completion date, etc., per local requirements. 3.5.6 P-V-T Users Manual. 3.6 Personnel/Skills. Not applicable. 4 Procedure 4.1 Preparation. 4.1.1 Documentation. Procure the referenc
20、e documents specified in Section 3.5. Record test information and test type, Test Work Order/Activity Request /Task Number, dates, sample part numbers, etc. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14785 C
21、opyright 2012 General Motors Company All Rights Reserved August 2012 Page 3 of 19 4.1.2 Facility Preparation. Procure the test facility as defined in Section 3.1. Note: Refer to test plan to confirm motion/vibration displacement. 4.1.3 Equipment Preparation. Procure the test equipment, instrumentati
22、on, and fixturing described in Section 3.2. 4.1.4 Test Setup. 4.1.4.1 Review P-V-T Users Manual for system operation. 4.1.4.2 Number all hose test samples in sequential order and label each joint which is “on test“, according to its fitting type, (i.e., engine, radiator, heater, surge tank, etc.) Fo
23、r example: The radiator connection of hose No. 1 would be labeled R1, engine connection E1, etc. 4.1.4.3 Measure fittings, hoses, and installation force, per GMW14870 and document results. This information will be helpful for root cause determination in the event of a leak, blow off or installation
24、effort concern. 4.1.4.4 Install the test sample(s) on the test frame per installation assembly layout, (i.e., orientation of clamps and hoses). Installation of the hoses should match the in-vehicle mounting dimensions and orientation. Any deviation from the installation assembly layout must be appro
25、ved by the Requesting Engineer and/or Validation Engineer. 4.1.4.5 Typically, more than one hose assembly is tested in the chamber at the same time. Document the location of each hose assembly, relative to the other hoses in the chamber (i.e., top or bottom, front or rear position). Also, document t
26、he position of drip sensors. (S1, S2, S3, S4, etc.) 4.1.4.6 If required, torque hose screw clamps to the desired torques (or torque ranges) using one of the tools defined in Section 3.2.2. Record the torque values obtained. If using a tool requiring rpm monitoring, also record actual tool speed. Not
27、e that constant tension spring band hose clamps do not require any torquing. 4.1.4.7 If alignment marks are not present, create an “index“ at the end of each hose after the clamps have been set/torqued. Use a permanent marker to draw a straight line the along the axis of the hose, from the clamp to
28、the end of the hose and onto the fitting. The intent is to provide a reference to determine if the hose moves and how much. Do not use a scribe or any other marking device which could scratch or otherwise damage the surface of the hose or clamp. 4.2 Conditions. 4.2.1 Environmental Conditions. 4.2.2
29、Test Conditions. Deviations from the requirements of this standard shall have been agreed upon by the Requesting Engineer and Validation Engineer before starting the test. Deviations shall be specified on component drawings, test certificates, reports, etc. 4.2.2.1 Test Tolerances. Tests shall be co
30、nducted under known conditions as defined in Section 3.1.1, maintaining temperature within ( 1.6) C ( 3) F), or according to the design specification requirements. 4.2.2.1.1 Instrumentation shall be calibrated as required. Record date of calibration on Test Data Sheet or Test Log Sheet. 4.2.2.1.2 Te
31、st setup and equipment shall be capable of maintaining test parameters (example: load, angles, temperature, etc.) within the limits outlined by the design specifications. 4.2.3 Sample Size. Validation Test six (6) samples or per Validation Engineers request. 4.2.4 Performance Objectives. Performance
32、 objectives are as provided by the Test Plan. 4.2.5 Test Criteria. The following joint conditions are acceptable: 4.2.5.1 Permissible Hose Movement. Movement of the hose to the point where the clamps are up against the blow off bead, or the actual hose movement is less than that specified by the Val
33、idation Engineer and/or as indicated in the Test Plan. 4.2.5.2 Acceptable Leak Rate. See Table 1. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14785 Copyright 2012 General Motors Company All Rights Reserved Au
34、gust 2012 Page 4 of 19 Table 1: P-V-T Cycle Segments Segment Number Temperature Range P-V-T Test Criterion for Acceptance 1 (-40 to -36) C (-40 to -32) F) Seepage Acceptable 1 (-36 to 0) C (-32 to +32) F) 1 drop/minute 1 (0 to +121) C (+32 to +250) F) 0 drops 2 +121 C (+250 F) 0 drops 3 (+121 to +10
35、4) C (+250 to +220) F) 0 drops 4 +104 C (+220 F) 0 drops 5 (+104 to 0) C (+220 to +32) F) 0 drops 5 (0 to -36) C (+32 to -32) F) 1 drop/minute 5 (-36 to -40) C (-32 to -40) F) Seepage Acceptable 6 -40 C (-40 F) Seepage Acceptable 7 -40 C (-40 F) Seepage Acceptable 4.3 Instructions. 4.3.1 Procedure.
36、4.3.1.1 Prior to testing, visually inspect all hoses for evidence of bloom, cuts/damage or residual oils or other residue from the manufacturing process. Record all observations. Discard any hoses that appear to be damaged and are not good candidates for use. 4.3.1.2 Pressure check the system and se
37、tup. Start the system with air regulators set at 105 kPa and 210 kPa (15 psig and 30 psig). An orifice or flow control valve in the main pressure line will allow for the following test pulse profile at ambient conditions: System pressure: 0 kPa to 105 kPa (0 psig to 15 psig) in 15 seconds 105 kPa (1
38、5 psig) stabilized for 15 seconds 105 kPa to 210 kPa (15 psig to 30 psig) in 15 seconds 210 kPa (30 psig) stabilized for 15 seconds Total Time: 1 minute 4.3.1.3 Examine the test setup for any of the following: Coolant leakage or seepage: Report pressure setting and amount of leakage (in drops/second
39、). Hose movement: Report approximate amount of hose displacement (in millimeters). Separation of hose from fitting: Report hose and location where separation occurred. Note: Flare at hose end due to clamp compression is permissible. Any other areas of potential concern. 4.3.1.4 Review pressure check
40、 results with Test Engineer. Note: If any parts are replaced or repaired, the pressure check described in paragraph 4.3.1.2 must be repeated. 4.3.1.5 Begin P-V-T test cycling as follows (See Figure A1 for a graphical representation of the profile.) 4.3.1.5.1 Segment 1. 55 minutes to 70 minutes (maxi
41、mum) Raise chamber temperature linearly from ambient to 121 C (250 F) and stabilize. Coolant circulation pump: ON System pressure: PUMP Motion: ( 1.27) cm ( 0.5) in) at 60 cycles per minute Coolant heater: ON Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I
42、HS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14785 Copyright 2012 General Motors Company All Rights Reserved August 2012 Page 5 of 19 4.3.1.5.2 Segment 2. 30 minutes to 45 minutes (maximum) Maintain chamber temperature at 121 C (250 F) while pressure cycling at 210 kPa (30 psig) for 0.5 minute and 1
43、05 kPa (15 psig) for 0.5 minute. Coolant circulation pump: ON System pressure: 210 kPa and 105 kPa (30 psig and 15 psig) Motion: ( 1.27) cm ( 0.5) in) at 60 cycles per minute Coolant heater: ON 4.3.1.5.3 Segment 3. 25 minutes Reduce chamber temperature linearly from +121 C to +104 C (+250 F to +220
44、F) and stabilize. Coolant circulation pump: ON System pressure: PUMP Motion: ( 1.27) cm ( 0.5) in) at 60 cycles per minute Coolant heater: OFF 4.3.1.5.4 Segment 4. 30 minutes Maintain chamber at +104 C (+220 F) while pressure cycling at 105 kPa (15 psig) for 0.5 minute and 0 kPa (0 psig) for 0.5 min
45、ute. Coolant circulation pump: ON System pressure: 105 kPa and 0 kPa (15 psig and 0 psig) Motion: 1.27 cm (0.5 in) at 60 cycles per minute Coolant heater: OFF 4.3.1.5.5 Segment 5. 95 minutes to 110 minutes (maximum) Reduce chamber temperature linearly from +104 C to -40 C (+220 F to -40 F) and stabi
46、lize. Coolant circulation pump: OFF System pressure: 105 kPa (15 psig) Motion: OFF Coolant heater: OFF 4.3.1.5.6 Segment 6. 35 minutes to 55 minutes (maximum) Maintain chamber at -40 C (-40 F). Coolant circulation pump: OFF System pressure: 10 kPa (15 psig) Motion: OFF Coolant heater: OFF Note: Soak
47、 period will be dependent upon ramp rate of Segment 5. 4.3.1.5.7. Segment 7. 30 minutes Maintain chamber at -40 C (-40 F). Coolant circulation pump: ON System pressure: 105 kPa and 0 kPa (15 psig and 0 psig) Motion: ( 1.27) cm ( 0.5) in) at 60 cycles per minute Coolant heater: ON 4.3.1.5.7.1 Monitor
48、 test and visually inspect for leakage, hose movement, or any other abnormalities, and record observations on the Daily Log Sheet (Appendix B). 4.3.1.5.7.2 Return to “Segment 1“ (4.3.1.5.1) for start of next cycle. 4.3.1.6 Repeat Section 4.3.1.5 based on type of test specified in test plan, e.g., Validation Test = 10 cycles total. 4.3.1.7 After the last test cycle has been completed, or at any other intervals as described in the Test Plan, measure hose samples as specified in the Test Plan, and record findings. 4.3.1.8 After completion of all segments, and when test samples
