1、WORLDWIDEENGINEERINGSTANDARDSTest Procedure GMW15794Repetitive Shock for Door Trim - Simulated Door Slams Copyright 2013 General Motors Company All Rights ReservedJune 2013 Page 1 of 81 ScopeNote: Nothing in this standard supercedes applicable laws and regulations.Note: In the event of conflict betw
2、een the English and domestic language, the English language shall takeprecedence.1.1 Purpose. The Repetitive Shock for Door Trim Simulated Door Slams durability test, is a “TimeAccelerated” success based test for door trim components that will enable rapid reliability assessment andfacilitate quick
3、learning cycles. The repetitive shock test is a subsystem level test, which uses only the doorsystem (as opposed to the traditional Body Slam Test which requires the entire body). This test can be usedeither as a validation test to replace the traditional door slam test or can be used earlier in the
4、 design processas a developmental test to uncover failure modes through quick learning cycles.1.2 Foreword. The repetitive shock test is a Dynamic test to uncover failure modes on door trim which is dueto dynamic input as follows:1.2.1 Fastener durability (fasteners coming loose).1.2.2 Door trim str
5、uctural integrity (cracking, etc.)1.2.3 Snap fit joint (detachment, broken, etc.)1.2.3.1 Dog house cracking.1.2.3.2 Two adjacent broken birds beaks (loss of integrity).1.2.3.3 Switch plate or other attached trim that deflects more than 1.5 mm with a 10 N force applied.1.2.3.4 Detached speakers.Note:
6、 This test does not uncover failures due to quasi-static pull effects including pull handle durability/fatigue.1.3 Applicability. This repetitive shock test is a subsystem level test and utilizes the door system.2 ReferencesNote: Only the latest approved standards are applicable unless otherwise spe
7、cified.2.1 External Standards/Specifications.None2.2 GM Standards/Specifications.None2.3 Additional References.CG190- GM Approved Test Report FormFront and Rear Side Door Global Subsystem Technical Specification (GSSTS)3 Resources3.1 Facilities. An International Organization for Standardization (ISO
8、) or equivalent certified laboratory.3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a validcalibration label.3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuringvariables as specified in this standa
9、rd shall be determined correctly with respect to their physical definition.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 GMW15794 Copyrigh
10、t 2013 General Motors Company All Rights ReservedJune 2013 Page 2 of 83.2 Equipment.3.2.1 A test plate and hydraulic/pneumatic system capable of inducing a 39 J input to the part.3.2.2 An environmental chamber capable of housing the test apparatus and maintaining the temperatureextremes as shown in
11、the profile.3.2.3 Three (3) accelerometers with the capability to provide accelerations versus time plots.3.3 Test Vehicle/Test Piece. The repetitive shock test involves testing only the door on a vertical input table.The test utilizes a built up door hardware with the appropriate trim, the entire b
12、ody is not required.Typically, the material required for this testing is as described below:x Fully Dressed Door Metal-Painted and Baked (door will need to be mass representative including speakersand all hardware, i.e., lock rod, outside handle, wire harnesses, door side hinge, as well as window gl
13、assand trim)x Fully Dressed Door Trim (All Part of Assembly (POA) electrical content including door trim wiring harness)x Handle Bracketsx All Fasteners (screws, birds beaks)x Shark Finx Screw Coversx Heaviest Switch Plate, Bezel, and All Clipsx Build Instructions with Torquesx Before Shipping Inspe
14、ct Trim for Good Heat Stakesx Speaker Grilles (if separately applied)x Latchesx Inside Release Handle (ISRH)x Push Nuts and J Nuts for metalx Belt Line Seal, Window Regulators, Window Crank, Lock Knobs, AppliquesNote: It is recommended that the tested sample is the most content and highest mass vers
15、ion. If Left Hand(LH) and Right Hand (RH) door trim are not mirror parts, both need to be tested.3.3.1 See Appendix A: Test Sampling and Fixturing. For best results, it is suggested that the door becompletely built up. This includes the door hardware with window glass and other components such asspe
16、akers, switches, switch plates, etc., as described above or a mass representative of the component. Thiswill simulate the actual inertia of the door and will be more representative of the actual slam vibrationconditions. The number of samples required is based on the reliability requirements. For R9
17、5C50, the requiredreliability and confidence interval, it is recommended to test three samples to four lives each or when failureoccurs. However, the number of samples should be determined by the appropriate GM engineer.3.4 Test Time.Calendar time: 22 daysTest hours: 60 hoursCoordination hours: 7 ho
18、ursNote: The 22 days are by door trim design (three samples, four lives). To validate the full set (car set) of doortrims (front and rear) would take approximately 42 days (assuming that the left hand and right hand door trimsare identical), depending on the test lab. When there is a different desig
19、n (for instance driver side having pullcup and passenger side having grab handle), both designs need to be tested and the test time will be longer.3.5 Test Required Information. Reference profile for test.3.6 Personnel/Skills. The following individuals are necessary to complete this test procedure:3
20、.6.1 General Motors Design Release Engineer.3.6.2 General Motors Validation Engineer.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 GMW1579
21、4 Copyright 2013 General Motors Company All Rights ReservedJune 2013 Page 3 of 83.6.3 Testing Organizations Test Engineer.3.6.4 Testing Organizations Test Technician.3.6.5 Testing Organizations Computer Aided Engineering (CAE) Engineer4 Procedure4.1 Preparation.4.1.1 Mount the test specimen onto the
22、 test plate and rigidly affix.4.1.2 Obtain the acceleration profile for the door trim on an on body condition using the same inputs suggestedin the Door Slam Test. If an acceleration profile is not available, use a standard acceleration profile(maintained by the body test lab) for similar type doors
23、 as a reference.4.1.3 The door is mounted horizontally on a shaker table as illustrated in Appendix A, Figure A1. Since thegoal of the accelerated test is to simulate the same acceleration conditions on the door using a shaker table,accelerometers are mounted in specific locations as agreed to by th
24、e design release engineer and the testengineer. These locations are typically at the latch and the hinge area. An accelerometer also placed on thecenter of the door trim is useful in calibrating the table.4.1.4 One (1) acceleration input per second will allow the trim to stop reverberation before th
25、e next cycle. Referto Appendix B.4.2 Conditions.4.2.1 Environmental Conditions. Conduct the test operating as shown in 4.3. There is no soak time requiredto start the sequence, the cycles are started after the chamber environment has reached the temperature andhumidity levels as stated in 4.3.4.2.2
26、Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Suchrequirements shall be specified on component drawings, test certificates, reports, etc.4.3 Instructions.4.3.1 Set the frequency of the input as described in the input profile (Appendix B).4.3.2 Set th
27、e input in the shaker table to 10G, 10 ms (a representative starting input profile).4.3.3 Measure the response from the accelerometers and correlate with reference profile. This will usuallyproduce 24G on the trim. Typically, the reference profile is obtained by putting three accelerometers in three
28、different locations (traditionally at the latch area, lower edge of the door and in the center of the pull cup orgrab handle) as shown in Appendix A, Figure A2. (See also Section 7).4.3.4 If the response profile and the reference profile match, then you have determined the input profile.4.3.5 If the
29、 response does not match, then adjust the input until the representative response is achieved.4.3.6 Run the test using input profiles to the number of cycles specified in the Front and Rear Side DoorGSSTS - refer to the Front and Rear Door Slam Durability Cycle Definition Section, otherwise, use the
30、 cyclesdefined by the requesting engineer.4.3.7 Use profile below to determine relative number of hot/humid cycles.4.3.8 Continue test to failure or for a maximum of 4 life cycles.4.3.9 Inspect samples and log observations at initial start of test and each subsequent temperature phase.Failure modes
31、are identified below:4.3.9.1 Fastener durability (fasteners coming loose).4.3.9.2 Door trim structural integrity (cracking, etc.)4.3.9.3 Snap fit joint (detachment, broken, etc.)4.3.9.3.1 Dog house cracking.4.3.9.3.2 Two (2) broken adjacent birds beaks (loss of integrity).4.3.9.3.3 Switch plate or o
32、ther attached trim that deflects more than 1.5 mm with a 10 N force applied.4.3.9.3.4 Detached speakers.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 ENGINEERIN
33、G STANDARDS GMW15794 Copyright 2013 General Motors Company All Rights ReservedJune 2013 Page 4 of 84.3.10 Inspection consists of applying a pull force onto the armrest of approximately 50 N. Also, apply a loadaround the perimeter of the trim to check for integrity. Note any loss of integrity of the
34、armrest or door trim ontest log.4.3.11 Repeat the cycles for a total of three samples or the number of samples agreed upon by the GMappropriate engineer.4.3.12 One life shall match the front and rear door slam durability cycle definition from the Closures SubsystemManagement Team (SMT), refer to 4.3
35、.6. The breakdown in temperatures is to be run in this order:x 30% Hot (80 3 C, Relative Humidity (RH) 10%)x 15% Humid (38 3 C, RH 95%)x 40% Ambient (23 3 C)x 15% Cold (-30 3 C)Note: Break down the cycles defined in 4.3.6 according to the percentages above.5 Data5.1 Calculations.5.1.1 Energy input o
36、f test = 39 J.5.1.2 Mass of door in kg X (accelerations in G).5.1.3 Typical mass of a door = approximately 37 kg.5.1.4 Typical accelerations on the door trim = 24G.5.2 Interpretation of Results. Not applicable.5.3 Test Documentation. The data presentation shall be in accordance with the standards. W
37、ith reference tothis test method the results shall be presented in a CG190 - GM Approved Test Report Form, including thefollowing:5.3.1 Complete identification of the structural subsystem or the structural components (part number, lotnumber, etc.)5.3.2 Condition of trim sample and identification, su
38、ch as part number.5.3.3 Test conditions (temperature, humidity, force applied, etc.)5.3.4 Number of cycles.5.3.5 Observations and conclusions.5.3.6 Pre-test and post-test pictures, as well as photographs to depict any issues.5.3.7 Energy profile of test.5.3.8 Sketch of part with placement of acceler
39、ometers.6 SafetyThis standard may involve hazardous materials, operations, and equipment. This standard does not propose toaddress all the safety problems associated with its use. It is the responsibility of the user of this standard toestablish appropriate safety and health practices and determine
40、the applicability of regulatory limitations priorto use.7 Notes7.1 Glossary.Input Profile: The input profile that results in the best match of the response profile with the reference profile.See Appendix B for an example of a suggested input profile. This is an accelerated test; the profile selected
41、should match the abusive profile of 39 J.Reference Profile: The acceleration profile that is obtained from actual door-on body slam conditions usingthe slam inputs specified in the door trim GSSTS.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for Resal
42、eNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15794 Copyright 2013 General Motors Company All Rights ReservedJune 2013 Page 5 of 8If there is no previous on body test conducted, use a representative profile suggested by GM Body Lab or the
43、GM design responsible engineer.Response Profile: The acceleration profile that is obtained from the accelerometers placed on the testsample. The response profile must be matched with reference profile.7.2 Acronyms, Abbreviations, and Symbols.CAE Computer Aided EngineeringGSSLT Global Subsystem Leade
44、rship TeamGSSTS Global Subsystem Technical SpecificationISO International Organization for StandardizationISRH Inside Release HandleLH Left HandPOA Part of AssemblyRH Relative HumidityRH Right HandSMT Subsystem Management Team8 Coding SystemThis standard shall be referenced in other documents, drawi
45、ngs, etc., as follows:Test to GMW157949 Release and RevisionsThis standard was originated in January 2008. It was first approved by Interiors in March 2008. It was firstpublished in March 2008.Issue Publication Date Description (Organization)1 MAR 2008 Initial publication.2 JUN 2013 5 Year Refresh.
46、Several Changes. (Interior Door Trim Global SubsystemLeadership Team (GSSLT)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 GMW15794 Copyrig
47、ht 2013 General Motors Company All Rights ReservedJune 2013 Page 6 of 8Appendix ATest Sampling and Fixturing.Sample door trim is placed horizontally on an electro-dynamic shaker. The door trim is mounted on the shakerthrough the use of an “Adjustable Fixture” that is available with GM Body Labs and
48、certified suppliers.Acceleration measurements are recorded to compare the response profile to the reference profile. In additionto the accelerometer on the trim, additional accelerometers placed at the latch and hinge point should beadded to show correlation to the door hardware test.Door windows sh
49、all be in the upper position for the data collection and test execution.In case of doors with no window frames (header-less), collect the data with the windows up first and thenwindows down. Use the windows up reference profile to match the response profile. If the window is damagedduring the test, stop testing, retrofit the door assembly with a new side window, use the windows downreference profile to
