1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW16861 Test Method to Quantify Cleanliness of Electric Motor and Components Copyright 2012 General Motors Company All Rights Reserved November 2012 Originating Department: North American Engineering Standards Page 1 of 4 1 Scope Note: Nothing in this
2、 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 document outlines a method for: a. Determining the weight and nature (if specified) of foreign material retain
3、ed in or on electric motor components prior to assembly. b. Verifying the functionality of the component in application after the cleaning procedure. 1.2 Foreword. Not applicable. 1.3 Applicability. This method may be used to quantify foreign material present in components, sub-assemblies and assemb
4、lies. 1.4 Principle. The test method involves washing electric motor and components with a specified solvent, collecting the rinse fluid, filtering solid materials from it and determining the weight (and nature, if specified) of solids present; The method also outlines drying requirement and method
5、for the post-washed components to be re-introduced to service. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. None 3 Resources 3.1 Facilities. Test shall be performed in wel
6、l ventilated area required by the safe handling of the solvent. 3.2 Equipment. A list of equipment and materials which may be necessary and useful in evaluating components for sediment levels is shown in Appendix A. 3.2.1 Nylon or Polytetrafluoroethylene (PTFE) filter membranes, 10 micron pore size
7、(maximum), shall be used. The use of 44 micron (maximum) and 10 micron (maximum) nylon or PTFE filters in series is permissible. 3.2.2 A 5 micron filter (or equivalent) shall be used for filtering wash fluid that is recycled to a reservoir for further use. 3.2.3 Wash fluid shall be chemically non-ag
8、gressive to insulation and other materials used on the motor components. It shall provide effective rinse and leave minimum residue. Acceptable wash fluids are listed in Appendix A for motor components that are to be re-introduced to service. 3.3 Test Vehicle/Test Piece. Components, subassemblies an
9、d assemblies shall be from the production process at the point of their inclusion into the assembly (if washed at the plant) or as shipped from a supplier (if shipped directly to the assembly line). Components may also be obtained from the production line at the final exit in order to monitor and co
10、ntrol sediment control effectiveness. 3.4 Test Time. Not applicable. 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 GMW16861 Copyright 2012
11、 General Motors Company All Rights Reserved November 2012 Page 2 of 4 3.5 Test Required Information. Not applicable. 3.6 Personnel/Skills. Per local requirements. 4 Procedure 4.1 Preparation. Prior to sediment evaluation, components shall not be rinsed, wiped, or cleaned in any way other than what i
12、s typical for the production process if quantitative debris assessment is required. Lot numbers or other pertinent shipment information should be recorded for samples to be tested. Protect samples from airborne debris during transport to the sediment test equipment and avoid rough handling. 4.2 Cond
13、itions. 4.2.1 Environmental Conditions. 4.2.1.1 When evaluating traction motor assemblies, rotor and stator shall be checked separately. 4.2.1.2 Test frequency and sample size should be determined per control plan. Sample size shall be sufficient to allow for statistical control of production proces
14、ses and establishment of control limits. Reduced sampling is possible based on statistical data showing process capability. 4.2.1.3 Reintroduction of test samples into the production process must occur before the end of line test. 4.2.2 Test Conditions. Deviations from the requirements of this stand
15、ard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Prepare Test Equipment and Materials. 4.3.1.1 Oven dry the required number of filters for 30 minutes to 35 minutes at 50 C to 55 C. Allow filters to c
16、ool for 15 minutes to 20 minutes in a desiccator prior to use. Times and temperatures may be adjusted to meet current plant practices and production schedules. 4.3.1.2 Ascertain the weight of filters to the nearest 0.1 mg (milligram) by means of an analytical balance and record the value in milligra
17、ms. 4.3.1.3 Rinse collection tub/tray before and after each test with a sufficient quantity of wash fluid to purge the system of any foreign material. Collect the fluid in a beaker and visually examine the sediment for unusual particles or amounts. Equipment and materials should be protected from en
18、vironmental contamination when not in use. 4.3.1.4 For reusable wash fluid, cleanliness shall be checked as follows. Collect at least 1 L of homogeneous rinse fluid in a clean beaker and note the volume used. Filter the fluid with vacuum assist through a pre-dried and pre-weighed 5 micron (maximum)
19、filter. Remove filter from the funnel and expose to drying cycle (4.3.2.5.1). Determine amount of residue collected by subtracting original filter weight from weight of filter plus (+) residue. If amount of residue exceeds 0.50 mg/L, wash fluid must be replaced with new. Wash fluid must be replaced
20、annually regardless of test results. 4.3.2 Cleaning and Measurement of Test Sample. Prepare the required number of filters per 4.3.1.1 and 4.3.1.2. 4.3.2.1 Place the component to be evaluated in the clean collection tub/tray. Thoroughly rinse the component with a maximum pressure of 300 kPa and a mi
21、nimum of 1 L of solvent. Efforts should be made to ensure that all foreign material and loose debris are removed from the motor component including those in the enclosed areas. 4.3.2.2 Burrs resulting from machining operations, assembly operations, etc., which remain firmly attached after rinsing an
22、d air blowout shall be noted but shall not be included in the total sediment weight. Appropriate equipment (mirrors, lights) shall be used to inspect enclosed areas for loose chips not removed by the rinse. In such cases, proper actions shall be taken to improve the cleanliness process. 4.3.2.3 Plac
23、e dried and weighed filters in the filtration funnel. 4.3.2.4 Filter the wash fluid using the pre-dried and pre-weighed filters. Vacuum assist is permissible. Rinse the collection chamber/beaker thoroughly and transfer completely the wash fluid to the funnel for filtering. 4.3.2.5 Carefully remove t
24、he filter from funnel and expose to the following drying cycle. 4.3.2.5.1 Filters must be dried 30 minutes to 35 minutes at 50 C to 55 C. Times and temperatures may be adjusted to meet current plant practices and production schedules as long as there is evidence that filter weight has stabilized for
25、 that cycle. 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 GMW16861 Copyright 2012 General Motors Company All Rights Reserved November 201
26、2 Page 3 of 4 4.3.2.5.2 After drying, the filters shall be placed in a desiccator to cool for 15 minutes to 20 minutes. Debris samples must be properly identified. 4.3.2.6 Weigh dried filter plus (+) sediment and record weight. 4.3.3 Post-Washing Component Handling. 4.3.3.1 Components and assemblies
27、 shall be scrapped after the sediment test unless they meet all requirements specified on the print and are approved by GM Engineering. Sealed bearing and seal containing components shall be discarded after the sediment test. 4.3.3.2 Traction motor components, rotor and stator, shall be dried to be
28、within 10 g of the initial component weight, if they are to return to service. Recommended drying procedure is ambient air dry for 24 hours for stators and 150 C for 30 minutes or less for rotors in addition to 24 h ambient air dry. 4.3.3.3 Washed components shall be rust-proofed to meet the origina
29、l requirements before they are re-introduced into GM applications. 5 Data 5.1 Calculations. Determine total sediment weight by subtracting filter weight (4.3.1.2) from weight of filter plus (+) sediment (4.3.2.6). When two filters are used (3.2.1), weights should be reported for each filter size. 5.
30、2 Interpretation of Results. Not applicable. 5.3 Test Documentation. 5.3.1 Reporting. Examine the filters under a light microscope. Report the presence of metallic and abrasive debris. Measure and report the sediment particles using a calibrated grid or scale. Note the size (longest dimension in mic
31、rons) of the largest particle and record and report to GM engineering. 5.3.2 Transfer motor data to Statistical Process Control (SPC) charts and plot the data, where applicable. 5.3.3 Notify Production Department Supervisor of any out-of-control points or otherwise undesirable conditions. 6 Safety T
32、his standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicabili
33、ty of regulatory limitations prior to use. Approved magnetic rotor handling procedures need to be followed (if applicable). 7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. PTFE Polytetrafluoroethylene SPC Statistical Process Control 8 Coding System This standard shall
34、 be referenced in other documents, drawings, etc., as follows: Test to GMW16861 9 Release and Revisions This standard was originated in September 2012. It was first approved by the Non-ferrous Metals and Castings GSSLT in November 2012. It was first published in November 2012. Issue Publication Date
35、 Description (Organization) 1 NOV 2012 Initial publication. 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 GMW16861 Copyright 2012 General
36、Motors Company All Rights Reserved November 2012 Page 4 of 4 Appendix A A1 Laboratory Equipment Some specific equipment that has proven useful in testing is listed below for reference. The use of other fluids shall be approved by GM Materials Engineer. Other brands/models of equipment may be used as
37、 long as the test procedure is not compromised. A1.1 Drying oven with thermometer. A1.2 Desiccator. A1.3 Nylon or PTFE filter membranes, 5 micron, 10 micron, and 44 micron (optional) maximum pore size. A1.4 Analytical balance. A1.5 Vacuum pump, manifold, and trap. A1.6 Drum pump. A1.7 Stainless rins
38、e collection sink/tub (washable, drainable). A1.8 Side-arm flask, filter set, beakers, wash bottles, spray nozzle (optional). A1.9 Sediment wash cart. A1.10 Air line and hose. A1.11 Wash Fluids. De-aromatized petroleum distillates and other non-aggressive organic solvents with a maximum boiling poin
39、t of 205 C are required with ambient air-dry residue less than 2% if the post-wash component is to be re-introduced into service. Such fluid shall be approved by GM Materials Engineer. The following are approved fluids. 1. Decafluoro pentane, 99% minimum. 2. Hexanes, technical grade minimum. 3. De-a
40、romatized petroleum distillates, including naphtha, 75% minimum. 4. Odorless mineral spirits, 75% minimum. A1.12 Stereomicroscope. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
