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1、 WORLDWIDE ENGINEERING STANDARDS General Specification Electrical/Electronics GMW14036 Global Generator Specification 1 Introduction 1.1 Scope. This specification defines the electrical, mechanical, environmental, reliability and durability performance and validation requirements for gen- erators us
2、ed in all GM Global common passenger car and light duty truck applications worldwide. 1.2 Mission/Theme. Generators are used in vehi- cles to supply the electrical system with electric energy and to recharge the battery. 1.3 Classifications. This specification is applica- ble to all future Global co
3、mmon generators used in GM passenger car and light duty truck vehicles and is intended to promote uniformity of application across all future GM passenger car and light duty truck vehicles. 2 References Note: Only the latest approved standards are ap- plicable unless otherwise specified. 2.1 Externa
4、l Standards/Specifications. ANSI S12.35 ISO 3745 ASTM 4804 ISO 11469 EN 10 204 ISO/DIS 18064 ISO 1043 QS 9000 ISO 1629 SAE J756b ISO 3741 VDA 260 ISO 3742 2.2 GM Standards/Specifications. GMW3001 GMW3100 GMW3044 GMW3103 GMW3059 GMW3106 GMW3091 GMW3119 GMW3094 GMW3172 GMW3097 GMW3200 2.3 Additional R
5、eferences. BE.TL.16.0004 Pulley Specifications BE.TL.16.0005 Pulley Specifications PPAP Production Part Approval Process ON 1396.5, 05.81 GM Trade Mark 3 Requirements 3.1 Component Definition. 3.1.1 Appearance. The generator appearance shall reflect quality design and the casting and visible protrus
6、ions shall be free of dents, nicks, scratches, blowholes, and any other abnormalities reflecting poor workmanship. 3.1.2 Content. 3.1.2.1 Physical Content. Shall be determined. 3.1.2.2 Functional Content. Shall be determined. 3.1.3 Ambient Environment. The generator shall be capable of meeting all p
7、erformance specifica- tions with inlet air temperatures ranging from -40 to 125C. The generator must also be capable of withstanding non-operating storage over the tem- perature range of -48.3 to 125C, and non- operating storage temperature of 150C for 30 minutes, without impairing its ability to su
8、bse- quently meet all specifications. 3.1.4 Interfaces. 3.1.4.1 Generator Output and Mechanical Inter- faces. Generator output power shall be provided via the output terminal connection that shall be an M8 x 1.25 threaded stud as specified in the outline drawing. The stud hardness shall be of grade
9、8.8 and be tin zinc plated as specified in GMW3200. In addition, the outside end of the threaded stud shall have a dog or P point to ease nut engagement. The stud assembly shall be designed to withstand an applied torque value up to 22 N.m, and shall not lose its structural integrity due to repeated
10、 loosen- ing and tightening of the terminal nut. To insure tight output connections, the output ter- minal may be designed to include a captive bush- Copyright 2004 General Motors Corporation All Rights Reserved August 2004 Originating Department: North American Engineering Standards Page 1 of 16 GM
11、W14036 GM WORLDWIDE ENGINEERING STANDARDS ing that permits the stud to stretch and maintain a significant clamping force on the output ring termi- nal. The ratio of stretch length to stud diameter shall be 2.5:1. An anti-rotation feature shall be provided to insure protection against cable rotation.
12、 The generator housing and mounting attachments also serve as the generator current return path. This path from chassis ground must be designed for low contact resistance and exhibit a voltage drop of less than 0.1V at the maximum generator output current. 3.1.4.2 Generator Control Interfaces. Gener
13、ator control shall interface using a Packard Electric 2- way sealed harness connector, part number 12186308 or Bosch part number 90563303. The mating regulator connector shall have the control functions arranged from left to right in the order F, L when viewing the generator with the connector latch
14、 tang up. Control Function PE Connector L = On /Off however, the regulator shall also provide an automatic self-start and default voltage regula- tion once generator speed exceeds 3100 rpm. Thereafter, the regulator shall remain in default mode regardless of generator speed until PWM pulses are rece
15、ived by the L-terminal. 3.2.2.2 Output Voltage Regulation without RVC. Generator output voltage shall be internally regu- lated to compensate for electrical loading, genera- tor speed, and generator inlet air temperature. At a generator air inlet temperature of 25 2C, the output voltage shall be 14.
16、5 0.3 V when supply- ing 50% of full load current at a speed of 6000 rpm. The temperature compensation shall be such that the output voltage shall decrease at a rate of typi- cally 10 1 mV per C of inlet air temperature in- crease. Below -15C, the slope of the voltage regu- lation curve shall be 0 m
17、V/C. In addition, stabi- lized regulated generator voltage as function of generator current in the range from 5 to 95% of the full current delivery, shall not deviate by more than 0.4 V. 3.2.3 Load Response Control (LRC). The gen- erator is required to control the rate of load it re- flects to the d
18、rive subsystem. LRC shall be pro- vided to ramp-up field current and avoid sudden increases in torque load. For generators with RVC regulators, field current ramp-up time shall be as specified in the SOR (either 2.5 or 8 s). For gen- erators with conventional regulators, field current ramp-up time s
19、hall be 8 s. LRC shall be inhibited above 3100 5 % rpm; however, LRC must oper- ate during each generator turn-on cycle until stable regulation is achieved. Conversely, upon turn-off, the voltage regulator shall decrease the field current to reduce the gen- erator load on the engine. The field curre
20、nt time constant is typically 100 ms. 3.2.4 Operating Speeds. The generator shall be capable of operation without degradation for drive shaft speeds up to 18 000 rpm. Transient opera- tion to 21 000 rpm for less than 3 s shall not cause any permanent performance degradation or dam- age. 3.2.5 Operat
21、ing Temperatures. The generator shall be capable of meeting all performance speci- fications with inlet air temperatures ranging from - 40 to 125C. Note: Inlet air temperature is measured at a point located 25 mm away from the regulator air inlet window at the rear of the generator. 3.2.6 Generator
22、Subcomponent Operating Temperatures. To achieve the reliability require- ments specified, generator cooling shall be so designed that the generator subcomponent temperatures do not exceed the maximum values specified in Table 2 when the generator is stabi- lized for 15 minutes in a thermal test cham
23、ber at full load anywhere within the speed range of 1600 to 6500 rpm at the ambient temperature specified. Table 2: Maximum Sub-Component Temperatures Generator Subcomponent At 125C Ambient Positive Diode Case 200C Negative Diode Case 200C Regulator Case 150C Drive Bearing 165C * Slip Ring Bearing 1
24、65C * Stator Copper, Drive End 235C Stator Copper, Slip Ring End235C * 180C allowable with Krytox or equivalent grease 3.2.7 Generator Efficiency. Generator operating efficiency and its impact on vehicle fuel economy is of utmost importance. The generator supplier shall measure generator operating e
25、fficiency, in 10 A increments, from 10 A load to full load as function of generator shaft speed from 1600 rpm to 10 000 rpm. Efficiency is measured at 25C under con- Copyright 2004 General Motors Corporation All Rights Reserved Page 4 of 16 August 2004 -,-,- GM WORLDWIDE ENGINEERING STANDARDS GMW140
26、36 stant voltage, and all operating efficiency values are obtained after the generator is thermally stabi- lized. As part of generator validation, generator- operating efficiency shall meet the requirements specified in the SOR. In addition, an efficiency index value, NG, specified in the SOR shall
27、also be met. This value is defined by the following formula: NG=0.25*N(1800)+0.40*N(3000)+0.25*N(6000)+ 0.1*N(10 000) Where N(1800), N(3000), N(6000) and N(10 000) are gen- erator efficiency values obtained at 1800 rpm, 3000 rpm, 6000 rpm and 10 000 rpm respectively, at 25C, when the generator is su
28、pplying 50% of rated current obtained at a speed of 6000 rpm. For generators with RVC regulator, efficiency values shall be measured at 14 V. For generators with conventional regulators, efficiency values shall be measured at generator regulated set-point voltage as determined by the generator inter
29、nal regulator. The generator supplier must state the stator cop- per wire gauge size and number of turns used to achieve these efficiencies that will become part of the technical specification. 3.2.8 Rotational Inertia. The supplier shall provide the rotational inertia of the power generation sys- t
30、em (including any pulleys directly attached to the generator). 3.3 Generator Performance Requirements. The verifiable technical requirements for the generator are identified in several different categories in the following sections. Refer to the verification cross- reference index, 0, for verificati
31、on of generator performance requirements. 3.3.1 Generator Output Current. The generator shall provide output currents as specified either on the outline drawing or in the SOR. These currents represent the minimum net stabi- lized output current into the specified battery bus voltage at the specified
32、 generator inlet air tempera- ture and at the specified generator shaft speed. That is, the net output current after field current excitation has been supplied and after the genera- tor has reached thermal equilibrium. The tolerance allowed on output current specifica- tions shall be such that 95% o
33、f the population of any production lot shall exceed the specified out- put current and no generator shall provide less than 97% of the specified output current. This re- quirement shall apply to the full speed range. 3.3.2 Generator Parasitic Current. Generator parasitic current shall be less than 0
34、.25 mA. 3.3.3 Generator Output Voltage Ripple. Output voltage peak-to-peak ripple, measured at the gen- erator, at full load, shall not exceed 0.0005 times the generator speed in rpm (5.0 V p-p at 10 000 rpm). For a typical 12-pole generator, ripple fre- quency in Hz with a three-phase bridge rectif
35、ier is 0.6 x the generator speed in rpm. Output Current peak-to-peak ripple is especially critical in the hot idle engine speed range. The generators regulator shall be so designed as to be relatively impervious to engine speed fluctuations and output voltage transients such that output volt- age an
36、d current ripple does not cause lamp flicker. Output current ripple is often associated with er- ratic field control waveforms having missing pulses or frequency shifts. The magnitude of allowable output current ripple is a systems issue and is specified in the SOR. 3.3.4 Generator Output Voltage wi
37、th Discon- nected Battery. If the battery becomes discon- nected from the generator output, the generator must maintain the output voltage specified in 3.2.2.1 or 3.2.2.2 0.5 V. The ripple voltage with- out battery connected shall not exceed 12 V (p-p) at full load and 10 000 rpm. 3.3.5 Generator No
38、ise. 3.3.5.1 Mechanical Noise. Generator mechanical noise shall be measured at 25C. The noise shall be quantified as Linear Weighted Sound Power and expressed in dB format. Mechanical noise shall not exceed the limits shown on the outline drawing or in the SOR. 3.3.5.2 Magnetic Whine Noise. Generato
39、r mag- netic whine noise, shall be measured at 25C. The noise shall be quantified as Linear Weighted Sound Power and expressed in dB format. Mag- netic whine noise shall be measured at full load generator output current and shall not exceed the limits on the outline drawing or in the SOR. 3.3.6 Elec
40、tromagnetic Compatibility. The gen- erator shall conform to the EMC requirements of GM specifications GMW3091 and GMW3097. 3.3.6.1 Load Dump Transients. The generator shall contain internal transient suppression to pro- tect itself and limit its transient output voltage in the event of an external l
41、oad dump. It must survive 100% full load dumps arising from either loose output, or loose ground path, or loose battery, or switched load connections. The generator transient over-voltage peak shall not exceed a voltage of Copyright 2004 General Motors Corporation All Rights Reserved August 2004 Pag
42、e 5 of 16 -,-,- GMW14036 GM WORLDWIDE ENGINEERING STANDARDS 39.0 V as measured by high-speed oscilloscope when the generator is supplying full load at 6500 rpm and full load is instantaneously dumped. The generator transient over-voltage peak shall not exceed a voltage of 33.0 V as measured by high-
43、 speed oscilloscope when the generator is supply- ing full load at 6500 rpm and all load except a re- sistive one-ohm load is instantaneously dumped. 3.3.6.2 Over-voltage Protection. The generator shall not exhibit any damage due to 60 s of 26 V boosted jump-start. 3.3.6.3 Reverse Voltage Protection
44、. The genera- tor shall not exhibit any damage due to 30 s of reverse battery voltage connection. This require- ment is applicable only if the vehicle has an over- current protection. 3.4 Product Assurance Requirements. The gen- erator shall be designed to perform with the Qual- ity, Reliability, an
45、d Durability Requirements as defined herein. 3.4.1 Quality Assurance Requirements. The supplier shall meet the expectations and require- ments consistent with and contained in the “Pro- duction Part Approval Process“ (PPAP) and the “Quality System Requirements“ (QS-9000). A quality program plan ackn
46、owledging the re- quirements and expectations in QS-9000 and PPAP, including the quality tasks and estimated task completion dates, shall be prepared by the supplier and submitted to the General Motors Sup- plier Quality for review and approval. 3.4.2 Reliability Requirements. Reliability is de- fin
47、ed as the probability of success in providing a specified function under rated conditions (tempera- ture, humidity, loading, etc.) for a given time. Gen- erator reliability shall be 0.999 or better for three years of application when operating at rated condi- tions. One year of application shall cor
48、respond to 500 operating hours representing 20 000 km (12 000 miles). Rated conditions are: Inlet air temperature = 125C - Generator output current = full load - Generator nominal speed = 3600 rpm - Generator speed range from zero to 21 000 rpm, Generator shaft accelerations from 3000 to 27 000 rpm/
49、s with 60 accel- erations/hr - Belt tension = 444 N (Drive End Bearing load = 1067 N) Since the probability of success (reliability) plus the probability of failure equals one, reliability greater than 0.999 means the probability of failure must be less than 0.001 or the failure rate must be less than 1.0 failures per thousand generators for three years of generator application. Furthermore, long term for the same operating conditions stated