1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW16295 Coolant Hose Coupled Assembly and Quick-Connectors Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 1 of 13 1 Introduction Note: Nothing in this standard supercedes applicable laws and regulations. Note: In t
2、he event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This specification defines the Design Validation (DV), Production Validation (PV) and Steady State Part Monitoring (SSPM) requirements for: coolant hose and tube assemblies, coolant
3、 quick-connect fittings, crimp connections, over-mold connections, or any non-standard connection that does not meet the GM best practice, Heating, Ventilation, Air Conditioning Powertrain Cooling (HVACPTC) - 264 the global metric coolant connection standards sizes for hoses/fittings. GM engineering
4、 may require any connection not described above be subjected to this specification prior to acceptance. 1.2 Mission/Theme. Not applicable. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Speci
5、fications. ASTM A254 ASTM D380 SAE J1344 2.2 GM Standards/Specifications. GMW3059 GMW3420 GMW14785 GMW15758 GMW3116 GMW8758 GMW14872 GMW15760 GMW3286 GMW14573 GMW15272 GMW15920 2.3 Additional References. 9985809 CG2046 3 Requirements 3.1 System/Subsystem/Component/Part Definition. Not applicable. 3.
6、1.1 Appearance. Not applicable. 3.1.2 Content. Not applicable. 3.1.2.1 Physical Content. Not applicable. 3.1.2.2 Functional Content. Not applicable. 3.1.3 Ambient Environment. Not applicable. 3.1.4 Interfaces. Not applicable. 3.1.5 Usage Definition. Not applicable. 3.2 Product Characteristics. All c
7、rimps, over-molds (plastic molded rings acting as crimps), and non-standard clamp joints shall be described as; coupled assemblies, for the remainder of this document. 3.2.1 Performance Requirements. 3.2.1.1 Fixed-Value Performance Testing Requirements. GM engineering to agree to samples before test
8、ing should begin. For sample requirements and quantities, see 3.7. 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 GMW16295 Copyright 2013 G
9、eneral Motors Company All Rights Reserved February 2013 Page 2 of 13 3.2.1.1.1 Leak Test. 3.2.1.1.1.1 Coupled Assemblies. There shall be no indication of air leakage at the coupling or in the hose member when the assembly is subjected to a minimum of 350 kPa of air pressure when tested per 4.3.1.1.
10、3.2.1.1.1.2 Quick-Connector Assemblies. There shall be no indication of air leakage from the connector assembly, or from the hose member, after allowance for temperature compression at a minimum of 500 kPa for quick connectors smaller than 20 mm sealing surface diameter, and 400 kPa for quick connec
11、tors greater than 20 mm sealing surface diameter when tested per 4.3.1.2. Temperature compression is defined as the compression set of the rubber compounds for either the hose construction or the O-rings in the quick connect which create the sealing. This means that the crimped hose assemblies and t
12、he internal seals of the quick connect can experience compression set in the compound but there can be no leakage attributed to this condition. The rubber compound and the coupling or sealing must allow for the compression set and still perform to the standard without leaking. 3.2.1.1.2 Cold Leak Te
13、st. Sample must weigh within 3.0 g of original weight when tested per 4.3.1.2. 3.2.1.1.3 Tensile Test. The load at failure either by separation of the hose specimen from the end fittings, or by a rupture of the hose structure, shall not be less than 668 N when samples at nominal hose compression are
14、 tested per 4.3.1.3. 3.2.1.1.4 Blow-Off. There shall be no indication of leakage at the coupled assembly, quick connect or in the bulk hose, during the 180 s hold period when samples at nominal hose compression are tested per 4.3.1.4. The final blow-off pressure shall exceed 550 kPa for coupled asse
15、mblies and 700 kPa for quick connectors. 3.2.1.1.5 Blow-Off After Heat Aging. There shall be no indication of leakage at the coupled assembly, quick connect or in the bulk hose, during the 180 s hold period when samples at nominal hose compression are tested per 4.3.1.5. The final Blow-off pressure
16、shall exceed 550 kPa for coupled assemblies and 700 kPa for quick connectors. 3.2.1.1.6 Vacuum Test. The assembly must hold the vacuum within 3% during the 10 minute hold period when samples at nominal hose compression are tested per 4.3.1.6. 3.2.1.1.7 Insertion Force Test (Quick Connect). The maxim
17、um insertion load shall not be more than 89 N when samples are tested per 4.3.1.7. 3.2.1.1.8 Pull-Out Force Test (Quick Connect). The quick-connector pull-out load must exceed 668 N when samples at nominal hose compression are tested per 4.3.1.8. 3.2.1.1.9 Cleanliness Test. There shall be no visual
18、evidence of corrosion of either internal or external metal surfaces when hoses at nominal hose compression are tested per 4.3.1.9. No greater than 0.25 g/m2 of internal surface area of contaminants is permitted. 3.2.1.1.10 Cyclical Corrosion Test. Sample must show no greater than 10% base metal corr
19、osion when tested per 4.3.1.10. The assembly must meet all of the requirements of the Leak Test (3.2.1.1.1) and the Blow-off Test (3.2.1.1.4) after the cyclical corrosion test has been performed. All test samples from this test must be forwarded to GM Global HVAC/PTC engineering for evaluation at th
20、e end of the test. 3.2.1.1.11 Salt Spray Test. After 168 h of the salt spray test, assembly shall not exhibit evidence of any red rust on ferrous parts when tested per 4.3.1.11. 3.2.1.1.12 Maximum Crimp Compression Condition (Coupling). No hose rubber or reinforcement damage generated by the crimpin
21、g operation is permissible in the samples when tested per 4.3.1.12. 3.2.1.1.13 Over-Crimp to Maximum Crimping (Coupling). Hose samples shall be tested per 4.3.1.13. Samples with maximum crimp, but without showing damage, shall be tested per and must meet the acceptance requirements of the Cold Leak
22、Test (See 3.2.1.1.2). Production controls and product design must be such that over-crimp to damage is not possible in production. 3.2.1.1.14 Error-Proofing Pull-Tab Test (Quick Connect Assemblies). 3.2.1.1.14.1 Partially Assembled Connectors. The pull-tab shall break through the finger pull area pr
23、ior to releasing from the connector when tested per 4.3.1.14. All pull-tab material shall remain with the connector. The force required to break the tab shall be a minimum of 12 N. 3.2.1.1.14.2 Fully Assembled Connectors. The pull-tab shall not break during the removal process. The maximum force req
24、uired to remove the pull-tab shall not exceed 2.5 N when tested per 4.3.1.14.2. 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 ENGINEERING STANDARDS GMW16295 Cop
25、yright 2013 General Motors Company All Rights Reserved February 2013 Page 3 of 13 3.2.1.1.15 Anti-Rotation Feature Torque Resistance (Quick Connect Assemblies). There shall be no loss of the anti-rotation feature, or any other damage that would cause loss of quick connect function when tested per 4.
26、3.1.15. 3.2.1.2 Endurance Testing Requirements. GM engineering to agree to samples before testing should begin. For sample requirements and quantities see 3.7. 3.2.1.2.1 Pressure/Vibration/Temperature Test. Samples must meet the acceptance requirements of GMW14785. Samples must meet the acceptance r
27、equirements of the Cold Leak Test (See 3.2.1.1.2), following test completion. For sample quantity guidelines see 3.7. 3.2.1.2.2 Pressure/Temperature Test. Assemblies shall be tested per 4.3.2.2 - Pressure/Temperature Test, no leakage is allowed during the test procedure. Assemblies must pass the req
28、uirements of the Cold Leak Test (see 3.2.1.1.2), following test completion. 3.2.1.2.3 Coolant Circulating Test. Assemblies shall be tested per 4.3.2.3 - Coolant Circulating Test. Assemblies must pass the requirements of the 3.2.1.1.4 Blow-Off, following test completion. 3.2.2 Physical Characteristic
29、s. Not applicable. 3.2.2.1 Dimensions and Capacity. Not applicable. 3.2.2.2 Mass Properties. Not applicable. 3.2.3 Reliability. 3.2.3.1 Reliability Evaluation Point. This specification, as written, provides a test exposure representing a Reliability Evaluation Point (REP) of 10 years of corrosion an
30、d 240 000 km (150 000 mi) of severe customer usage at the vehicle level. 3.2.3.2 Reliability Requirements. This specification, as written, supports the demonstration of the required reliability of 99% or greater at a 50% confidence (R99C50), at the REP for the coolant hose assembly. The supplier sha
31、ll utilize “vehicle equivalent” laboratory test setups to simulate “in-vehicle” orientations. If the orientation may be different from one vehicle to another, use the orientation which will provide the worst case loads for all physical level reliability demonstration testing. The reliability demonst
32、ration is provided by the Design Validation (DV) Endurance Tests specified in 3.7.1.3. Note: Test to Failure (TTF) is always the preferred method. Failure is defined as, but not limited to, the loss of function, unacceptable performance degradation and nonconformance of the component as stated in th
33、is specification. Note: The required number of test samples may be negotiable if it is not practical to run, for example, 23 samples. Negotiation of sample size should consider test equipment limitations, physical size of test samples, test duration, etc. However, reduction of the sample size may re
34、quire inclusion/use of longer test durations or other test methods such as Highly Accelerated Stress Screening (HASS), Highly Accelerated Stress Testing (HAST), Calibrated Accelerated Life Testing (CALT), Highly Accelerated Life Testing (HALT), etc. Weibull slope values available from previous failu
35、re testing may be considered as a way to reduce the sample size and/or test duration. 3.2.3.3 Accelerated Test Methods. GM encourages the use of appropriate accelerated test methods, wherever possible; for example, the use of accelerated stress testing to reduce test time (GMW8758 - Calibrated Accel
36、erated Life Testing). Note: GM Validation Engineering shall review and accept reliability demonstration test plans prior to the supplier submitting the Analysis Development Validation (ADV) Test Plan for approval. 3.2.4 Serviceability. Not applicable. 3.2.5 User Interface. Not applicable. 3.3 Design
37、 and Construction. 3.3.1 Materials, Processes and Parts Selection Guidelines. 3.3.1.1 Material Guidelines. Not applicable. 3.3.1.2 Processes Guidelines. Not applicable. 3.3.1.3 Parts Guidelines. 3.3.1.3.1 Coupling Design. The coupling shall be designed and manufactured (for example, over-molded, ins
38、erted, swaged, or crimped) so that no internal tube abrasions, cuts or flaws shall result under any condition or combination of assembly component dimensioning or tolerances allowed by supplier production Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot f
39、or ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16295 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 4 of 13 specifications, or under any condition of rubber hose compression allowed by supplier product
40、ion specifications. 3.3.1.3.2 Sharp Corners. Sharp corners are not permitted where the coupling contacts the tube in order to prevent cutting of the hose when the hose assembly is subjected to internal pressure. 3.3.1.3.3 Tube Insert. The tube insert must not extend past the end of the crimp shell a
41、fter crimping, and the end of the tube insert must have a radius and be manufactured to eliminate burrs or sharp edges which might cause hose damage under conditions of assembly vibration or pressure impulse. 3.3.1.3.4 Damage. Damage to hose rubber or reinforcement generated by the coupling of the h
42、ose is not permissible under any possible production manufacturing conditions or supplier production tolerance stack-up, including variations in hose compression concentricity. 3.3.1.3.5 Tube Collapse. Metal tube insert collapse during crimping is not permissible, except when this collapse is limite
43、d, predictable, controllable, and does not increase the potential for assembly leakage or other malfunction. Approval is required from the GM global HVAC/PTC engineer. 3.3.1.3.6 Design Restrictions. Grooves, upsets, or serrations are not permitted on the tube stem Outside Diameter (OD), or on the cr
44、imp shell Inside Diameter (ID), except that these grooves, upsets, or serrations do not cause hose cutting or other damage under any condition or combination of assembly component dimensioning or tolerance allowed by supplier production specifications, or under any condition of rubber hose compressi
45、on allowed by the supplier production specifications. 3.3.1.3.7 Skiving, Adhesives. Skiving of the hose is not permissible. Use of adhesives in the joint is not permissible. 3.3.1.4 Recycling. Materials shall be recyclable per GMW3116. Attempts should be made to minimize the variety of materials use
46、d, to make recycling more viable. 3.3.2 Design Guidelines and Constraints. 3.3.3 Identification and Marking. All assemblies must be labeled with the GM part number, date code and tool/cavity number in a visible location. All labels shall conform to GMW14573. All plastic parts shall be identified for
47、 recycling per SAE J1344. 3.3.4 Workmanship. Not applicable. 3.3.5 Interchangeability. Not applicable. 3.3.6 Packaging. Not applicable. 3.4 Documentation. See GMW15920 - Record Management for Suppliers. 3.5 Support of System/Subsystem/Component/ Part after Sale. Not applicable. 3.6 System/Subsystem/
48、Component/Part Operator Training. Not applicable. 3.7 Testing Requirements. 3.7.1 DV Phase (GMW8758 - Design Validation and Production Validation). Table 1: DV/PV Test Table Section Test Number of Samples for Couplings Note 1 Number of Samples for Quick Connect Test Type 3.2.1.1.1 Leak Note 2 Note 2
49、 3.2.1.1.2 Cold Leak 24 12 Performance 3.2.1.1.3 Tensile 24 12 Performance 3.2.1.1.4 Blow-Off 24 12 Performance 3.2.1.1.5 Blow-Off After Heat Aging 24 12 Performance 3.2.1.1.6 Vacuum 24 12 Performance 3.2.1.1.7 Insertion Force Not applicable 12 Performance 3.2.1.1.8 Pull-Out Force Not applicable 12 Performance 3.2.1.1.10 Cyclical Corrosion 24Note 3 12 Performance 3.2.1.1.11 Salt Spray 24Note 3 12 Performance Copyright General Motors Company Provided by IHS under license with General Motors Company
