1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW3079 Plenum - Heating Ventilation/Heating Ventilation Air Conditioning Inlet Water Ingestion (Includes Dynamic Water Separation Test) Copyright 2011 General Motors Company All Rights Reserved December 2011 Originating Department: North American Engi
2、neering Standards Page 1 of 13 1 Scope Note: Nothing in this standard supersedes 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 test procedure determines the ability of the plenu
3、m to manage water and the Heating and Ventilation (HV) or Heating, Ventilation and Air Conditioning (HVAC) system to resist water ingestion under various static and dynamic test conditions. 1.1.1 This procedure also includes a Wet Road Test that is only applicable to vehicles having unconventional,
4、side mounted, ventilation inlets. 1.2 Foreword. Note: For reasons of personal safety, test vehicles equipped with one or more Supplemental Inflatable Restraint (SIR) systems shall not be used in any de-trimmed vehicle test unless all SIR systems are disabled. Refer to the appropriate service manual
5、for instructions. 1.2.1 During dynamic tests an observer shall be required in test vehicle if a video camera is not used to monitor the HVAC air inlet for water leaks. 1.2.2 This procedure can be used for development or validation of water management. 1.2.3 This test does not evaluate failure modes
6、of plenum flapper valves. It assumes a proper functioning flapper valve system. 1.2.4 The intent of testing with drivers window lowered 50 mm is to obtain a high negative interior body pressure which allows maximum airflow through the Blower Air Inlet (BAI). However, for some new vehicle designs, hi
7、gher negative body pressure may be obtained under different conditions, i.e., all windows closed, sunroof open, etc. This should be investigated and additional tests run accordingly. 1.2.5 Dynamic tests except for the Wet Road Test are run at lower speeds since increased airflow at higher speeds can
8、 cause water from the spray bar to skip over the plenum. 1.2.6 This procedure includes the following Static and Dynamic Water Test. 1.2.6.1 Static Test. 1.2.6.1.1 Low-Pressure Hose Washes. Simulates a home car wash. 1.2.6.1.2 High-Pressure Wand Washes. Simulates commercial high pressure hand car was
9、h. 1.2.6.1.3 Commercial Automatic Car Washes. Simulates vehicle being driven through an actual car wash cycle. 1.2.6.1.4 Spray Arches. Simulates touch-less car wash station. 1.2.6.1.5 Canadian Spray Bar. Simulates car prewash station in high snow-belt areas. 1.2.6.1.6 Universal Water Test Booth (UWT
10、B). Simulates field usage and automatic car wash. 1.2.6.2 Dynamic Test. 1.2.6.2.1 Attitude Test. Simulates vehicle in various stationary attitudes during rainstorm. 1.2.6.2.2 Shipping Angles Test. Simulates vehicle on car carrier during rainstorm. 1.2.6.2.3 Dynamic Maneuvers. Simulated during rainst
11、orms such as: Steady State Driving, Acceleration/Braking, Lane Changes and Cornering and Snap Turns. 1.2.6.2.4 Wet Road Simulation. (See 1.1.1). Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without lic
12、ense from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3079 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 2 of 13 1.3 Applicability. This procedure applies to all vehicles with an enclosed passenger or sealed cargo compartment. Note: Wet Road Test section of this proc
13、edure only applies to test vehicles with unconventional ventilation air inlets. (See 1.1.1). 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.
14、Test facilities and equipment shall be in good, safe working order. Test equipment shall have a valid calibration label affixed to it and located in a prominent place. 3.1.1 Low Pressure Hose Test. Standard water supply outlet with a capacity for delivering and measuring 30 L/minute (8 gpm) through
15、a 16 mm (5/8 in) Inside Diameter (ID) hose. A calibrated flow measurement device is recommended to accurately measure water flow rate. Facility should be approximately level with adequate drainage capability. 3.1.2 Universal Water Test Booth. UWTB shall have capability for metering Chemfil Additive
16、132 or equivalent with surface tension reliever and fluorescent dye into the water being delivered to the nozzles. 3.1.3 Commercial Automatic Car Wash. Reference the Milford Proving Ground car wash or equivalent. Any equivalent car wash must have similar soap output to evaluate soap ingestion into t
17、he plenum inlet. 3.1.3.1 The facility must have one or more high-pressure oscillating soaker arches. Each arch shall have eleven nozzles, three per each side and five across the top, each nozzle producing 3.8 L/minute (1.0 gpm) at 6895 kPa (1000 psi). 3.1.3.2 The facility is required to have a Flood
18、er Bar with four Vjet nozzles (H1/2 V50/150) each with an output of 91 L/minute (24 gpm) at 7584 kPa (1100 psi). This Flooder Bar is typically used in Canada and the Northeast US to clear snow and ice from vehicles before entering a car wash. 3.1.4 Dynamic Tests. Milford Proving Ground road system,
19、or equivalent, to run the dynamic road maneuvers specified in this procedure. The circular track at the Proving Grounds is preferred for the Steady State Speed Tests since the different directions obtained by driving in a circle will average the wind conditions. Other roads may only be used if the w
20、ind speed is less than 8 km/h (5 mph) since the wind directions may not average for oval or straight tracks. 3.1.5 Attitude Tests. Equipment, roads or inclines to produce vehicle attitudes specified in 4.3.6 and 4.3.7. 3.1.6 Wet Road Test. Straight road with a sprinkling system capable of thoroughly
21、 wetting (saturating) road surface with water. Facility must have capacity to safely drive a test vehicle at speeds of 48 km/h (30 mph), 80 km/h (50 mph) and optional 113 km/h (70 mph). 3.1.7 Attitude and Shipping Angle Tests. Equipment, roads or inclines sufficient to produce vehicle attitudes spec
22、ified in 4.3.6 and 4.3.7. 3.2 Equipment. 3.2.1 Trailer with system capable of storing and delivering water flow rate, as determined by engineer in 4.1.1, to the spray bar specified in this procedure. Trailer system must have a means of measuring the water flow rate. The water pump on the trailer mus
23、t not use the vehicle battery for power since this would reduce the power available to run the vehicle HVAC blower and may affect test results. 3.2.2 Water spray bar with six (6), (or number needed to get specified flow rate), Spraying Systems Company, 10 mm (3/8 in) GG Full Jet Nozzle (model number
24、 QHSS15, or equivalent) to produce a cone-shaped spray. The nozzles are to be equally spaced. For example, six (6) nozzles would be spaced 190 mm (7.5 in) apart. The spray bar is to be mounted on a stand that places the nozzle orifice 100 mm (4 in) above the hood surface. The spray bar must be able
25、to rotate the spray angle in the side view. (See Figure 1.) In order to simulate the equivalent rainfall of 20 mm/minute, the spray bar must deliver 20 L/minute/m2 of water over the Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproductio
26、n or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3079 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 3 of 13 total equivalent test surface area of the buck or vehicle. The equivalent area is the surface area of the vehicle pro
27、jected onto a horizontal surface above the vehicle. The projected vehicle surface goes the full width of the vehicle or buck and the total fore/aft direction from a point 100 mm behind the upper edge of the windshield (or where ever water would flow “down hill” onto the windshield) to a point 50 mm
28、forward of the leading edge of the air inlet panel (or wherever water would drain onto the air inlet panel). 3.2.3 Equipment for determining flow rates for static hose tests. 3.2.4 Equipment for observing the HVAC air inlet for water intrusion. This may include a flashlight, mirror, fiber optic scop
29、e, etc., as desired by engineer. 3.2.5 A collection bottle is required to measure water from the evaporator drain. A fiber optic scope may also be used as an aid. 3.2.6 High-pressure spray wand system equipped with 6.35 mm ( in) MEG-SSTC2507 fan spray nozzle. Operating pressure set to at 12.9 L/minu
30、te (3.4 gpm) at 7584 kPa (1100 psi). 3.2.7 Instrument to measure acceleration and deceleration in Acceleration/Braking Test. 3.2.8 Hose for Low-Pressure Hose Test is 16 mm (5/8 in) ID. 3.3 Test Vehicle/Test Piece. 3.3.1 Test Vehicle. Equipped with proper HV or HVAC components, ventilation relief sys
31、tems and a trailer hitch. Note: Air flow over and around the vehicle may affect pressures across the HVAC air inlet. Therefore, consider original equipment options (i.e., front hood air deflector) which may affect air flow over the hood. Note: Consider the effect that nearby components, i.e., wiper
32、system may have on the flow of water or air into the plenum. 3.3.2 HV or HVAC Systems. Consider running both HV and HVAC systems. Verify for design intent and proper functioning. 3.4 Test Time. Not applicable. Calendar time: days Test hours: hours Coordination hours: hours 3.5 Test Required Informat
33、ion. Not applicable. 3.6 Personnel/Skills. Experienced driver having proper training for all required road tests. Experience and knowledge about facility operation and equipment safety. Water leak detection experience or training is recommended. Root cause analysis experience is recommended. Reporti
34、ng: (writing, speaking and basic computer knowledge recommended). 4 Procedure 4.1 Preparation. The engineer shall: 4.1.1 Determine the flow rates for the spray bar in the Dynamic, Attitude and Shipping Angles Tests. For the dynamic, the minimum flow rate shall be 5.7 L/minute (1.5 gpm). For the Atti
35、tude and Shipping Angles tests, the flow rate shall be the equivalent flow of 20 L/minute/m2 as defined in 3.2.2. 4.1.2 Insure the AC compressor is disabled to prevent evaporator core condensation from affecting test results. 4.1.3 Check the HV/HVAC mode and temperature controls for proper functioni
36、ng of system doors/dampers. 4.1.4 Determine if the ventilation inlets are of unconventional design (i.e., side mounted) which only require the flooded road portion of this test procedure to be performed. 4.2 Conditions. Consult technical specifications for requirements considering the following: Any
37、 water that enters the plenum air inlet must be decided on a case-by-case basis and determined whether the water is being managed properly. Water entering through the plenum could reach the heater core, or cause damage to Copyright General Motors Company Provided by IHS under license with General Mo
38、tors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3079 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 4 of 13 other components. No water on the heater core is important because there migh
39、t be a possibility that water could condense on the windshield. 4.2.1 Environmental Conditions. Temperatures shall be above freezing. Wind speed shall be less than 13 km/h (8 mph) constant and 19 km/h (12 mph) gusts. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have
40、 been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Low-pressure Hose Test. Perform this test under each HVAC mode setting listed in Table 1. 4.3.1.1 Adjust water flow from a 16 mm (5/8 in) ID hose to 30 L/minute (8
41、gpm). 4.3.1.2 Direct water from side-to-side of vehicle, covering the plenum cover/grille area at all possible angles for 3 minutes. Hold hose outlet approximately 15 cm (6 in) away from cowl cover/grille and moving at 15 cm/s (6 in/s). 4.3.1.3 Inspect for water intrusion into the HV/HVAC module and
42、 into the passenger compartment. Record observations. 4.3.2 High-pressure Spray Wand Test. Perform this test under each HVAC mode setting listed in Table 2. 4.3.2.1 Direct spray from side-to-side of vehicle to cowl cover/grille area at all possible angles for 1 minute at 15 cm/s (6 in/s). The spray
43、orifice outlet shall be 30 7.5 cm (12 3 in) away from cowl cover/grille. The fan spray shall be oriented fore-aft of the vehicle. 4.3.2.2 Inspect for water intrusion into the HV/HVAC module and into the passenger compartment. Record observations. 4.3.3 Water Booth Test. Perform this test under each
44、condition in Table 1. 4.3.3.1 Subject vehicle to Universal Water Booth as specified by engineer in 4.1.1. 4.3.3.2 Inspect for water intrusion into the HV/HVAC modules and into the passenger compartment. Record observations. 4.3.4 Commercial Automatic Car Wash Test. Perform this test under each condi
45、tion in Table 2. 4.3.4.1 Conduct one car wash cycle of the commercial automatic car wash, reference 3.1.2. This shall include the high-pressure and low-pressure soaker arches. 4.3.4.2 Inspect for water intrusion into the HV/HVAC module and into the passenger compartment. Record observations. 4.3.4.3
46、 Conduct one pass through the flooded bar reference 3.1.2, at a vehicle speed of one vehicle length per minute. 4.3.4.4 Inspect for water intrusion into the HV/HVAC module and into the passenger compartment. Record observations. 4.3.5 Dynamic Tests. General instructions for each dynamic test: a. Loc
47、ate spray bar on hood per Figure 1. Locating spray bar per Figure 1 should direct water spray to the center of the gap between the hood and windshield with the vehicle at test speed. b. Open drivers window 50 mm (2 in) and close all other windows. See 4.6.4 for additional information. c. Adjust wate
48、r flow rate to spray bar as specified by engineer. d. Perform 4.3.5.1 though 4.3.5.4 maneuvers under each condition in Table 2. Inspect for water intrusion into the HV/HVAC module and into the passenger compartment after each event. Record observations. 4.3.5.1 Steady State Speed. Drive vehicle on C
49、ircular Track (See 3.1) for: a. One lap at 50 km/h (30 mph). b. One lap at 70 km/h (45 mph). c. One lap at 90 km/h (55 mph). 4.3.5.2 Acceleration/Braking. Drive vehicle to appropriate road system and do the following: a. If plenum is dry, turn on spray bar for 1 minute to wet the plenum for consistent surface tension to improve repeatability. b. Accelerate to 70 km/h (45 mph). c. Allow water in plenum to stabilize for 15 s. Copyright General Motors Company Provided by IHS under
