1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 1 of 8 NAVISTAR, INC. Material, Parts, and Process Specificati
2、ons (MPAPS) NUMBER: MPAPS P-9564 Former Designation: TMS-9564 TITLE: Truck Instrument Panel Material and Testing Requirements CURRENT REV No.: 1512 DATE: Dec. 2015 WRITTEN/EDITED BY: D. Baker APPROVED BY: R. Goluch SUPERSEDES: Rev. 1406 June 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR
3、CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicabili
4、ty of regulatory limits prior to use. Change Notice: Changed Air Register Vane Movement Effort requirements; Removed Model and Frequency Analysis requirement; Changed Instrument Panel Foot Load surface area requirement; editorial changes 1.0 APPLICATION This specification covers material, performanc
5、e testing, and durability testing requirements for the complete instrument panel assembly, including the cross car beam. 2.0 SCOPE This specification covers the material, durability, performance, quality, qualification, shipping and identification, and KCC requirements to meet the commercially reaso
6、nable Instrument Panel performance needs for truck and bus instrument panel assemblies. Service categories that are covered include: heavy/line haul, regional haul, severe service, medium duty and bus. 2.1 Restricted Chemical Substances All product supplied to the requirements of this specification
7、must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO
8、9001 or TS-16949 CFR Title 29, Part 1910 AWS D1.1 AWS D1.2 NAVISTAR Manufacturing Std. MS-D-13 AWS D1.3 NAVISTAR Engineering Design Std A-16 AWS G1.2/M NAVISTAR MPAPS B-50 NAVISTAR MPAPS D-28 NAVISTAR MPAPS G-9009 NAVISTAR MPAPS L-6505 NAVISTAR MPAPS P-9516 NAVISTAR TMS-7028 AWS B2.4 NAVISTAR MPAPS
9、DT-18 NAVISTAR MPAPS DT-19 NDR 004 4.0 MATERIAL REQUIREMENTS 4.1 Material 4.1.1 Molded Plastics The most common Instrument Panel (IP) material requirement is listed below. Plastic IP trim resins should meet the following material spec as a minimum. Exceptions require NUMBER: MPAPS P-9564 TITLE: Truc
10、k Instrument Panel Material and Testing Requirements REVISION: 1512 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015
11、Page 2 of 8 approval from Navistar Materials and Engineering groups. Color, grain, and finish to be specified on the drawing by Navistar Design. 4.1.1.1: Plastic IP trim: PP, TEO, or TPO, A2 BE120 C10 K23 M20 R240 SA120 U YA3600 AC1, per NAVISTAR MPAPS D-28. 4.1.2 Painted Metallic Parts - Unless oth
12、erwise specified, metallic components shall be painted NAV0004 Black, Class IIIA, per MPAPS G-9009. 4.1.3 Acoustic Foam All acoustic insulation shall meet MPAPS L-6505, TYPE II, Grade B. 4.2 Adhesion and Joining Requirements 4.2.1 Welds 4.2.1.1 Spot welds shall comply with MPAPS P-9516. 4.2.1.2 Non-
13、resistance welds will comply with the applicable American Welding Society (AWS) standard: AWS D1.3 or D1.1 for steel and AWS D1.2 for aluminum. 4.2.1.3 Plastic welds including but not limited to: sonic welds, ultrasonic welds, heats staking, etc shall comply with AWS G1.2M/G1.2:1999 (R2010) or AWS B
14、2.4:2012 4.2.2 Adhesives All adhesive bonded trim must meet TMS-7028. 4.3 Component Level Material Requirements 4.3.1 Interior Part Performance Requirements (MPAPS DT-19): All materials in the IP shall be tested to the procedures and requirements called out in NAVISTAR MPAPS DT-19. Navistar Engineer
15、ing shall be contacted prior to testing to confirm testing locations and data requirements. (MPAPS DT-19 includes testing procedures and requirements for: flammability, colorfastness to artificial light, scratch and mar resistance, colorfastness to cleaning and chemicals, fogging, odor emissions, im
16、pact, environmental cycling and dimensional stability, environmental stress cracking, and oxidative stability.) 4.3.2 Mildew Odor Requirements 4.3.2.1 Procedure Place a 50 mm X 50 mm sample of each proposed material in a container. Add enough distilled water to saturate the bottom 10 mm of sample. C
17、lose the container tightly. Expose the container to 38 +/-2 deg C for 14 days. 4.3.2.2 Required The specimen shall be inspected for mildew growth and related odor. No mildew growth or related odor is permitted. 5.0 PERFORMANCE AND DURABILITY REQUIREMENTS 5.1 Automatic Shifter Duty Cycle 5.1.1 Proced
18、ure: a) Apply a load of 6.0N to the shifter push button, at the shifter area, perpendicular to the surface for 100,000 cycles. b) Apply a fore/aft push/pull load 44N (10 lbs) for 100,000 cycles to the automatic T handle shifter. 5.1.2 Requirement: The automatic shifter bezel or instrument panel beze
19、l shall not exhibit any loss of function, excessive wear, or fracture over the simulated life test of the vehicle. At the end of the cycle, deflection shall not exceed 3mm, measured at the rearward most edge of the shifter. 5.2 Automatic Shifter Ultimate Load Cycle 5.2.1 Procedure: Apply a load of 4
20、44N (100lbs) at the shifter area perpendicular to the surface of the automatic shifter push button. Load locations shall be specified by Navistar Engineering. NUMBER: MPAPS P-9564 TITLE: Truck Instrument Panel Material and Testing Requirements REVISION: 1512 This document is restricted and may not b
21、e sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 3 of 8 5.2.2 Required: The automatic shifter bezel or instrument panel bezel shall not exhibit any loss
22、of function, excessive wear, fracture or permanent deformation. Permanent deflection shall not exceed 3mm. 5.3 Cigar Lighter Duty Cycle 5.3.1 Procedure: Apply an insertion force of 27N and an extraction force of 36N for 20,000 cycles to the cigar lighter. Each cycle shall consist of both an insertio
23、n and extraction. Load locations shall be specified by Navistar Engineering. 5.3.2 Required: The panel housing for the cigar lighter and IP shall not exhibit any loss of function, excessive wear, or fracture over the simulated life test of the vehicle. 5.4 Cigar Lighter Ultimate Load 5.4.1 Procedure
24、: Apply a 260 N pull force along the central axis of the housing panel for the cigar lighter. Load locations shall be specified by Navistar Engineering. 5.4.2 Required: The panel housing for the cigar lighter and IP shall not exhibit any loss of function, excessive wear, or fracture over. The device
25、 shall not unseat from the panel. 5.5 Durability System Level Instrument Panel Shaker Test 5.5.1 Procedure: Perform the Navistar specified shake duty cycle for the IP shown below. The IP shall contain a fully loaded option content including 5lbs weight in the cup holder and representative steering w
26、eights attached. The test shall be run prior to a full vehicle shaker test. Vibrate in the vertical direction using the random vibration profile shown below. Sound pressure levels were recorded (3 Ten second recordings per location) during the random vibration using a 1/2” free field microphone (wit
27、h built-in 20 Hz. High-pass filter) placed 250 mm from the instrument panel at the driver/passenger head locations. 5.5.2 Required: The instrument panel assembly must sustain vibration and cycling without structural collapse and must not exhibit any weld or component cracks or failures. The IP assem
28、bly shall not exhibit any loss of function, excessive wear, or fracture over the test. The instrument panel will not exhibit any buzz, squeaks & rattles (BSR) during any life cycle or non-destructive tests. BSR, functional attachments, and DSAOs shall be evaluated at before and after the completion
29、of the test in locations specified by Navistar Engineering. The sound pressure level shall remain less than 60dB at beginning of test and less than or equal to 65dB at conclusion of test. There shall be no loss of functional attachments (i.e. clips and fasteners) evaluated via torque markings at beg
30、inning and conclusion of test. The DSAOs may not change more than 15 %. 5.6 Durability Vehicle Level Shaker Test 5.6.1 Procedure: Perform the Navistar specified vehicle level shake duty cycle. The IP shall contain a fully loaded option content including 5lbs weight in the cup holder and representati
31、ve steering weights attached. 5.6.2 Required: The instrument panel assembly must sustain vibration and cycling without structural collapse and must not exhibit any weld or component cracks or failures. The IP assembly shall not exhibit any loss of function, excessive wear, or fracture over the test.
32、 BSR, functional attachments, and DSAOs shall be evaluated at before and after the completion of the test in locations specified by NUMBER: MPAPS P-9564 TITLE: Truck Instrument Panel Material and Testing Requirements REVISION: 1512 This document is restricted and may not be sent outside Navistar, In
33、c. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 4 of 8 Navistar Engineering. The sound pressure level shall remain less than 60dB at beginning of test and less than or equal to 65
34、dB at conclusion of test. There shall be no loss of functional attachments (i.e. clips and fasteners) evaluated via torque markings at beginning and conclusion of test. The DSAOs may not change more than 15 %. 5.7 Instrument Panel Bezel Retention 5.7.1 Procedure: Condition bezels at -30C and 90 C an
35、d 95% R.H for two hours prior to testing. Apply a retention pull force of 50 N to the bezel. Additionally, apply a push force of 129 N at specified retention locations on the bezel. Push and pull locations to be specified by Navistar Engineering. Finally, measure the force required to remove the bez
36、el in 2 seconds. 5.7.2 Required: The bezel shall not become loose or rattle following the push and pull forces. Additionally, the bezel must be removed with a force less than 220 N applied over 2 seconds. 5.8 Instrument Panel Deflection Criteria: Cyclic driver entry loads (NDR 004) 5.8.1 Procedure:
37、Apply a cyclic driver entry load (oriented at 54 degrees from vertical and 80 degrees from horizontal) through the steering wheel rim at a force of 480N (108 lbs.) (this load is to simulate a person from outside the truck climbing in by pulling themselves up ) and a rate of 60 cycles per minute for
38、100,000 cycles. Apply the load at the midpoint of the largest wheel span between spokes. Reference NDR 004. Load locations shall be specified by Navistar Engineering. 5.8.2 Required: The instrument panel assembly shall have no permanent set. All switches and components shall maintain functionality d
39、uring and after the application of this load. A visual inspection of the instrument panel assemblies shall not exhibit any cracking or breaking. 5.9 Instrument Panel Deflection Criteria: Ultimate Driver Entry Load (NDR 004) 5.9.1 Procedure: Apply a driver entry load (oriented at 54 degrees from vert
40、ical, and 80 degrees from horizontal) through the steering wheel rim at a force of 1333N (300lb). The load is to be applied at the midpoint of the largest wheel span between spokes. Reference NDR 004. Load locations shall be specified by Navistar Engineering. 5.9.2 Required: The instrument panel ass
41、embly shall have permanent set no greater than 5.0mm. All switches and components shall maintain its functionality during and after the application of this load. A visual inspection of the instrument panel assemblies shall not exhibit any cracking or breaking. 5.10 Instrument Panel Foot Load 5.10.1
42、Procedure: Apply a horizontal force of 250N within a 160 mm x 80 mm surface area. Load location shall be specified by Navistar Engineering prior to testing. Apply the force within two seconds and hold for five seconds. 5.10.2 Required: The instrument panel assembly shall not exhibit any loss of func
43、tion, excessive wear, fracture, shall not deflect more than 5mm, and no measureable permanent set is allowed. 5.11 Instrument Panel Resting / Sitting Load 5.11.1 Procedure: Apply a 667N (150lbs) downward force over a 4inch diameter disc to the IP. The load shall be applied in both a straight vertica
44、l orientation to the IP as well as at a 45 vector angle to the IP surface. This load is to simulate a person sitting on the instrument panel and dropping their weight in this direction. Locations shall be specified by Navistar Engineering. 5.11.2 Required: The instrument panel assembly shall not exh
45、ibit any loss of function, excessive wear, fracture, shall not deflect more than 5mm, and no measureable permanent set is allowed. 5.12 Close out panel cyclic load 5.12.1 Procedure: Apply a cyclic load of 89N (20lbf) over a 160mm x 80mm surface area (representing 1/2 of 95% male foot) for a minimum
46、of five seconds on and one second off for 35,000 cycles. Load location shall be specified by Navistar Engineering prior to testing. NUMBER: MPAPS P-9564 TITLE: Truck Instrument Panel Material and Testing Requirements REVISION: 1512 This document is restricted and may not be sent outside Navistar, In
47、c. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 5 of 8 5.12.2 Required: The assembly shall not exhibit any loss of function, excessive wear, or fracture. No measureable permanent
48、offset greater than 5 mm is allowed. 5.13 Close out Panel Ultimate Load 5.13.1 Procedure: Apply a load of 1245 N over a 160mm x 80mm surface area (representing 1/2 of 95% male foot) for five seconds. Load location shall be specified by Navistar Engineering prior to testing. 5.13.2 Required: The asse
49、mbly shall not exhibit any loss of function, excessive wear, or fracture. No measureable permanent offset greater than 5 mm is allowed. 5.14 On Board Diagnostic (OBD) Connector Duty Cycle 5.14.1 Procedure: Apply an alternating push/pull load of 100 N to the OBD bracket on the cross car beam for 1,100 cycles. One cycle is a push and a pull. Load location shall be specified by Navistar Engineering prior to testing. 5.14.2 Required: The OBD bracket or instrument panel t
