1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15080 Door Window System, Operating Durability Copyright 2011 General Motors Company All Rights Reserved June 2011 Originating Department: North American Engineering Standards Page 1 of 8 1 Scope Note: Nothing in this standard supercedes applicable
2、laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To determine the performance characteristics and operating endurance capabilities of power and manual window systems. 1.2 Foreword. Not applicable.
3、 1.3 Applicability. This procedure applies to all passenger cars, light duty trucks, and medium duty trucks having conventional “raise and lower” side door mounted window systems. It can also be applied to quarter windows, station wagon end-gate systems, etc. However, modifications in fixturing and/
4、or setup may be necessary to accommodate these different systems. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GMW15081 GMW15663 GMW15094 GMW15938 2.3 Additional Reference
5、s. 1987 C-Car Customer Measurement Program Report dated November 30, 1990. CG2910 Pre-Test Checklist for Test Ready Properties (Contact GM Engineering). CG2916 Design Review Based on Test Results (DRBTR) Checklist (Contact GM Engineering). Front and Rear Side Closures Global Subsystem Technical Spec
6、ifications (GSSTS). Studies made in August 1991 (TWO 03950-384, Report No. 001-696-091-014). Window Regulator Statement of Requirements (SOR) Appendix R. 3 Resources 3.1 Facilities. 3.1.1 Major Facility. GMNA Body Test Lab or similarly equipped test lab. 3.1.2 Minor Facility. Designated body slot, e
7、nvironmental chamber. 3.2 Equipment. Note: The following list(s) include fixturing and instrumentation typically used by the GMNA Body Test Lab to perform this test. Other equipment may be substituted at the discretion of the testing facility as long as it provides the same data and/or data record,
8、with equivalent accuracy as specified herein or by the requestor. Handheld Voltmeter 0 to 20 V/50 A DC power supply Programmable Sequence Controller, i.e., Micromaster, computer, etc. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduct
9、ion or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15080 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 2 of 8 Fan or air line to cool motor AC Servo Motor with torque transducer (manual window systems) Adapter for window regulato
10、r handle (manual window systems) 3.2.1 Fixturing. 3.2.1.1 If testing a power window system, an electrical wire lead is necessary between the window regulator motor and the sequence controller connector; recommend 14 gauge wire, approximately 6 inches long, to approximate 0.0 resistance. Refer to Fro
11、nt and Rear Side Closures GSSTS section 3.1.5.3. 3.2.1.2 Adapter for window regulator handle. 3.2.1.3 Fan or air line to cool the window motor during cycling. 3.2.1.4 A body or door cart. Note: If testing a frameless glass system, a body or buck is required for validation testing. It is difficult to
12、 represent on a fixture factor such as window seals, door overcrown, etc. If testing a door with an upper frame, discuss with the requesting engineer to determine if door overcrown affects the window system performance, and if a body is necessary to create the overcrown condition. 3.2.2 Instrumentat
13、ion. 3.2.2.1 Power Window System. 3.2.2.1.1 Regulated power supply (20 V DC, 50 A). 3.2.2.1.2 Programmable sequence controller, i.e., Micromaster, window performance console, etc. 3.2.2.1.3 Handheld voltmeter. 3.2.2.1.4 Proximity Sensors or equivalent to detect window movement and desired positionin
14、g. 3.2.2.2 Manual Window System. 3.2.2.2.1 AC Servo Motor. 3.2.2.2.2 Manual Window Regulator Console (including Data Acquisition equipment). 3.3 Test Vehicle/Test Piece. 3.3.1 A fully assembled door, including a manual or power window system, and a complete glass guidance system, including belt stri
15、ps, run channels, stops, and any items affecting window system performance. A body may be necessary for reasons stated in note in 3.2.1.4. A door trim pad may be required since it may add stiffness to the inner panel, or the inner belt strip may be integral with the door trim pad. It is recommended
16、that the door assembly be dimensionally certified before testing is started. Please see Pre-Test Checklist for Test Ready Properties in GDM under document number CG2910. 3.4 Test Time. The following is an estimate of the amount of time (work hours) needed to perform this procedure. Calendar time: 51
17、 days Test hours: 124 hours Coordination hours: 28 hours Note: These time estimates are approximate averages. Actual times vary considerably depending on early component failures (and subsequent availability of replacement parts), testing to varying multiples of cycle lives, varying requirements for
18、 frequency of environmental test conditions, scheduling problems for test facilities, test equipment malfunctions, scheduling of overtime and/or multiple shifts, scheduling of “witnesses” for tests, actual readiness of test samples upon receipt, unique or additional requests for test details, runnin
19、g multiple samples (times shown are for one system), etc. These times consider preparation and other downtime, actual test, and analysis of data in capturing a total calendar time. Report writing, approval, processing, etc., are not part of this time. 3.5 Test Required Information. The requesting en
20、gineer is responsible for providing specifications appropriate to the particular vehicle line being tested. Reference Vehicle Technical Specifications (VTS)/Subsystem Technical Specifications (SSTS) paragraph numbers if applicable. Testing worst-case scenarios may uncover some potential problems. Di
21、scuss with the requesting engineer if testing should include some worst-case scenarios. Depending on which test is being performed and which level of parts or systems is being tested, consider if any of the following may apply: tolerance stack-ups, build Copyright General Motors Company Provided by
22、IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15080 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 3 of 8 variations, misalignment, minimum/maximum fasten
23、er torque(s), lubrication, environmental extremes, location of customer representative load application, symmetry (Left Hand vs. Right Hand), color, mold or die source, etc. The following specifications or information are required to run this test: 3.5.1 Durability Cycle Requirement, including cycle
24、 definition. See Side Closure SSTS, table 3.1.5.3-I. 3.5.2 Sequence and Percentage of Cycle Count in Environmental conditions. 3.5.3 Manual Window System Stall Torque. 3.5.4 Power Window System Stall Voltage. 3.5.5 Power Window Stall Time. 3.5.6 Stall Seal Force (can help during setup of window syst
25、em). 3.5.7 Environmental test conditions, i.e., temperature, humidity, wet, salt, dust, etc. 3.6 Personnel/Skills. Prior experience in setting up and running similar tests and experience in the use of the referenced test equipment are critical to achieving the estimated times shown in “3.4 Test Time
26、”. 4 Procedure 4.1 Preparation. 4.1.1 Sample Inspection. The test and requesting engineers should inspect the test items to ensure all material listed in 3.3 is of correct design level and assembled properly. Check for cracks, paint chips, dents, etc., document any variation/deviation in assembly, e
27、tc. Note: If applicable, check that rivet mandrils are secure. Inspect regulator for adequate lubrication. 4.1.2 Sample Preparation. This test is normally run on the test subject in an “as received” condition. If it is requested to be run in a specifically adjusted condition, follow the applicable p
28、rocedure(s). 4.1.2.1 If it is necessary to assemble the door, use proper rivet gun tips and torque specifications. If applicable, adjust all stops and window channels properly. See the requesting engineer for information. 4.1.2.2 Mark all window system fasteners and attachments to check for movement
29、 and rotation during test. 4.1.2.3 If on a body, measure and adjust the gap and seal margin dimensions to ensure they meet design specifications. Reference GMW15938. 4.1.3 Facilities and/or Equipment Preparation. Record the instrumentation calibration information on Instrument Calibration Data Sheet
30、 A1. 4.2 Conditions. 4.2.1 Environmental Conditions. Unless otherwise specified in this documents text or by the requesting engineer, the typical environmental conditions for this test are the temperature, humidity and pressure at the major test facility (3.1.1). Unless otherwise noted, these condit
31、ions are typically 22 3 C, relative humidity of 40 20% and atmospheric pressure equivalent to the local barometric pressure (which is variable during any given day and from day to day). 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such require
32、ments shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. The following instructions are divided into manual window systems and power window systems. Use the applicable set of instructions. 4.3.1 Setup Instructions. 4.3.1.1 Setup Instructions for Manual Windo
33、w System. 4.3.1.1.1 Perform any functional/operational tests/evaluations as requested by responsible engineer. Specifically, cycle the window system through at least 5 cycles to ensure proper operation and seating of all system components. As applicable, note any irregular sounds or erratic operatio
34、n indicating a potential problem with design, manufacture, or assembly and verify observations with the requesting engineer. 4.3.1.1.2 If not testing on a body, mount the door securely in body position on a door cart. Use Unistrut or equivalent structural members for additional support (to any area
35、of test setup/fixturing) necessary to withstand higher torque seen during up/down stalls. If testing on a body, extra fixturing will be necessary to support the servo motor. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or net
36、working permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15080 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 4 of 8 4.3.1.1.3 Adjust the servo motor until the shaft centerline coincides with the handle spindle shaft centerline and the handle ada
37、pter engages the handle. 4.3.1.1.4 Using the console and the plotter, adjust stall torque and stall time to the specified values. 4.3.1.2 Setup Instructions for Power Window System. 4.3.1.2.1 If not testing on a body, mount the door securely, in body position, on a door cart. 4.3.1.2.2 Place proximi
38、ty sensors at appropriate locations along glass surface to coincide with desired positioning of windows for complex or block cycles. See Side Closure SSTS for proper cycle definition. 4.3.1.2.3 Adjust the supply voltage until the specified stall voltage is reached. This may be done using a handheld
39、voltmeter to read the voltage at the motor terminals during stall. To ensure accurate readings, maintain power at the stall condition for approximately 3 s to allow the voltage to normalize. 4.3.1.2.4 Perform any functional/operational tests evaluations as requested or as may be referenced in as req
40、uested by responsible engineer. Specifically, cycle the window system through at least 5 full cycles to ensure proper operation and seating of all system components. As applicable, note any irregular sounds or erratic operation indicating a potential problem with design, manufacture, or assembly and
41、 verify observations with requesting engineer. 4.3.1.2.5 Set the stall time to the specified value. 4.3.1.2.6 Set the cycle time and the rest time. These settings are dependent on environment. For room temperature and cold environment, a maximum of 1 cycle/2 minutes is generally used. For hot enviro
42、nment, a maximum of 1 cycle/3 minutes is generally used. The use of forced air or blowers directed over the window regulator motor is a standard method for helping to cool the motor. It avoids actuating the motors circuit breaker or Positive Temperature Coefficient (PTC). Note: This is an accelerate
43、d test. Repeated activation of the motors circuit breaker/PTC may require an analysis of the motor relative to pertinent electrical performance specifications for the motor/components involved. 4.3.2 Test Operation Instructions. 4.3.2.1 At the start of test, perform any functional checks required by
44、 the requesting engineer. Make performance plots (reference GMW15081).Other typical functional checks may include noise and glass chatter evaluations in wet/dry/hot/cold conditions, glass fore/aft movement, etc. In addition, before the test begins, the window glass should be washed in the following
45、manner. With window glass in the full up position, use a typical spray bottle filled with plain water. Spray water generously all around window periphery and onto the seals, allowing excess water to run down glass and along run channels; wipe off with a clean cloth until dry. Glass should be cleaned
46、 in this manner once a day throughout the life of the test. The purpose of this glass cleaning is to simulate periodic car washes and rain, which would reduce the amount of dust/dirt that may cause premature wear to the glass seals. Complete the specified number of cycles. Make performance plots and
47、 perform functional tests at approximately 5000 cycle intervals during room temperature cycling. As feasible, examine the system at each interval for deterioration or damage in the areas mentioned in 4.1.1. At each specified environmental condition, these tests should be performed “at temperature”,
48、prior to cycling, and after cycling. Note: If testing a frameless window system on a body with T-tops or a convertible, run some cycles with the top off/down. Also, periodically attempt to open/close the door to determine if the Full Up Position changes or if any damage to the window systems up-stop
49、 is occurring. 4.3.3 Post-Test Instructions. Note: Every post-test operation/measurement/inspection must typically have a pre-test equivalent to have any meaning or significance. A crack detected at end of test means nothing unless there is pre-test documentation verifying no crack existed prior to start of test. Check for rivet and attachment looseness or movement. Please see DRBTR Checklist for this test procedure in GDM under document number CG2916. 5 Dat
