1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW16580 Thermal Bypass Valve Validation Test Copyright 2011 General Motors Company All Rights Reserved August 2011 Originating Department: North American Engineering Standards Page 1 of 18 1 Introduction Note: Nothing in this standard supercede
2、s applicable laws and regulations. Note: In the 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), Product Validation (PV), and Post Validation Audit (PVA) requirements for a mecha
3、nical Thermal Bypass Valve (TBV). 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/Specifications. ASTM B221 SAE J1344 2.2 GM Standards/Specifications. 998633
4、3 GMW8758 GMW14872 GMW15758 GMW3059 GMW14156 GMW15272 GMW15760 GMW3172 GMW14157 GMW15724 GMW16449 2.3 Additional References. GM1829 Analysis Development Validation (ADV) Test Plan 3 Requirements 3.1 System/Subsystem/Component/Part Definition. The Thermal Bypass Valve regulates oil flow to the remote
5、 located cooler in order to control the operating temperature of the transmission. In a cold state, a thermally actuated valve contained inside the bypass housing will allow the oil to short circuit the transmission oil cooler (TOC). In a predetermined hot state, the valve closes off the bypass and
6、forces all the oil to go through the TOC which, in turn, will regulate the oil temperature of the transmission. 3.1.1 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. The TBV po
7、tentially could be located under the hood of a vehicle. The TBV may be exposed to temperatures from -40 C to 150 C and subject to salt mist and water splash. 3.1.4 Interfaces. Approved GM quick connect fittings and/or directly to steel or aluminum tubes. 3.1.5 Usage Definition. The TBV will be locat
8、ed in the underbody and will be exposed to fluids in GMW16449 (see Appendix A - “Fluid Applicability Per Vehicle Location” table). 3.2 Product Characteristics. 3.2.1 Performance Requirements. Test fluid used during each test shall be 9986333 (ATF-212B) transmission fluids or a program specific fluid
9、 as specified by GM Engineering in the Component Technical Specification (CTS) provided. Ultraviolet dye shall be added to the test fluid prior to testing. All pipe connections on the TBV must be approved by GM Engineering and meet requirements of GMW15724. Copyright General Motors Company Provided
10、by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16580 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 2 of 18 3.2.1.1 Fixed-Value Performance Testing Re
11、quirements. The following tests (excluding Cleanliness Test and Burst Test) shall be conducted both before and after the tests in 3.2.1.2 Endurance Testing Requirements. In pre-tests, the TBVs shall meet the requirements for each test as described in the procedures and the CTS. In post-tests, the TB
12、Vs still must meet the requirements for each test as described in the procedures and the CTS, and shall not have degraded in performance by more than 5% from the initial pre-test measurement. 3.2.1.1.1 Pressure Drop Tests. The TBV shall have a maximum pressure drop of 50 kPa when oil at 5 C below th
13、e start to open temperature is flowed at 11 L/minute through the device (4.3.2). The TBV shall have a maximum pressure drop of 25 kPa when oil at Full Open (FO) +10 C is flowed at 11 L/minute through the valve (4.3.2). 3.2.1.1.2 Leakage Test. 3.2.1.1.2.1 Internal Leakage. The TBV internal leakage pa
14、st the sealing feature shall not exceed 0.3 L/minute with fluid flowing at 12 L/minute at 1000 kPa and the following valve positions: Full Open (FO) with fluid temperature at FO +10 C and Full Closed (FC) with fluid temperature at FC -10 C when tested (4.3.3.1). Full Open (FO) and Full Closed (FC) r
15、equirements shall be defined as according to the CTS. 3.2.1.1.2.1.1 Internal Leakage (In-process Check). The TBV internal leakage past the sealing feature shall not exceed 0.05 L/minute when tested (4.3.3.1.1). 3.2.1.1.2.2 External Leakage. No external leakage of oil is permissible from the TBV asse
16、mbly including crimped/quick connect pipe interfaces when tested (4.3.3.2). (Refer to Table 3). 3.2.1.1.2.2.1 External Leakage (In-process Check). The leakage shall not exceed 200 L/minute when tested (4.3.3.2.1). 3.2.1.1.3 Hysteresis Test. The TBV must exhibit the hysteresis response defined in the
17、 CTS document (“Thermal Bypass Requirement” section) when tested (4.3.4). 3.2.1.1.4 Response Time Test. The FC -10 C position to FO +10 position shall be less than 45 s when tested (4.3.6) Thermal Durability Test. 3.2.1.1.5 Cleanliness Test. The total weight of contaminants shall not exceed 0.5 mg a
18、nd all dimensions of any piece of contaminant cannot exceed 0.5 mm when tested (4.3.1). 3.2.1.1.6 Burst Test. Minimum burst strength shall be no less than 6895 kPa when tested (4.3.5). 3.2.1.1.7 TBV Drop Test. The five (5) samples tested shall meet the requirements of all endurance and performance t
19、ests when tested (4.3.11). Each sample will then be tested in an endurance test leg shown in Appendix A. 3.2.1.1.8 TBV Assembly Drop Test. The five (5) samples tested shall meet the requirements of all endurance and performance tests when tested (4.3.12). Each sample will then be tested in an endura
20、nce test leg shown in Appendix A. 3.2.1.2 Endurance Testing Requirements. These requirements are subject to sample size and reliability requirements (3.2.3.2). 3.2.1.2.1 Thermal Durability Test. The TBV shall meet the pressure drop requirements (4.3.2), internal leakage requirements (4.3.3.1), exter
21、nal leakage requirements (4.3.3.2), and hysteresis requirements (4.3.4) after three (3) lives of 30 000 cycles each (4.3.6). 3.2.1.2.2 Thermal and Pressure Cycle Test. The TBV shall meet the pressure drop requirements (4.3.2), internal leakage requirements (4.3.3.1), external leakage requirements (4
22、.3.3.2), and hysteresis requirements (4.3.4) after 1000 cycles (4.3.7). 3.2.1.2.3 High Temperature Aging Test. The TBV shall meet the pressure drop requirements (4.3.2), internal leakage requirements (4.3.3.1), external leakage requirements (4.3.3.2), hysteresis requirements (4.3.4), and vibration r
23、equirements (4.3.10) after completion of high temperature aging test (4.3.8). 3.2.1.2.4 Corrosion Test. The valve assembly shall meet the Underbody Cosmetic and Functional corrosion requirements for Class 1/2 Regional Corrosion, per GMW15272. The valve shall meet Underhood Cosmetic Corrosion require
24、ments per GMW15272 (see Appendix A - “Cosmetic Corrosion Resistance Requirements” table), and GMW14872 (see Appendix A - “Mass Loss Targets (3.18 mm thick coupons) - Cosmetic and Functional” table) Underhood All Splash, Method 1/2 cosmetic and functional corrosion requirements. The valve assembly sh
25、all meet “Thermal Soak Addition” deviation in GMW14872. 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 GMW16580 Copyright 2011 General Moto
26、rs Company All Rights Reserved August 2011 Page 3 of 18 3.2.1.2.5 Vibration Test. The TBV shall meet the pressure drops requirement (4.3.2), internal leakage requirements (4.3.3.1), external leakage requirements (4.3.3.2), and hysteresis requirements (4.3.4) after completion of vibration test (4.3.1
27、0). Mount TBV (GMW3172), truck duration, transmission mounted. 3.2.2 Physical Characteristics. 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
28、 test exposure representing a Reliability Evaluation Point (REP) of 10 years of corrosion and 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 grea
29、ter at a 50% confidence (R99C50), at the REP for the TBV. The supplier shall 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
30、 physical level reliability demonstration testing. The reliability demonstration is provided by the Design Validation (DV) Endurance Tests specified in 3.7.1. In contrast to DV, the endurance tests specified for Product Validation (PV) in 3.7.2 are intended to confirm conformance to the reliability
31、demonstrated during DV. Test to Failure is always the preferred method. Failure is defined as, but not limited to, the loss of function, unacceptable performance degradation and non-conformance of the component as stated in this specification. Note: The required number of test samples may be negotia
32、ble if it is not practical to run, for example, 23 samples. Negotiation of sample size should consider test equipment limitations, test sample physical size, test duration, etc. However, reduction of the sample size may require inclusion/use of longer test durations or other test methods, such as Hi
33、ghly 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 failure testing may be considered as a way to reduce the sample size and/or test d
34、uration. (For detail refer to GMW14156 and GMW14157). 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). Note: GM Validation Engineering shall review and
35、 approve reliability demonstration test plans prior to the supplier submitting the Analysis Development Validation (ADV) Test Plan, GM1829 form, for approval (GM1829 is located in the Statement of Requirements (SOR). 3.2.4 Serviceability. Not applicable. 3.2.5 User System/Subsystem/Component/Part In
36、terface. Not applicable. 3.3 Design 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. Not applicable. 3.3.1.4 Recycling. Materials shall be recyclable per S
37、AE J1344. 3.3.2 Design Guidelines and Constraints. Not applicable. 3.3.3 Identification and Marking. Materials must be labeled with the GM part number, date code and tool/cavity number in a visible location. 3.3.4 Workmanship. Not applicable. 3.3.5 Interchangeability. Not applicable. 3.3.6 Packaging
38、. Not applicable. 3.4 Documentation. All test samples must be qualified dimensionally. All data points must be reported. For samples destructively tested, mode of failure must be reported and include digital photographs of failure mode. All test specimens must be retained by the supplier for a minim
39、um of one year and be available for review by GM Engineering, if requested. Test Procedures referencing specific minimum test values must be met by the Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted with
40、out license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16580 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 4 of 18 -3 sigma limit of the sample population tested. For PV testing, documentation shall be provided as required by the normal Production Part Approval P
41、rocess (PPAP). 3.5 Support of System/Subsystem/Component/Part After Sale. Not applicable. 3.6 System/Subsystem/Component/Part Operator Training. Not applicable. 3.7 Testing Requirements. 3.7.1 Design Validation (DV) Phase. For a detailed description of the intent of DV, refer to GMW15758, Design Val
42、idation. Refer to Appendices A and B in GMW16580 for details on the test flow and ADV structure. Table 1 provides a list of required DV tests. Table 1: DV Test Table Section Test No. of Samples Test Type 4.3.2 Pressure Drops 32 Performance 4.3.3.1 Internal Leakage 32 Performance 4.3.3.2 External Lea
43、kage 32 Performance 4.3.4 Hysteresis Test 32 Performance 4.3.1 Cleanliness 8 Performance 4.3.5 Burst Test 8 Performance 4.3.6 Thermal Durability Test 8 Endurance 4.3.7 Thermal and Pressure Cycle Test 8 Endurance 4.3.8 High Temperature Aging Test 8 Endurance 4.3.9 Corrosion Test 8 Endurance 4.3.10 Vi
44、bration Test 8 Endurance 4.3.11 Drop Test 5 Performance 3.7.1.1 Test Samples. Design representative test samples may be produced from prototype tooling or from equivalent production tooling, but shall represent design intent, including design tolerances and material variation within the materials sp
45、ecification. 3.7.1.2 Approval Requirements. Approval shall be provided by the GM Design Responsible Engineer and the GM Validation Engineer. 3.7.2 Product Validation (PV) Phase. For a detailed description of the intent of PV, refer to GMW15758, Product Validation. Refer to Appendices A and B in GMW1
46、6580 for details on the test flow and ADV structure. Table 2 provides a list of required PV tests. 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 STA
47、NDARDS GMW16580 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 5 of 18 Table 2: PV Test Table Section Test No. of Samples Test Type 4.3.2 Pressure Drops 32 Performance 4.3.3.1 Internal Leakage 32 Performance 4.3.3.2 External Leakage 32 Performance 4.3.4 Hysteresis Test 32
48、 Performance 4.3.1 Cleanliness 8 Performance 4.3.5 Burst Test 8 Performance 4.3.6 Thermal Durability Test 8 Endurance 4.3.7 Thermal and Pressure Cycle Test 8 Endurance 4.3.8 High Temperature Aging Test 8 Endurance 4.3.9 Corrosion Test 8 Endurance 4.3.10 Vibration Test 8 Endurance 4.3.11 Drop Test 5
49、Performance 3.7.2.1 Test Samples. Production test samples shall be produced on production representative equipment including the effects of manufacturing-induced variation. Sample selection of components to be utilized for the purpose of PV Reliability requirements demonstration shall be in concurrence with the guidelines set forth in GMW15760. 3.7.3 PVA (GMW15758, Post-Validation Audits). 3.7.3.1 Test Samples. Test samples must be produced on regular prod
