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1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure Body Closures GMW15081 Window System, Dropping Type Power and Manual Performance/Stall Test Copyright 2006 General Motors Corporation All Rights Reserved August 2006 Originating Department: North American Engineering Standards Page 1 of 19 1 Scope Note
2、: Nothing in the specification 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. 1.1 Purpose. To determine the operating performance characteris
3、tics of dropping, power and manual, window systems. 1.2 Foreword. 1.2.1 Power window system operating performance tests can be used to obtain the following data: 1.2.1.1 Travel time. 1.2.1.2 Average run current. 1.2.1.3 Peak run current (excluding motor start up). 1.2.1.4 Average stall current. 1.2.
4、1.5 Average stall voltage. 1.2.1.6 Peak stall current. 1.2.1.7 Average run voltage. 1.2.1.8 Peak run voltage. 1.2.1.9 Peak stall force. 1.2.1.10 Plots of current and voltage vs. time. 1.2.2 Manual window system operating performance tests obtain data for the spindle torques required for window trave
5、l. 1.3 Applicability. This procedure applies to all passenger cars, light duty trucks and medium duty trucks having dropping, power or manual, window systems. The procedure also applies to midgates and endgates with dropping windows. 2 References Note: Only the latest approved standards are applicab
6、le unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GMN6541 2.3 Additional References. EDS Window Performance software package Version 1.1. 3 Resources 3.1 Facilities. 3.1.1 Major Facility. GMNA Body Test Lab or a similarly equipped test facili
7、ty. 3.2 Equipment. Note: The following list(s) include fixturing and instrumentation typically used by the GMNA Body Test Lab to perform this test. Other equipment may be substituted at the discretion of the testing facility as long as it provides the same data and/or data record, with equivalent ac
8、curacy as specified herein or by the requestor. Torque Transducer Power Window Performance Console Includes 0 to 20 V/50 A DC power supply, computer, printer, wiring harness to connect motor terminal to console, EDS window performance software Stall Force Gage (with sufficient wire to reach console)
9、 Tape Measure 3.2.1 Fixturing. 3.2.1.1 A body is preferred (with all seals that interface with the doors) to provide upper door frame support and for door over crown. Note: Headerless doors (doors with no upper frame) require a body for test purposes. If the test door is not on a body, it may be cla
10、mped to a fixture, such as a lab door cart, that will constrain it in approximate design position and prevent it from tipping. 3.2.1.2 Spindle adapter (if using the hand-held torque transducer) (for manual window systems only). 3.2.1.3 Power window regulator motor assembly converted to a manual spin
11、dle drive assembly (if required). See 3.3.3 and Appendix A Figure A1. -,-,- GMW15081 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 2 of 19 August 2006 3.2.2 Instrumentation. 3.2.2.1 Power Window Systems. 3.2.2.1.1 Power window performance conso
12、le, which includes 0 to 20 V/50 A DC power supply, personal computer, color printer for computer, wire harness that connects the regulator motor terminal to the performance console and EDS Window Performance software package Version 1.1. 3.2.2.1.2 A stall force gauge and sufficient wiring to connect
13、 it to the power window performance console. 3.2.2.1.3 Marking pen. 3.2.2.1.4 Linear measuring device (tape measure). 3.2.2.2 Manual Window Systems. Manual window operating performance console or hand held torque transducer, torque display/calibration box, power supply, XY time base plotter and prop
14、er wire connections. 3.3 Test Vehicle/Test Piece. 3.3.1 One (1) door assembly including a manual or power window system and a complete glass guidance system, including belt strips, run channels and any items affecting window system performance. 3.3.2 Vehicle body and associated door mounting hardwar
15、e, weatherstrips, etc. (refer to 3.2.1.1). 3.3.3 A power window regulator motor assembly converted to a manual spindle drive assembly (if necessary). See Appendix A Figure A1. 3.3.4 It is recommended that the test parts/assembly be dimensionally certified before testing is started. 3.4 Test Time. Th
16、e following is an estimate of the amount of time (work hours) needed to perform this procedure. Calendar time: 1 day Technical Resource: 1 hour Engineering Resource 3 hours Note: These time estimates are approximate averages. Actual times vary considerably depending on early component failures (and
17、subsequent availability of replacement parts), testing to varying multiples of cycle lives, varying requirements for frequency of environmental test conditions, scheduling problems for test facilities, test equipment malfunctions, scheduling of overtime and/or multiple shifts, scheduling of “witness
18、es” for tests, actual readiness of test samples upon receipt, unique or additional requests for test details, running multiple samples (times shown are for 1 system), etc. These times consider preparation and other downtime, actual test, and analysis of data in capturing a total calendar time. Repor
19、t writing, approval, processing, etc. are not part of these times. 3.5 Test Required Information. The requesting engineer is responsible for providing specifications appropriate to the particular vehicle line being tested (reference VTS/SSTS paragraph numbers). Testing worst case scenarios may uncov
20、er some potential problems. Discuss with the requesting engineer if testing should include some worst case scenarios. Depending on which test is being performed and which level of parts or systems is being tested, consider if any of the following may apply tolerance stack-ups, build variations, misa
21、lignment, minimum/maximum fastener torque(s), lubrication, environmental extremes, location of customer representative load application, symmetry (Left Hand vs. Right Hand), color, mold or die source, etc. 3.5.1 Power Window Specifications. The following specifications or information are required to
22、 run this test: 3.5.1.1 Stall time (amount of time that power is supplied to the window system after the glass reaches a full up/full down position. 3.5.1.2 Power supply voltage settings (stall voltage or supply voltage). 3.5.1.3 Resistance of the wires between the power supply and the window motor
23、(if a known supply voltage is used). 3.5.1.4 Location(s) on the window glass to measure stall force. 3.5.1.5 If new seals are installed, the length of time the seals are to be in compression prior to running the performance test (4.3.1.2). 3.5.2 Manual Window Specifications. No specifications are re
24、quired. Currently, at the GMNA Body Test Lab, the test equipment limits maximum stall torque to 5.6 Nm. 3.6 Personnel/Skills. Prior experience in setting up and running similar tests and experience in the use of the referenced test equipment are critical to achieving the estimated times shown in “3.
25、4 Test Time”. 4 Procedure 4.1 Preparation. 4.1.1 Sample Inspection. The test and requesting engineers should inspect the test items to insure all material listed in 3.3 is of correct design level and assembled properly. -,-,- GM WORLDWIDE ENGINEERING STANDARDS GMW15081 Copyright 2006 General Motors
26、Corporation All Rights Reserved August 2006 Page 3 of 19 4.1.2 Sample Preparation. This test is normally run on the test subject in an “as received“ condition. If it is requested to be run in a specifically adjusted condition, follow the applicable procedure(s). If installing a spindle modified powe
27、r regulator assembly in a door, a hole may need to be drilled to allow spindle egress through the door inner panel. 4.1.2.1 Measure and adjust gap, flushness and seal margin dimensions, if necessary (refer to GMN6541TP) to ensure the test material meets design specifications (required only if testin
28、g a door mounted on a body). 4.1.3 Facilities and/or Equipment Preparation. Record any instrumentation calibration information on Appendix A Data Sheet A1. 4.2 Conditions. 4.2.1 Environmental Conditions. Unless otherwise specified in this documents text or by the requesting engineer, the typical env
29、ironmental conditions for this test are the temperature, humidity and pressure at the major test facility (3.1.1). Unless otherwise noted, these conditions are typically 22+3C, relative humidity of 40 +20% and atmospheric pressure equivalent to the local barometric pressure (which is variable during
30、 any given day and from day to day). 4.2.2 Test Conditions. Deviations from the requirements of the procedure shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.3 Instructions. 4.3.1 Set-up Instructions. 4.3.1.1 If not mounted
31、on a body, secure the door in approximate design position to a door cart. 4.3.1.2 It may be required to wait a specified length of time with the window glass in the full up position with new seals before performing window performance tests. Reference 3.5.1.5. 4.3.1.3 Motor temperature affects perfor
32、mance test results. If the power windows have been running durability tests, allow the motors to cool approximately 20 minutes before running performance tests. 4.3.1.4 Perform any functional/operational tests/evaluations as requested by responsible engineer. If the window system has not been previo
33、usly cycled, cycle the window “full up” and “full down” a minimum of 5 times prior to the start of test to assure proper operation and seating of all system components. As applicable, note any irregular sounds or erratic operation indicating a potential problem with design, manufacture, or assembly
34、and verify observations with the requesting engineer. 4.3.2 Test Operation Instructions. Note: Based on the window system to be tested, go to 4.3.2.1 (power) or 4.3.2.2 (manual). 4.3.2.1 Power Window System. 4.3.2.1.1 Plug the window performance console into a 120 V AC wall outlet. Press the green p
35、ower button on the front of the console and the power button on the printer. Turn on the DC power supply at the bottom of the console. 4.3.2.1.2 When prompted, enter the appropriate password. See a Body Test Lab support technician for the current password. The “Window Performance Test System, Live S
36、tatus Info“ screen will then be displayed. See Appendix A Figure A2. 4.3.2.1.3 On the toolbar, left click on “Edit“. From the dropdown menu, left click on “Setup Specs“. This causes the “Edit Setup Specifications“ screen to be displayed. 4.3.2.1.4 Enter Motor Maximum Stall Time (see 3.5.1.1) in the
37、appropriate location. This value is typically 0.75 s. Enter the Test Temperature in the appropriate location. Test Temperature is for informational purposes only and is printed on the window performance plots. 4.3.2.1.5 Supply voltage can be set in one of two ways. If a known supply voltage is desir
38、ed, enter that number in the location “Power Supply Voltage“. Alternatively, if a known motor stall voltage is desired, enter it in the location “Motor Stall Voltage“. 4.3.2.1.6 Left click on “OK“ to exit the “Edit Setup Specifications“ screen. Any changes made are automatically saved. 4.3.2.1.7 Mak
39、e the proper electrical connections between the performance console and the regulator motor. If setting the power supply to a specific voltage, use an electrical connection with a known resistance; otherwise, a short, 12 gauge wire harness with the proper matching connectors to minimize voltage drop
40、 is suggested (reference 3.5.1.3). 4.3.2.1.8 Left click on the “Up“ or “Down“ button in the area titled “Window Motor Control“ on the “Window Performance Test System, Live Status Info“ screen (Appendix A Figure A2). Note: If the window travels in the opposite direction of the polarity in the area en
41、titled “Polarity“ on the “Window Performance Test System“ screen. 4.3.2.1.9 If a known “Power Supply Voltage” was entered in 4.3.2.1.5, skip to 4.3.2.1.10. If a known -,-,- GMW15081 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2006 General Motors Corporation All Rights Reserved Page 4 of 19 August 2
42、006 “Motor Stall Voltage” was entered in 4.3.2.1.5, left click on “Test“ in the toolbar. From the dropdown menu, left click on “Stall Voltage Adjust“. The “Stall Voltage Adjust Test“ screen is displayed. Note the advisories on this screen and left click on “Continue Test“ when ready. This test will
43、automatically adjust the supply voltage from the performance console to give the desired stall voltage. 4.3.2.1.10 Install the wire for connecting the stall force gauge and plug it into the front of the window performance console. Using 3.5.1.4 for a location, install the stall force gauge on the wi
44、ndow and mark its location (gauge location should be consistent during multiple testing). Position the stall force gauge so no rotation of the glass or gauge occurs during step 4.3.2.1.11. Do this by adjusting the tilt feet on the gage to make the gage align with the glass. See Appendix A Figure A3.
45、 4.3.2.1.11 On the “Window Performance Test System“ screen, left click on the “Cal“ button in the section entitled “Cal Load Cell“. Left click on “Test“ in the main window toolbar. From the dropdown menu, left click on “Stall Force“. The “Stall Force Test“ screen is displayed. Note the advisories on
46、 this screen and left click on “Continue Test“ when ready. This will cause the window to rise until the stall force gauge seats into the upper glass run channel at which time the stall force will be measured. The window will then return to a partially open position. When the window stops, remove the
47、 stall force gauge. 4.3.2.1.12 An option is now given to plot the stall force data. If this plot is desired, left click on “Yes“, otherwise, left click on “No“. See Appendix A Figure A4 for a sample plot. 4.3.2.1.13 Return the window to the full up position using the “Up“ button on the “Window Perfo
48、rmance Test System“ screen. 4.3.2.1.14 Testing requirements from 3.5.1.2 may require changing the motor supply voltage after performing the stall force test and before the window performance test. If required, do so as in 4.3.2.1.5. 4.3.2.1.15 Left click on “Test“ in the main window toolbar. From th
49、e dropdown menu, left click on “Window Performance“. The “Test Window Performance“ screen is displayed. Note the advisories on this screen and left click on “Continue Test“ when ready. The window will travel to the full down position, pause and then return to the full up position. 4.3.2.1.16 The “Window Performance Test Plot“ screen will now be displayed. If a stall force was measured as in 4.3.2.1.11, left click on “Yes“. If no stall