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1、 WORLDWIDE ENGINEERING STANDARDS General Specification HVAC and Powertrain Cooling GMW14788 Variable A/C Compressor Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Originating Department: North American Engineering Standards Page 1 of 27 1 Introduction Note: Nothing in the s
2、pecification supersedes applicable laws and regulations unless specific exemption has been obtained. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. Note: Unless otherwise stated as gage, pressures listed within the specification
3、are absolute. 1.1 Scope. This specification establishes the minimum requirements for the air conditioning compressor to be used with refrigerant R-134a. The functions, performance, reliability, and validation required of any compressor are defined in this document. This specification is for variable
4、 capacity compressors. All requirements of this specification must be met in order to demonstrate design and production validation. 1.2 Mission/Theme. Not applicable. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified.
5、2.1 External Standards/Specifications. ANSI SI.34 ISO 3745-1983 ANSI S1.35-1979 JIS Z8732-1986 ASHRAE 23-1993 JIS Z8733 ASTM D1474 SAE J639 BE.TL.16.0004 SAE/USCAR-2 ISO 3744 2.2 GM Standards/Specifications. 9986181 GMW3059 GM10009C GMW3097 GM10014C GMW3103 GME3191 GMW3116 GME R-0-17 GMW3172 GMN3600
6、 GMW3425 GMN10066 GMW14782 2.3 Additional Standards/Specifications. Roush GM Test Procedure #96255 (soon to be GMW14477) SOR Appendix C2 Appendix B of the SOR Drawing 52477000 3 Requirements 3.1 General Materials. 3.1.2 Recycling. Materials shall be recyclable per GMW3116. 3.2 Component Definition.
7、The Compressor assembly accepts low pressure, low temperature refrigerant at an inlet port, compresses this refrigerant by a variety of mechanisms, and exhausts a high temperature, high pressure refrigerant at an outlet port. Power to drive the compressor is supplied by a separate power source, such
8、 as the vehicle power plant. The compressor assembly must conform to all requirements in this specification, as well as, the approved engineering drawings. 3.2.1 Drawing Requirements. The supplier shall insure that all technical attributes identified in the General Motors Reuse tool are called out o
9、n the drawing/in the UG files. In regions where the tool is operational, the releasing engineer will be required to load these attributes in the tool during the release process and will use the information supplied by the drawing to that end. 3.3 Appearance. 3.3.1 Color and Finish. Typical appearanc
10、e is compressor body with a natural aluminum finish and the clutch with a low gloss black finish to match with other under-hood components. Deviations from this are permissible, but must be approved by the releasing GM engineering group. 3.3.2 Laboratory Corrosion. There shall be two laboratory corr
11、osion requirements based on GMW14782 (Method B). First is a cosmetic/general corrosion requirement after 16 cycles (2 phases) of test and second is a functional requirement after 80 cycles (10 phases) of test. The standard procedure of GMW14782 (method B) is modified in the following way: GMW14788 G
12、M WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 2 of 27 April 2006 a. The number of salt mist applications shall be reduced from those shown in table 5 (in the above referenced GMW14782 to one salt mist application in the first and one grit/salt (
13、Mixture of salt/grit can be obtained from the GM Corrosion Technology Center at Milford Proving Grounds upon request) application in the seventh cycle (To be repeated in each phase). b. The compressors shall be running for one and one-half hours each day during the 26.6C ambient, cycling (12 sec on
14、/ 3 sec off), with suction/discharge ports connected and a 255 gram oil charge. Voltage to the coil shall be 9 volts or lower (goal is to allow some burnishing of the clutch surface to take place while still maintaining the requirement of being able to pass the end-of-test functional checks). (This
15、test was developed to simulate 10 years of vehicle corrosion.) Daily schedule of exposure shall be as follows: a. 48.8C/100% RH-8 hr. b. 60C at less than 30% RH-8 hr. c. 26.6C/50% RH-8 hr., (The salt applications shall be made as described above with the compressor running and the grit application s
16、hall be made with the compressor static in order to keep the mixture from being thrown off) One day=one cycle, Eight cycles=one phase (Weekends are not counted as part of the number of cycles and samples are left in ambient condition.) 3.3.2.1 Requirements after Corrosion Test. 3.3.2.1.1 After 16 cy
17、cles (two phases): Red rust shall be less than 10% of exposed steel surface area of the compressor and clutch. 3.3.2.1.2 After 80 cycles (10 phase): 3.3.2.1.2.1 Corrosion shall not result in loss of compressor function, leakage of refrigerant (Per 3.11.), or loss of clutch function. 3.3.2.1.2.2 All
18、serviceable parts shall be capable of service with normal GM compressor service tools. 3.4 Content. The following paragraphs specify the requirements for the physical and functional content of the A/C Compressor. 3.4.1 Physical Content. The physical content of the compressor includes the following:
19、a. Inlet port. (Suction) b. Outlet port. (Discharge) c. Clutch/pulley. d. Mounting provisions. e. High Pressure Relief Device f. Control Device g. Electrical Connector for Clutch h. High temperature cut-out switch (optional) i. High Pressure Cutout switch (optional) j. High side low-pressure switch
20、(optional) k. Shipping Caps l. Lubricant 3.4.2 Functional Content. The A/C Compressor is to provide the following functions: 3.4.2.1 The compressor circulates refrigerant in the A/C system. 3.4.2.2 The compressor affects pressure out of the evaporator. 3.4.2.3 The compressor provides high pressure a
21、nd high temperature gas to the condenser. 3.4.2.4 The compressor shall provide provisions for a high pressure relief device that complies with SAE J639. 3.4.2.5 The control valve controls compressor displacement to meet system needs. 3.5 Ambient Environment. The electrical components contained on th
22、e A/C Compressor shall be able to withstand ambient air temperatures from -40 to 125C, with intermittent temperature requirements of 150C for up to one hour of run time. The A/C Compressor shall be able to withstand humidity of up to 100% within 25 mm envelope around compressor body and clutch witho
23、ut damage to function or appearance. As required, part or all of the compressor may be used as a fixturing device for the component testing. Test according to GMW3172 with mounting location at the engine with high temperature load Electrical loadCode letter C Mechanical loadCode letter A Operating T
24、emperature Code letter H (-40C until +125C) Climatic loadsCode letter A Chemical loadsCode letter E Dust and Water ProtectionIP6K9K 3.6 Electrical. 3.6.1 Control Devices, if applicable. All switches, transducers, or other control devices mounted in the compressor shall meet GM specification for thes
25、e devices. These will be supplied upon request. 3.6.2 Electrical Connectors. All electrical connectors must comply with GME3191 -,-,- GM WORLDWIDE ENGINEERING STANDARDS GMW14788 Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Page 3 of 27 (temperature class 3, vibration clas
26、s 2, sealing class 1) and SAE/USCAR-2. 3.6.3 Electromagnetic Compatibility. The compressor must meet GMW3097 and GMW3103. 3.7 Mounting Interfaces. 3.7.1 Sealing Surfaces. All Surface finishes of sealing surfaces shall be maintained at a maximum of 1.6 R a and 12.5 Rt with a cutoff of 0.25. Flatness
27、is to be within 0.13 mm on all sealing surfaces. Any variation from this shall be shown on the approved Engineering drawing. 3.7.2 Seal Washer. The inlet and outlet ports shall be designed to accommodate the seal washer design. The specifics of the dimension shall meet 52477000 Drawing. The compress
28、or shall accommodate a double block type design except as noted on the Engineering Drawing. 3.7.3 Mounting Surfaces. All Mounting Surfaces shall be free of nicks and burrs. Flatness and parallelism of these surfaces shall be maintained per the approved Engineering drawing. 3.8 Performance. The follo
29、wing paragraphs specify the functional requirements for the A/C Compressor. Data shall be submitted on compressors run sequentially through these performance tests for validation purposes at each stage of development. (Quantities are specified in 4.1). 3.8.1 Minimum Capacity and COP. Capacity tests
30、will be run per the VDA standard Superheat /C 10 0.5, Subcool /C 5 0.5, at 2000 crpm, Oil circulation rate 3.5 0.5%. If the compressor is equipped with an oil separator, run at 1.0 0.5%. Minimum capacity and coefficient of performance (COP) shall be per the following table. Data shall be taken after
31、 one hour of break-in at the stable load condition. Variation in random samples taken from production shall not exceed 10% total. Coefficient of Performance is defined as the capacity divided by the mechanical power consumption. Table 1: Capacity and COP Requirements RPM Suct. Pres. Disch. Pres. Cap
32、acity Type A Capacity Type B Capacity Type C COP Type A COP Type B COP Type C (kPa) (kPa) (kW) (kW) (kW) Idle Capacity 800 500 2000 3.8 5.1 6.0 2.3 2.1 1.9 Stable Capacity 2000 280 1600 4.8 6.0 7.2 2.0 1.8 1.6 Stable Capacity 5000 set point 1600 4.8 6.0 7.2 1.2 1.1 1.0 Note: Compressor Capacity Type
33、 (A, B or C) clarification for a given compressor is to be found in Appendix C2 (CTS exceptions document) or Appendix B (General Program Description) of the SOR and is to be later documented in the drawing/UG information. 3.8.1.1 Maximum Speed Definition. 3.8.1.1.1 Maximum Continuous RPM. Maximum co
34、ntinuous speed is defined per the durability test specification at condition 10 of Appendix A. The compressor must run a minimum of 10 hours at this condition at 8500 rpm (all compressor types). 3.8.1.1.2 Maximum Excursion RPM. Maximum excursion speed is defined per the durability test specification
35、 at condition 11 of Appendix A. The compressor must run a minimum of 10 minutes at this condition at 10 500 rpm (all compressor types). 3.8.1.1.3 Minimum RPM. Compressor shall be capable of running at a minimum speed of 600 compressor RPM. 3.8.1.2 Minimum Compressor Displacement. The Minimum displac
36、ement of the compressor shall be 25C GMW14788 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 26 of 27 April 2006 B3 Off condition (part 3) Table B5: Test Setup - Off condition 1 Off condition (part 3) 2 Particularly the critical operating condit
37、ions for the compressor at off condition should be considered. These requirements have to be defined due to each application. 3 Compressor Pre-conditioned with min. one cycle (70h) according to durability spec. part 1. 4 Condenser Vehicle component: air or water cooled or special test bench condense
38、r 5 Receiver Vehicle component 6 Accumulator Vehicle component 7 Expansion Device Vehicle component 8 Evaporator Complete HVAC with heater core and blower or separate with test bench blower. Air distribution and air flow rate in reference to vehicle A/C system. Evaporator load must be documented in
39、reference to test bench 9 Refrigerant Optimization of R134a charging amount due to subcool; (5K to 10K after condenser during 1st step of the durability test) 10 Oil Type and amount must be documented 11 Operation Off (no current) 12 The ambient temperature of the main A/C components compressor, con
40、denser, receiver resp. accumulator has to be varied during the cycles as follows: No. of cycle 1 2 3 4 5 6 7 89 10 Ambient temp. C 10 20 30 20 10 0 - 10 010part 1 Last with load The ambient temperature of the evaporator can be maintained at room temperature = 20C. GM WORLDWIDE ENGINEERING STANDARDS
41、GMW14788 Copyright 2006 General Motors Corporation All Rights Reserved April 2006 Page 27 of 27 Table B6: Durability test specification - Off condition Prog. Step Duration (hr) Comp Speed (rpm) Discharge pressure (kPa abs) Evaporator load (kW) Remark 1 5 3000 Pressure balance 0 Stabilization 2 20 57
42、5 Pressure balance 0 Idle 3 1 7000 Pressure balance 0 4 2 575 to 8000 Pressure balance 0 Increase: 10s Decrease: 10s 5 10 575 to 8000 Pressure balance 0 Increase: 20s Decrease: 20s 6 3 2000 to 6000 Pressure balance 0 Increase 10s Decrease 6s 7 10 2000 - 6000 Pressure balance 0 Increase: 20s Decrease
43、: 20s 8 18 8000 Pressure balance 0 9 1 8650 Pressure balance 0 10 1min Maximum operating rpm of the compressor Pressure balance 0 11 3 min 3000 1600 / 260 3.0 A/C On Variation of test sequences is possible; one cycle is approximately 70hrs, total cycle duration of 700 hrs is composed of 9 cycles and a 10th cycle with system load. -,-,-