1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW3431 General Procedures for Testing Switches Copyright 2012 General Motors Company All Rights Reserved June 2012 Originating Department: North American Engineering Standards Page 1 of 46 1 Scope This test procedure defines the test conditions and th
2、e test procedures for functional, environmental and durability tests of Switches which are installed in the vehicle. Additional necessary requirements, (e.g., definition of the function of the switches and the functional accuracy including the determination of the tolerance range, or the establishme
3、nt of specific test procedures) are specified in relevant specifications (i.e., Component Technical Specification (CTS) or part drawing. Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English la
4、nguage shall take precedence. 1.1 Purpose. This standard is intended to document unique or specific electrical, mechanical, environmental and durability tests for automotive switches. 1.2 Foreword. Not applicable. 1.3 Applicability. This procedure covers the laboratory testing of automotive switches
5、 containing sliding or separating electrical contacts. The method of actuation includes, but is not limited to, differentials in: temperature, pressure, vacuum, fluid level, mounting angle (tilt), or displacement. This procedure applies to the following types of devices: Mechanical Switches Devices
6、containing electrical contacts without electronic content. Electromechanical Switches Mechanical switches containing any of the following: resistors, capacitors, diodes, Light Emitting Diodes (LED), and discrete transistors. Electronic Switches Electromechanical or Solid-State (semiconductor based)
7、switches with electronic content for logic or decision making. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM B539 FMVSS 206 IEC 60068-2-60 SAE J726 ASTM D4728 IEC 60068-2-6 ISO 1431-1 SAE J1330 CMVSS 206 I
8、EC 60068-2-27 ISO 12103-1 SAE J1885 2.2 GM Standards/Specifications. GMW3172 GMW3208 GMW14528 GMW16449 GMW3191 GMW3232 GMW14829 2.3 Additional References. TS/ISO 16949 or ISO 9000 registration 2.3.1 Missing information or other applicable tests and the test order can be found on the Part Drawing, th
9、e CTS, or other relevant document. Note: The information and requirements in the CTS and the Part Drawing supercede requirements in this document. Test Description. The laboratory test order shall provide location and documentation of test samples, identify the type of test to be performed (investig
10、ative or validation) and describe special tests when not part of this procedure. 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 GMW3431 Cop
11、yright 2012 General Motors Company All Rights Reserved June 2012 Page 2 of 46 Investigative Tests. Investigative tests are frequently used to evaluate specific areas of the design, as a tool in the designing of the product for trouble checks or to evaluate proposed quality improvement or cost saving
12、s concepts. Special instrumentation or measurements requiring sample disassembly preclude investigative tests for validation or supplier approval samples. Investigative tests may be continued even after a technical part failure has occurred to learn more about the device under test (DUT). Validation
13、 Tests. Validation tests or sample approval tests are tests which are used to confirm that the product meets the requirements stipulated in the CTS, component drawing, material specification, Federal Motor Vehicle Safety Standards (FMVSS), and any other specification used to define the product requi
14、rements. 3 Resources 3.1 Facilities. The test facilities shall be ISO 9000 or TS/ISO 16949 registered. 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
15、be used. However, all alternative test facilities must meet all test facility and equipment requirements. 3.2 Equipment. Power Sources, Performance, and Static Characteristics. 3.2.1 Output Current. The power source shall be capable of supplying a continuous output current as required by the design
16、loads including inrush and stall currents. 3.2.2 Regulation. The output voltage shall not deviate more than 1.0 V from zero to maximum load (including surges) and shall recover 63% of its maximum excursion within 5.0 ms. 3.2.3 Ripple Voltage. Ripple voltage shall not exceed 300 mV peak to peak for n
17、ominal 12 volt sources or 100 mV peak to peak for nominal 5 volt sources. 3.2.4 Auxiliary Battery Requirements. An automotive battery of 450 cold cranking amperes to 650 cold cranking amperes shall be connected in parallel with the power supply. Where all test samples are energized instead of in seq
18、uence, or where more than eleven (11) samples are tested, use a battery or batteries capable of at least 100 cold cranking amperes per sample. The supplier must ensure that the battery maintains consistent operation throughout the test sequence. 3.3 Test Vehicle/Test Piece. If not otherwise stated,
19、the number of test pieces and conditioning shall be as specified in the relevant technical specification. Production samples shall be selected at random from pieces which have been subjected to all normal processing including final packaging. 3.3.1 Conditioning. Reference individual conditioning req
20、uirements. 3.4 Test Time. Not applicable. 3.5 Test Required Information. Not applicable. 3.6 Personnel/Skills. Not applicable. 3.7 Parameter Definition and Tolerance. 3.7.1 Test Tolerances. Test setups and equipment shall be capable of maintaining test parameters within the limits found in Table 1 u
21、nless otherwise stipulated in the CTS or in this procedure. Table 1: Parameters and Tolerances Test Parameter Applied Tolerance Air Pressure (Laboratory) 6540 mm Hg to 800 mm Hg Room Temperature (23 5) C High Ambient Temperature, Reference GMW3172 (Tmax -0/+5) C Low Ambient Temperature, Reference GM
22、W3172 (Tmin -5/+0) C Chamber Humidity As specified 5% 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 GMW3431 Copyright 2012 General Motors
23、Company All Rights Reserved June 2012 Page 3 of 46 Test Parameter Applied Tolerance Time As specified 5% Forces As specified 5% Distances As specified 1% Nominal Operating Voltage (14.0 0.1) V Voltage (As specified 0.1) V Current (Performance Test) As specified 15% Current (Durability Test) As speci
24、fied 15% Vibration As specified 0.2G or 20% (whichever is greater) Shock As specified 20% Frequency As specified 1% 3.7.2 Measurement Accuracy. Meters and gauges used to assess the performance dependent variable as defined by the basic function of the test sample shall be capable of measuring to one
25、 count better than the specified value. For example, even though a 0.1 mm shaft and a 0.10 mm shaft might be the same diameter, a technician could use calipers capable of 0.01 mm resolution to measure the first but would need a micrometer to obtain 0.001 mm resolution for the latter value. 3.7.3 Tes
26、t Repeatability. Equipment repeatability studies shall be performed on all laboratory equipment after initial calibration and before use for product evaluation. Individual meters and gauges may be certified by manufacturer specifications. All equipment used for product evaluation shall be repeatable
27、 to within 10% of the specification value (e.g., ten consecutive readings on the same switch which actuates at 0.10 mm must be within a 0.01 mm range). 3.7.4 Test Default Conditions. Unless otherwise specified, all test samples shall be mounted in the in-car position with the appropriate trim piece
28、or bezel attached. When specific test conditions are not given either by the product design specification or elsewhere in this procedure, consult with the responsible GM Engineer. Otherwise, the following basic conditions shall apply: 3.7.4.1 When a mounting view is not provided by the part drawing,
29、 samples shall be mounted with terminal centerlines as indicated in Table 2. The mounting environment shall include baffles or enclosures which simulate vehicle air flow restrictions and production, prototype, or simulated bezels and bolts which may pinch or stress mounting lugs or case side walls.
30、Table 2: Terminal Centerline Position Vehicle Mounting Position Terminal Centerlines Instrument Panel Horizontal Door/Console/Trunk Lid Vertical Pointing down Engine/Chassis 45 degrees from horizontal 3.7.4.2 Test or measurement shall be performed at room temperature unless otherwise stated. 3.7.4.3
31、 Open circuit voltage shall be 14.0 V at switch terminals for nominal 12-volt system, 5.0 V at switch terminals for nominal 5-volt system, 28.0 V at the switch terminals for nominal 24-volt system and 42.0 V at the switch terminals for nominal 36-volt system. 3.7.4.4 Load current shall be the resist
32、ive, inductive or bulb load given by the test specification. Inrush and stall currents shall be considered. 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 ENGINE
33、ERING STANDARDS GMW3431 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 4 of 46 3.7.4.5 Unless otherwise specified, for Resistive and Inductive loads, the Duty Cycle shall be 3 seconds on, 5 seconds off. For load currents less than 20 mA, an alternate Duty Cycle of 1 second
34、on, 2 seconds off, may be used. For bulb loads, the Duty Cycle shall be 3 seconds on, 25 seconds off. An alternate Duty Cycle of 3 seconds on, 5 seconds off may be used provided that 100% of the inrush current is guaranteed from cycle to cycle. This can be accomplished by cooling the bulb filaments
35、with a fan or ventilator and switching between lamp racks or banks after every cycle. Electrical load simulation may also be used with agreement from the responsible GM engineer. 3.7.4.6 Connections shall be made using the production approved connection system (including connector body, terminal, se
36、als, crimp, Terminal Position Assurance (TPA), Connector Position Assurance (CPA) listed on the part drawing. Deviation from this requirement shall require GM Engineering approval. 3.7.4.7 Application test circuits used for performance and durability testing shall use the appropriate application spe
37、cific wire gage and length. The actual in-vehicle length or maximum of 3 m should be used if possible. Table 3 depicts recommended wire gage selection as a function of test load for use when application specific wire gage information is not available. Table 3: Wire Gauge Selection Test Load Acceptab
38、le Customary Wire Gage Metric less than 3.0 A 20 ga 0.5 mm2 3.1 A to 15.0 A 18 ga 1.0 mm2 15.1 A to 20.0 A 14 ga 2.5 mm2 greater than 20.0 A 10 ga 6.0 mm2 3.7.4.8 The rate of actuation shall be as noted in Table 4. Table 4: Rate of Actuation Mode of Actuation Rate of Actuation Air Temperature (3 1)
39、C per minute Pressure (2500 500) mm Hg per second Vacuum (40 10) mm per second Fluid Level (25.0 5) mm per minute Angular Displacement (5.0 1) degrees per second Linear Displacement (20.0 5) mm per second Fluid Temperature (10 3) C per minute 3.8 Failure Determination. 3.8.1 Test failure is defined
40、by any of the following conditions: 3.8.1.1 Performance outside specification limits. 3.8.1.2 Initial or final tear down inspection reveals a condition that could cause customer dissatisfaction. 3.8.1.3 A missed cycle during durability test, if verification is provided as follows: a. Check basic set
41、up and instrumentation including mounting, stroke, rate of actuation and actuation force. b. Attach oscilloscope, chart recorder or other data acquisition equipment across the circuit in question. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for Resal
42、eNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3431 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 5 of 46 c. Allow test to continue while continuously monitoring for a failure to make, a failure to break, or a nu
43、isance cycle as indicated by the original test equipment. d. Check to assure the miss was also captured by the auxiliary monitoring equipment. e. Re-check basic setup and instrumentation. 3.8.2 Failures observed during product validation or compliance testing shall require resolution through the sub
44、mission of an irreversible corrective action plan (e.g., 5 Phase, etc.) to GM Product Engineering, containing a problem description, root cause analysis, interim and permanent corrective action and action verification plan. 3.8.3 Disposition of Samples. Should a test failure occur, contact the reque
45、sting party to determine if the test is to be continued to gain additional product experience or if testing is to be stopped. When contact cannot be immediately made, the type of test shall determine the disposition of the samples. If the test order indicates the test is investigative in nature, con
46、tinue until the requesting party is available. If the test order is for sample approval or validation testing, stop the test and wait for further instructions. 4 Procedure Note: Section 4 is divided into five sections. Section 4.1 Performance Requirements Section 4.2 Electrical Loads Section 4.3 Mec
47、hanical Loads Section 4.4 Climatic Loads Section 4.5 Chemical Loads 4.1 Performance Requirements. The tests detailed in 4.2 through 4.5 are not expected to stress any part or component beyond its anticipated application limit. Performance measurements are performed at room temperature using test hea
48、ds or new production or prototype connectors unless otherwise noted. Tests which are not called out by the CTS or test order do not need to be performed. See Table 5. Table 5: Performance Checks and Frequencies Performance Check Performance Check Frequency Voltage Drop (Recommended for High Current
49、devices) Initial; Continuous Open Circuit Resistance Initial; 100% Expected Life; End of Test (3 Life, typically) Isolation Resistance Initial; 100% Expected Life; End of Test (3 Life, typically) Temperature Rise Initial Function Check Initial; After Individual Test; 100% Expected Life; End of Test (3 Life, typically) Displacement Initial; Conditioning, Dust, Humidity, Corrosion; 100% Expected Life; E
