1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW16642 Headlamp Washer Systems/High Pressure Nozzle Jets or Nozzle Jets with Telescopic Drives Copyright 2012 General Motors Company All Rights Reserved September 2012 Originating Department: North American Engineering Standards Page 1 of 9 1 Scope N
2、ote: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. This specification stipulates the requirements, test conditions and test procedures for functio
3、n, material and durability testing of nozzle jets as well as nozzle jets with telescopic drives used in vehicles with high-pressure headlamp washer systems, in the following referred to as “nozzles“ or “drives“. 1.2 Foreword. Not applicable. 1.3 Applicability. In addition to the requirements of this
4、 specification, the nozzles, if applicable with drives, shall also fulfill the legal requirements of the countries in which they are operated, in conjunction with a high-pressure headlamp washer system. 2 References Note: Only the latest approved standards are applicable unless otherwise specified.
5、2.1 External Standards/Specifications. ECE R45 ISO 845 ISO 1798 ISO 3386 IEC 60068-2-27 ISO 1431-1 ISO 1856 ISO 8067 ISO 37 2.2 GM Standards/Specifications. GMW3059 GMW3221 GMW14359 GMW14797 GMW3172 GMW3286 GMW14363 GMW15622 GMW3191 GMW14234 GMW14650 GMW16331 2.3 Additional References. Program Speci
6、fic Subsystem Technical Specification (SSTS) 3 Resources 3.1 Facilities. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measurin
7、g variables as specified in this specification shall be determined correctly with respect to its physical definition. 3.1.3 Pressure System. According to the relevant test methods, test specifications, DIN standards, etc. Copyright General Motors Company Provided by IHS under license with General Mo
8、tors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16642 Copyright 2012 General Motors Company All Rights Reserved September 2012 Page 2 of 9 3.1.3.1 Temperature Chamber. Recirculating air temperature chamber with air
9、extraction system: Test Room: Suitable size Passages: Suitable Temperature Range (-40 C to +120 C): Continuously adjustable Permissible temperature deviation: 3 C 3.1.3.2 Pressure Generation System. Pressure-generating system for up to 5 bar (72.5 psi) (e.g., high-pressure pump for headlamp washer s
10、ystem). 3.2 Equipment. 3.2.1 Vibration Test Equipment. Electromagnetic vibration table with control unit for vibration test. 3.2.2 Shock Test Equipment. Shock testing machine with appropriate adjustment options. 3.2.3 Durability Testing Equipment. Suitable durability testing equipment for the perfor
11、mance of the durability test, consisting of counter, time control and pressure generating system. The durability testing equipment is a device used to operate the nozzles, if applicable with drive, for the total number of durability test cycles according to preset operating and pause times. Upon com
12、pletion of the specified number of cycles, the durability testing equipment shall automatically shut off. 3.2.4 Testing Instruments. For the performance of the release test, the following devices and equipments are required: Pump (to 600 kPa), Hoses, Pressure Gauge (to 600 kPa) Stopwatch, Test Beake
13、r Ex-protected temperature cabinet and return air furnace. (-40 C to +120 C) Serial high-pressure pump, power supply, switch clock with numerator Agitator for the test of the vibrating strength Material testing instrument to ISO 37, GMW14363, ISO 845, ISO 1798, ISO 8067, ISO 1856, GMW3221, GMW14359,
14、 and ISO 3386. All devices and instruments must be so constructed that their accuracy is better than the tolerances allowed for the test. 3.2.4.1 According to the relevant test methods, test specifications, DIN standards, etc. 3.2.4.2 Device. Device for mounting and installation of the nozzles and,
15、if applicable, the drives to be tested. 3.2.4.3 Pressure Measuring Instrument. Digital displayed overpressure measuring instrument with analog output (printer and recorder output). Indicating range (0 to 500) kPa, resolution 2 kPa 3.2.4.4 Voltage Stabilizer. Voltage and current (100 amp minimum) adj
16、ustable. 3.2.4.5 Voltmeter. With appropriate measurement range, accuracy class 0.5 or higher. 3.2.4.6 Measuring Container. Measuring glasses of appropriate size for volume measurement. 3.2.4.7 Time Switch with Counter. The time switch with counter is a device used to operate the test setup for the t
17、otal number of test cycles according to preset operating and pause times. Upon completion of the specified number of cycles, the time switch with counter shall automatically shut off. Intervals: (variable) Continuously (1 to 30) seconds Pause intervals: (variable) Continuously (1 to 60) seconds Read
18、ing accuracy: 0.5 seconds Counter Frequency: 0.1 Hz Counter Range: 4000 pulses 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 GMW16642 Copy
19、right 2012 General Motors Company All Rights Reserved September 2012 Page 3 of 9 3.2.4.8 Test Medium. As described in the individual test points, the following test medium shall be used: a. Tap water b. 50% tap water with 50% alcohol (Isopropanol) Note: If no medium is specified in the individual te
20、st points, test medium using item “a“. 3.2.4.9 Set of Hoses. A set of hoses to connect the individual components filled with the test medium. Released production hoses shall be used for the test, if available. The connection between the individual components shall be as short as possible. Where poss
21、ible, rigid tube connections with identical flow cross sections are also allowed. 3.3 Test Vehicle/Test Piece. 3.3.1 Test Samples. If not otherwise specified, for the purpose of initial sampling and release testing according to this specification, at least forty (40) nozzles (twenty (20) pair) shall
22、 be used. The test samples shall be successively numbered. The factory test certificate shall contain the rated values and the actual values measured by the supplier as required in the specification and the drawings from the material and operational data. 3.3.2 Conditioning. If not otherwise specifi
23、ed in the individual tests, the tests shall be performed in the as received condition at (+23 3) C without any preconditioning. Prior to function testing with the test medium, the system shall be subjected three (3) times to a pressure of 3 bar (43.5 psi) for (1 to 2) seconds. 3.3.3. Number of Test
24、Samples. For the performance of a test according to this specification, twenty (20) pairs of samples (for the right and left) are requisite, which are to be delivered with a test certificate. 3.3.4 Quality Control. For the control of the quality of production the Division Quality Control and Inspect
25、ion is responsible. Any change at the jet horn compared to the released test samples requires GM approval. 3.4 Test Time. Not applicable. 3.5 Test Required Information. Not applicable. 3.6 Personnel/Skills. Not applicable. 4 Procedure 4.1 Preparation. 4.1.1 Marking. In accordance with the minimum re
26、quirements to ECE R45, an important part of the headlamp washer system shall be clearly and indelibly marked with the following inscription: Trade name or trademark. The rated voltage, for electrically operated components. A sufficiently large area for the authorization codes. The design of the nozz
27、le is normally vehicle dependent. The authorization code should be applied to the nozzle in such a way that it is visible in the installed condition on the vehicle. If possible, a suitable point on the nozzle and, if applicable, the drive should also be clearly and indelibly marked with the followin
28、g according to GMW16331: GM trademark. The manufacturing date. The manufacturers trademark (if not already present). The part number and, If possible for plastic parts, the material identification. 4.1.2 Visual and Dimensional Check. In the as received condition, the test samples shall not show any
29、visible damages or defects which could adversely affect the function or the appearance. The dimensions and their tolerances as specified in the design drawings and/or releases shall be fulfilled from all parts. 4.2 Conditions. 4.2.1 Environmental Conditions. Not applicable. Copyright General Motors
30、Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16642 Copyright 2012 General Motors Company All Rights Reserved September 2012 Page 4 of 9 4.2.2 Test Conditions.
31、Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.2.3 Materials. All materials used for the nozzles and drives shall meet the drawing specifications and material specifications
32、, as well the requirements of the releases. 4.2.3.1 Ozone Resistance of Elastomer Parts. The ozone resistance of elastomer parts shall meet Ozone per ISO 1431-1 Procedure A, 100 pphm, 40C. Zero Rating required. 4.2.3.2 Painted Plastic Parts. Painted plastic parts of the nozzles or the drives shall f
33、ulfill the requirements according to GMW14797. 4.2.3.3 Plastic Parts. All unpainted plastic parts of the headlamp washer system, which are visible in nonoperational as well as in operational mode, shall be weatherproofed according to GMW14650 “Class 2”. 4.2.4 Environmental Protection. Must comply wi
34、th GMW3059, Restricted and Reportable Substances for Parts. 4.2.5 Current Connections. The electrical connections, if available, shall be performed according to GMW3191. 4.3 Instructions. Note: The tests shall be performed according to the test sequence (Appendix A). The prescribed sequence at the t
35、ests shall be observed to ensure that comparable results are attained. 4.4 General Requirements. 4.4.1 Tests. The tests are to be performed in the sequence and with the division of the test samples which are given in Appendix A. If not differently specified, they are to be performed at (23 3) C. 4.4
36、.2. Water Pressure Test. The jet horn/nozzle is connected to a water pump or approved pressure source by means of hoses. Turn the pump on for (5.0 0.2) seconds, a total of 10 times with a pressure of (600 30) kPa (87 psi). The pause time is 10 seconds for each test. At the end of test, water may not
37、 be present at any point on the jet horn, except the jet opening. The individual parts of the jet horn/nozzle must remain in their position and may not be forced out. The settling position of the jet may not be changed. The water quantity issued out of the jet opening is measured. 4.4.3 Pressure Res
38、istance and Tightness. The drive shall be subjected three times to a pressure of 5 bar (72.52 psi) with the nozzle closed. The test time shall be 5 seconds for each test, the pause time 10 seconds and the test temperature +60 C. 4.4.4 Temperature Storage. The nozzles and, if applicable with the driv
39、es (test pieces), shall be stored without test medium (empty) at the following temperatures: 0.5 hours at +95 C then (30 5) minutes at (+120 3) C: Afterwards 168 hours at +70 C then (168 5) hours at (+90 3) C: Afterwards (8 0.5) hours at (-40 3) C: Afterwards Fill with water: End of Test (4 0.5) hou
40、rs at (-40 3) C: (Frozen in) Note: The times are valid for reaching given temperature. Note: Afterwards no deficiency is permissible. 4.4.5 Final Test After Temperature Storage. The test (4.4.2) is repeated. The measured quantity of water may deviate from the maximum by only 10% from that measured a
41、t the test (4.4.2). 4.5 Detaching and Mounting Forces. 4.5.1 Mounting Forces. The mounting force between the nozzle and the drive, or a corresponding connector, shall not meet requirements in GMW14234.The mounting force shall be determined in the direction of the axle shaft. 4.5.2 Detaching Forces.
42、The detaching force between the nozzle and the drive, or a corresponding connector, shall withstand a force of FA = 130 N opposed to the mounting direction, with a permissible deviation of 45 degrees. The required detaching forces shall be achieved both in the new condition as well as following the
43、individual 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 STANDARDS GMW16642 Copyright 2012 General Motors Company All Rights Reserved Septemb
44、er 2012 Page 5 of 9 4.6 Ventilating Characteristics. The nozzles, and if applicable the drives, shall be capable of self-bleeding during normal operation with rated voltage, in conjunction with the other components of the headlamp washer system. 4.7 Function Tests. 4.7.1 Function Tests for Nozzles w
45、ithout Drives. Refer to Section 4.4.2. 4.7.2 Function Tests for Nozzles with Drives. The following values shall be determined for one actuation cycle: a. Extension time at 2.5 bars b. Return time c. Actuation time for one cycle d. Volume for one actuation cycle Provided that the values are not repro
46、ducible, the average value can be calculated from 10 actuations. For this purpose, however, the minimum and maximum values shall also be noted. 4.7.3 Leak Rate. A 2 meter water column shall not fall within 24 hours. Following ventilating, the test piece shall be connected to a vertical hose of 10 mm
47、 internal diameter, which is filled with water and which is open at the upper end. The permissible quantity of water escaping between the moving parts is 0.1 cm3 maximum. 4.7.4 Requirement. The function according to paragraphs 4.4.2 and 4.4.3 shall subsequently be guaranteed and the determined value
48、s shall correspond to those in the General Requirements. 4.8 Metallic Surfaces, Paint and Corrosion per GMW15622. 4.8.1 Test of Surface Protection. 4.8.2 Metallic Coated Invisible Surfaces. Salt spray fog test according to GMW3286. 4.8.3 Painted Surfaces. Salt spray fog test according to GMW3286. 4.
49、9 Temperature Cycle Test. Fill the test pieces with test medium item (a) in 3.2.4.8 (tap water) and subject them three times to the following temperature cycle: 4 hours at -30 C 4 hours at +95 C The rate of change of temperature shall be 3 C/minute 4.9.1 Requirement. The function according to Section 4.4 shall subsequently be guaranteed and the determined values shall correspond to those
