1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW15091 Door System - Theft Resistance Security Test Copyright 2011 General Motors Company All Rights Reserved June 2011 Originating Department: North American Engineering Standards Page 1 of 10 1 Scope Note: Nothing in this standard supercedes applic
2、able 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 door system theft resistance performance. 1.2 Foreword. This test determines the ability of the door locking system and the movab
3、le window system to resist attempts to gain forced entry into a vehicle. This test procedure describes two very specific test methods, but depends on the test and requesting personnel to investigate and evaluate other potential theft test methods and to obtain any “equipment”, as necessary, to perfo
4、rm additional tests. See 6.1 of this document. 1.3 Applicability. This procedure applies to all passenger cars, light duty trucks and medium duty trucks having swing-open doors, endgates, and sliding side doors, and can be used to evaluate any body mounted, movable, glass systems (doors, quarters, s
5、unroof, etc.) 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 2.3 Additional References. Front and Rear Side Doors Subsystem Technical Specifications (SSTS) 3 Resour
6、ces 3.1 Facilities. GMNA Body Test Lab or similarly equipped test facility. 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
7、long as it provides the same data and/or data record, with equivalent accuracy as specified herein or by the requestor. 3.2.1 Fixturing. The following fixturing is for the two theft methods specifically covered by this procedure. Other theft methods, as determined by the test or requesting engineers
8、, may require additional fixturing. 3.2.1.1 For the Door Lock System Theft Test. 3.2.1.1.1 Rigid hinge and lock pillar fixture or a door cart, to mount the doors on, if not testing on a body. 3.2.1.1.2 “Slim Jim” (Theft Entry Tool Figure A1). 3.2.1.2 For the Door Window System Theft Test. 3.2.1.2.1
9、Rigid hinge and lock pillar fixture or a door cart, to mount the doors on, if not testing on a body. 3.2.1.2.2 Mounting fixture for a Linear Variable Differential Transformer (LVDT) or similar displacement measuring device. 3.2.1.2.3 Load cell “T” handle, or equivalent for applying load through the
10、load cell, such that the edge of the window system can be loaded toward the “open” position (See 4.3.2.2). 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 ENGINEE
11、RING STANDARDS GMW15091 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 2 of 10 3.2.1.2.4 Wiring/switches to achieve power window dynamic braking and to allow normal window operation. (if not in existence on the test door/body). 3.2.1.2.5 Manual window crank handle, if appli
12、cable. 3.2.1.2.6 A marking pen. 3.2.1.2.7 A device which fits over the edge of the window, attaches to the load cell, is padded at the glass contact area and is wide enough to minimize “point loading” of the window glass (and possible glass shattering), and which allows load application approximatel
13、y parallel to the window travel path. 3.2.2 Instrumentation. The following instrumentation is for the two theft methods specifically covered by this procedure. Other theft methods, as determined by the test or requesting engineers, may require additional instrumentation. 3.2.2.1 For the Door Lock Sy
14、stem Theft Test. 3.2.2.1.1 Stop Watch. 3.2.2.1.2 Torque Wrench(es) with a capacity of approximately 1.5 times each fastener torque referenced. 3.2.2.2 For the Door Window System Theft Test. 3.2.2.2.1 A Load cell with a capacity approximately 1.5 times the load specification. 3.2.2.2.2 Regulated powe
15、r supply 12 VDC, for power window systems. 3.2.2.2.3 Plotting device for window glass loading versus displacement. 3.2.2.2.4 A Linear Variable Displacement Transducer (LVDT) with a range of at least one and a half times the maximum expected glass displacement. 3.2.2.2.5 LVDT Signal Conditioner, Dayt
16、ronic model 3230 or equivalent. 3.2.2.2.6 One hundred fifty millimeters (150 mm) measuring scale. 3.2.2.2.7 Window System Performance Console. (See GMW15081 - Window System, Dropping Type Power and Manual Performance/Stall Test). 3.3 Test Vehicle/Test Piece. One fully assembled door with the entire
17、window and lock systems, including, but not limited to: glass and glass guidance components, window regulator and attaching hardware, all seals, applicable interior and exterior trim, door key and key cylinder, and door latch, handle and lock rods. For the most realistic theft evaluation, a vehicle
18、or body is recommended. Also recommended is an evaluation of both manual and power window systems. It is recommended that the door assembly and door components be dimensionally certified before testing is started. Note: Painting the door gloss black over white primer may aid the test engineer in vis
19、ual damage detection (gloss black to highlight panel deformation, white primer to highlight scratching and chipping). 3.4 Test Time. The following is an estimate on the amount of time (work-hours) needed to perform this procedure. Calendar time: 1 day Test hours: 8 hours Coordination hours: 8 hours
20、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 frequency of environmental test conditions, scheduling p
21、roblems 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, running multiple samples (times shown are for one system), etc.
22、 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 engineer is responsible for providing specifications approp
23、riate to the particular vehicle line being tested (reference Vehicle Technical Specification (VTS)/Subsystem Technical Specification (SSTS) paragraph numbers if applicable). See 2.3. Testing worst case scenarios may uncover some potential problems. Discuss with the requesting engineer if testing sho
24、uld include some worst case scenarios. Depending on which test is being performed and which 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
25、GMW15091 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 3 of 10 level of parts or systems is being tested, consider if any of the following may apply: tolerance stack-ups, build variations, misalignment, minimum/maximum fastener torque(s), lubrication, environmental extreme
26、s, 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 Door Lock System Theft Test. 3.5.1.1 Maximum time allowed to gain forced entry into the vehic
27、le. 3.5.1.2 Door system fasteners torque values. 3.5.1.3 Maximum allowable visible or functional damage. 3.5.1.4 Likely rods, levers, etc., to attempt to move. 3.5.1.5 Allowable efforts for the inside/outside door handles, inside manual lock actuator and key cylinder. 3.5.2 Door Window System Theft
28、Test. 3.5.2.1 Loading application point(s). 3.5.2.2 Window position(s) at start of test. 3.5.2.3 Maximum load to be applied to window. 3.5.2.4 Load increment and/or rate of loading. 3.5.2.5 Maximum window displacement and set. 3.5.2.6 Duration of loading. 3.5.2.7 Door Window System Operating Perform
29、ance Test Specifications. 3.5.2.8 Door window system fasteners torque values. 3.5.3 Other Methods (service tools and special electronic circuit packages). Discuss and resolve if any testing is needed with the requesting engineer. 3.6 Personnel/Skills. Prior experience in setting up and running simil
30、ar tests, and experience in the use of the referenced test equipment, are critical to achieving the estimated times shown in “3.4 Test Time”. 4 Procedure 4.1 Preparation. 4.1.1 Sample Inspection. The test and requesting engineers should inspect the test items to insure all material listed in 3.3 is
31、of correct design level and assembled properly. Check for cracks, paint chips, dents, etc. Document any variation/deviation in assembly, etc. This is done for post test analysis purposes. 4.1.2 Sample Preparation. This test is normally run on the test subject in an “as received” condition. If it is
32、requested to be run in a specifically adjusted condition, follow the applicable procedure(s). 4.1.2.1 It is recommended that the door be heat cured (per the production paint bake process) to ensure proper strength of the structural adhesives. Install and adjust the window and lock systems per the pr
33、oduction process and torque all fasteners to specified torque values (see 3.5). Do not apply tape to the door glass for safety considerations (to contain glass fragments should shattering occur) when performing the window system theft test. This is because shattering the glass is a failure mode and
34、tape could affect the stiffness of the glass, altering test results. Follow safe operating procedures, including wearing safety glasses and safety gloves, when performing this test. 4.1.2.2 Mark all window system fasteners and attachments to check for movement or rotation during test. 4.1.3 Faciliti
35、es and/or Equipment Preparation. 4.1.3.1 Record the instrumentation calibration information on the attached Data Sheet A1 Instrument Calibration or an equivalent document. 4.1.3.2 As applicable, clamp the door securely to the fixture (i.e., door cart) in approximate body position so the door lock cy
36、linder or the exterior panel surfaces are accessible. 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 facil
37、ity (3.1). Unless otherwise noted, these conditions are typically 22 +3 C, relative humidity of 40 +20% and atmospheric pressure equivalent to the local barometric (variable during any given day and from day to day). Copyright General Motors Company Provided by IHS under license with General Motors
38、CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15091 Copyright 2011 General Motors Company All Rights Reserved June 2011 Page 4 of 10 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have b
39、een agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Setup Instructions. Perform any functional/operational tests/evaluations as requested or as may be referenced in Section 2. Specifically, cycle the window system and/
40、or the locking 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 verify observations with the requesting enginee
41、r. 4.3.1.1 Setup Instructions for the Door Lock System Theft Test - Using the “Slim Jim”. 4.3.1.1.1 Remove the door trim pad, if applicable. Note: The trim pad is removed to aid the engineer in determining the best areas to attempt to access for unlocking the door locking system. 4.3.1.1.2 Run the w
42、indow system into its full up, stall position. 4.3.1.1.3 Measure and record the operating efforts of the various lock system handles, levers, etc. Note: It may be necessary to simulate the door striker if testing a door on a door cart or fixture. Using a pen, pencil, or your finger engage the door l
43、atch fork bolt. Operate the outside or inside door handle while pulling inboard on the simulated lock striker. If the latch fork bolt returns to its free position the door was not locked. Note: Record if the Child Security feature is engaged. 4.3.1.1.4 Lock and latch the door. 4.3.1.2 Setup Instruct
44、ions for Door Window System Theft Test. Note: This procedure covers the typical roll up/down window system used in most vehicle doors. Sliding, swing out, etc., window systems will require unique methods of evaluation, reorientation of load directions, etc. Record all methods used. 4.3.1.2.1 Perform
45、 initial Door Window System-Performance Test (GMW15081) for baseline performance characteristics. 4.3.1.2.2 Lower the window, from the full up position, so that the load cell with adapters can contact the top edge of the glass surface, while not contacting the body or door header. 4.3.1.2.3 Install,
46、 adjust, and calibrate the load cell or equivalent, at a specified location (see 3.5.2.1) and connect it to the load/deflection plotting device. 4.3.1.2.4 Install the LVDT in line with, or as close as possible to the load cell. 4.3.1.2.5 Adjust and calibrate the LVDT at a specified location (see 3.5
47、.2.1) and connect it to the load/deflection plotting device. 4.3.1.2.6 Mark a line near the bottom of the window and onto a stationary part of the door or body to provide a visual “zero” reference position. This can be done at both the front and rear edges of the window. While this is not an accurat
48、e measurement of deflection or set, it can indicate if the window is cocking as a result of the loading. 4.3.2 Test Operation Instructions. 4.3.2.1 Test Operation Instructions For Door Lock System Theft Test. 4.3.2.1.1 Insert the “Slim Jim” tool between the glass and outer belt line-sealing strip. S
49、ee 6.1.1 for use of the “Slim Jim”. 4.3.2.1.2 Determine where the “Slim Jim” can be positioned to contact and unlock the door locking system. Record the areas and techniques that can be used to unlock the door. Without using any direct visual reference to the inside of the door, determine the amount of time required to unlock the door latching system. Record all information on the Data Sheet A2 provided with this procedure (a sketch may also be used to illustrate vulnerable areas). 4.3
