Maximum Temperature Tmax Maximum limit value of the ambient temperature at which the component is required to operate. Post Heating Temperature soak back TPH Maximum limit value of the ambient temperature which may temporarily occur after vehicle cut-off and at which the component may be operated for a brief period, i.
Accounts for high temperature storage and paint booth exposure. Room Temperature Troom Ambient room temperature. Minimum Voltage Umin Minimum limit value of the supply voltage at which the component is required to operate during the test. Nominal Voltage Unom Nominal supply voltage at which the component is operated during the test. Maximum Voltage Umax Maximum limit value of the supply voltage at which the component is required to operate during the test.
Unless stated otherwise, the following shall define the test environment GMW parameters and tolerances to be used for all validation testing see Table 2 : Table 2: Parameters and Tolerances Parameter Tolerance Ambient Temperature Spec.
The component is electrically connected with supply voltage UB battery voltage, generator not active with all electrical connections made.
The FSC defines the functional performance of the component. B All functions of the component perform as designed during the test. However, one or more of them may go beyond the specified tolerance. All functions return automatically to within normal limits after the test. Memory functions shall remain FSC A. C One or more functions of the component do not perform as designed during the test but return automatically to normal operation after the test. E One or more functions of the component do not perform as designed during and after the test and cannot be returned to proper operation without repairing or replacing the component.
Include Material Test Requirements. Analysis: Present results from analytical procedures and simulation models. Inform SQE of issues. Based on the corrective action, the Component Environmental Test Plan shall be modified as required. The purpose of this meeting is to review the design to suggest solutions for Environmental robustness and discuss the Component Environmental Test Plan expectations.
Appendix B Component Environmental Test Plan shall be completed by the supplier and submitted in an electronic, editable format to GM 6 weeks after supplier sourcing. Approval shall occur 10 weeks after supplier sourcing. Reuse allowed for other tests.
Additional activities may be required based on the results of Design Validation DV. This includes any hardware-related modifications such as internal part swaps or material changes and manufacturing process changes such as tooling, solder process, or manufacturing location.
Software changes that may affect GMWrelated requirements shall also be considered. The objectives of the Hardware Design Review shall be to: Note: When available, actual hardware samples or physical mock-up for visual examination is required. Components that have failed during a test shall be analyzed immediately by the supplier.
The component shall not be repaired or further used in the Test Flow. Test samples shall be provided to GM, according to the Component Environmental Test Plan, and this may include parts before testing and parts after testing. The life requirement used in this document is 10 years of environmental exposure and km miles of customer usage. When the Vehicle Technical Specification VTS defines a different target life in km or miles, adjustments shall be made only for vibration testing.
For example, a mile requirement shall dictate 1. When the VTS defines a different target life in years, no adjustments shall be made. In case of different reliability and confidence requirements, adjustments shall be made accordingly.
Component reliability shall be demonstrated for the failure mechanisms of: GMW 5. Supplemental Environmental testing for failure mechanisms not covered by this document must be specified in addition to GMW and documented in the Appendix B Component Environmental Test Plan. Table 6 defines the steady state minimum and maximum test voltages to be used as measured at the connector of the component. The table shall also be used in specifying the component criteria requirements unless otherwise specified in the CTS.
The Coding defines the requirements related to the position of the component in the vehicle and the appropriate tests for chemical loads. Table 11 identifies chemical origins that shall be covered by the appropriate material specification. No additional testing is required by this document. The coding behind IP definitions is similar to ISO , Protection of electrical equipment against foreign objects, water and access. For details see ISO , Protection of electrical equipment against foreign objects, water and access.
This document distinguishes between the following mounting locations and defines the minimum Electrical, Mechanical, Temperature, Climatic, Chemical, Dust and Water Protection requirements. Other mounting locations are possible and can be addressed using a custom combination of Z code letters see Table These procedures shall be defined in the Component Environmental Test Plan. Purpose: This check shall verify full functionality of the component as defined in the CTS while exposed to 3 temperatures and 3 voltages.
Applicability: This check shall be performed at the beginning and at the end of all test legs. Operating Type: Monitoring: 2.
These parameters shall be defined in the Component Environmental Test Plan. Comparisons to the original measurements, individually and as a group statistically, shall be made to identify and quantify any performance degradation. Criteria: A. Functional Status Classification shall be 6. Purpose: This check shall verify full functionality of the component as defined in the CTS while exposed to a single temperature and single voltage.
Applicability: This check shall be performed during or after tests as defined in the Component Environmental Test Plan. All loads shall be documented in the Component Environmental Test Plan. The power supply shall be capable of supplying sufficient current to avoid current limiting under high in-rush conditions.
The temperature shall be stabilized for at least 0. Purpose: Continuous Monitoring shall detect the functional status of the component during and after exposure to the test environment. This shall be documented in detail in the Component Environmental Test Plan.
Applicability: This check shall be performed during the tests as defined in the Component Environmental Test Plan. Operating Type: Monitoring: As defined in each individual test. The monitoring sampling rate shall be defined in the Component Environmental Test Plan.
Criteria: Continuous Monitoring test setup shall be verified with respect to accurate and comprehensive data storage. Purpose: Functional Cycling shall simulate customer usage during and after exposure to the test environment.
Criteria: Functional Cycling test setup shall be verified with respect to accurate and comprehensive component state changes. Applicability: All components. Operating Type: Monitoring: 1. All samples shall be available for GM review upon request. The following samples shall be submitted to GM Engineering upon request for dissection and inspection: one sample from Mechanical Fatigue, two samples from Thermal Fatigue one from Constant Humidity and one from Cyclic Humidity , and one sample from Corrosion.
Perform an external inspection of the component housing. Then perform a dissection of the component followed by an internal inspection. The inspection shall use visual aids e. Also, parts in high flexure areas of the circuit board.
Also, surface mounted parts located in high flexure areas of the circuit board and near connector terminations. All foreign residues shall be analyzed for material composition and conductivity. Indicators of poor manufacturing processes. Objectionable squeak and rattles, especially after vibration fatigue. A close examination of the circuit boards with a magnifying device shall occur on all components, particularly on the components that experienced PTC.
The appearance of whiskers during environmental testing will indicate the probability of similar whisker formations occurring in the field.
The formation of whiskers poses a risk to close-pitched parts, and may result in a short-circuit situation of parts or components that are stored for service. Solder joints most at risk include interfaces with large CTE differentials or corner pins of surface mounted parts with large diagonal lengths. The supplier may be required to perform further investigation to determine the degree or type of degradation.
GM Engineering will decide as to the necessity of corrective action. The Analysis shall be used to aid in designing reliability into the component during the time when physical components are not yet available. All Analytical activities shall be documented in the Component Environmental Test Plan, including results. Purpose: This analysis shall identify the resonant frequency to detect structural weaknesses that may lead to mechanical fatigue.
Analytical activities shall be completed prior to the design freeze for building development level hardware. Applicability: 7. Procedure: Considering the circuit board mounting configuration, calculate the resonant frequency of the circuit board by using appropriate software such as Finite Element Analysis. Purpose: This analysis shall identify that the design of the circuit is capable of producing the required functions.
Criteria: Verify that the design of the circuit is capable of producing the required functions under all conditions. The All components with a circuit board. The supplier must provide evidence of appropriate corrective action when the resonant frequency is below Hz.
The corrective action is to be reviewed with the GM Validation Engineer. Purpose: This analysis shall identify mechanical destruction that may occur during shipping in an un-pressurized aircraft up to an altitude of 15 m above sea level.
Applicability: All components or parts that are hermetically sealed and may be shipped at high altitude. Use a worst case analysis process considering the variation of material parameters such as the minimum wall thickness and the effects of material weakening relative to temperature effects glass transition temperatures. The glass transition temperature Tg is the temperature whereupon the material properties, such as stiffness, changes its characteristics.
Purpose: This analysis shall identify structural weaknesses of the housing that could either lead to excessive stress to parts inside the component or to the housing itself. Applicability: All components where forces from elbow or foot loads from assembly or servicing are possible. This may include use as a supporting surface for other assembly operations. Paltitude: Pressure in the freight section of the airplane at 15 m, use 11 kPa. Operating Type: Design Margin DM : 4 Monitoring: Criteria: The component or part burst pressure must exceed the resulting internal pressure during air shipment by a factor of 4.
Purpose: This analysis shall ensure that the snap fit is adequately designed. Applicability: All components that incorporate plastic snap fits. Criteria: Evidence that the design meets the four design elements stated in the procedure. Criteria: Sufficient clearance between parts of the component and housing shall be demonstrated when the necessary forces are applied.
The deflection of the component cover must not generate forces on parts within the component or on the circuit board. Purpose: This analysis shall identify cooling weaknesses that may lead to overheating on parts as a result of low air density at high altitude. High altitude analysis is to be performed on all components that contain significant heat generating elements on their circuit board and are cooled by air flow i.
The reduced air density at high altitude will reduce convective heat transfer and may cause marginal designs to overheat while operating within the vehicle. Applicability: All components where heat dissipation may be reduced due to low air density caused by high altitudes. Identify the Coefficient of Thermal Expansion CTE of each package type, and all variants within the package type, of the parts of the component.
The multipliers as noted in Table 15 are used to adjust the temperature rise for high altitude effects in the equation. Identify the differences of the CTEs for each package type of the parts and for the part to which they are attached. Identify the analysis method used to determine the fatigue life and provide the evidence of the validation for that analysis method. Purpose: This analysis shall identify thermal fatigue weaknesses caused by cyclic temperature change when materials with different Coefficients of Thermal Expansion CTE are attached to each other.
For example, the different CTEs of circuit board parts result in fatigue stress to the junctions used to attach those parts to the circuit board e. The expansion rates of different materials added to a circuit board assembly e. Perform the analysis to quantify fatigue life of the part junctions from the expansion and contraction during temperature cycling of the component.
Criteria: The calculated fatigue life shall be three times greater than the required life of the component. Purpose: This analysis shall identify solder joint weaknesses that may occur due to the use of lead-free solder.
This analysis supports the Hardware Design Review to evaluate the soldering process. Applicability: All components manufactured with lead-free solder. Provide full disclosure throughout the supply chain regarding risks when lead-free solder is used. Criteria: The analysis shall show evidence that the lead-free solder effects are reviewed and adjustments made to the test plans, design, and process.
Development activities are designed to detect weaknesses or design oversights that were not comprehended, or could not be evaluated, during Analysis activities.
The Development activities shall be performed on first samples to provide the earliest opportunity to qualitatively evaluate and improve physical components. HALT is a typical example of this type of activity. Weaknesses detected during Development activities shall be corrected prior to validation. All Development activities shall be documented in the Component Environmental Test Plan, including results. Applicability: All components that have power supplied by the vehicle battery 12 V wiring system.
This test is not applicable to generators or components that have an exemption stated in the CTS. Operating Type: in Table Monitoring: 3. Repeat the test for both Operating Types. Table Reverse Polarity Requirements 8. This condition can be caused by a double-battery start assist. Monitoring: inputs. This condition can be caused by an accidental reversal of the charging device. Criteria: C.
Functional Status Classification shall be 8. Continuous Monitoring. All functions needed to start the engine must meet Class A during the test, if not stated differently in the CTS. These conditions can be caused by generator regulator failures or battery charging events. Applicability: All components in the vehicle that have power supplied by the vehicle battery 12 V wiring system.
Procedure: 8. All applicable power modes shall be executed during the test time. Functional Status Classification shall be 2 Cycle the component in such a way that the maximum current change rate over time at the ground path occurs.
This may be achieved by simultaneously activating all inputs to the component that will generate outputs switching at the maximum rate of change.
This includes relay switching. Purpose: This test shall verify that the component behaves adequately during state changes e. Operating Type: All transitions between possible operating types e. Monitoring: Continuous Monitoring. Additionally, the voltage and current output is reviewed in graphical form with an oscilloscope. Procedure: 1 Change operation state.
Evaluate output signal integrity for proper performance by using an oscilloscope. Criteria: Functional Status Classification shall be A. State change transients shall not produce disruptive levels of disturbance to downstream components. One consideration in analyzing the waveform is to detect inadvertent actuation of outputs and floating inputs.
Purpose: The HALT test shall identify structural and functional weaknesses due to vibration and temperature effects. Applicability: This test applies to new technology. This test can also be used to evaluate product improvements. Operating Type: 3. Procedure: GMW Use the test methods according to Criteria: Functional Status Classification is not applicable to this test. HALT test results shall support the Hardware Design Review to improve components and evaluate new hardware technologies and product improvements.
Purpose: This test shall verify that the component is immune to ground path inductance that may interfere with fast signal changes. Purpose: This method shall identify overheat areas in the component that may lead to part degradation.
Tmin of the operating temperature range is the low temperature that is to be used. Procedure: Perform the measurement in the highest power consumption scenario possible. This can be done by various methods, using infrared imaging or thermocouple measurements. For infrared imaging, use the procedure in GMW For non-accessible parts, use thermocouples or equivalent for part temperature measurement. Time 3. Tmax: Maximum temperature from Temperature Code rating in this document.
Operating Type 1. Criteria: Functional Status Classification is not applicable to this test. The part shall meet the maximum allowable temperature with the Design Margin. Applicability: tronics. Operating Type: Purpose: This test shall evaluate that the component is robust against rapid temperature change in a high humidity environment.
This can produce intermittent failures and sneak path circuits that may affect function. Applicability: All sealed or closed components. All components equipped with elec- Operating Type: 1. Monitoring: Continuous Monitoring during the time it is energized.
Monitoring: Continuous Monitoring during Operating Type 3. Procedure: Use the test methods according to IEC , Test Db, Damp heat, cyclic, with the temperature and humidity profile defined in Figure 8.
The HAST test results shall support the Hardware Design Review to improve components and evaluate new hardware technologies and product improvements. Reference to Table 19 for the number of cycles performed. Table Frost Test Requirements Number of cycles performed Component Type Sealed components with or without a pressure exchange membrane 10 Non-Sealed components without vent openings 1 Non-Sealed components with vent openings 0 Criteria: Functional Status Classification shall be A.
An inspection shall show no signs of electro-migration and dendritic growth. Purpose: The HAST test shall identify structural and functional weaknesses due to humidity and temperature effects. If this test is performed without prior exposure to temperature or humidity, then the component shall be pre-treated with 2 h at Tmax or TRPS, whichever is greater.
The Dimensional Test shall be performed at Troom. All dimensional and physical requirements on the GM released part drawing shall be validated and documented unless indicated otherwise by GM Engineering. Any Dimensional Test results that do not meet the part drawing requirements shall be considered a nonconformance. The Design Validation DV shall be a quantitative and qualitative verification that the component design meets the requirements for Environmental, Durability, and Reliability.
The DV activities shall be executed on production design-intent components with production-intent parts, materials, and processes including solder and fluxes. Applicability: All components directly connected to the vehicle battery. Operating Type: 2. The current value shall be stored graphically. Procedure: Measure the current in all of the component supply lines. The current measuring device must have a sampling rate that is ten times higher than the shortest current peak duration that the component creates.
All inputs and outputs are to be electrically connected to their original load or equivalent. Measure the current according to step 3. This ramp down shall include at least 2 internal wakeup events, with a maximum slope of 0. The maximum allowable average parasitic current shall be 0. Analyze the stored current waveforms for any random fluctuations. Purpose: This test shall verify the proper reset behavior of the component. It is intended primarily for components with a regulated power supply or a voltage regulator.
This test shall also be used for microprocessor-based components to quantify the robustness of the design to sustain short duration low voltage dwells. Applicability: All components that may be affected by a momentary drop in voltage. This includes components supplied by regulated voltage provided by other components. Operating Type: Monitoring: 3. The component shall be at Troom. Figure 9: Power Supply Interruptions Profile 4 Decrease the supply voltage at a linear slope until Measure a minimum of five internal wakeup events for components that wake up i.
For components that do not wake up, wait in OFF Asleep mode for 10 minutes. While waiting, watch the current value for random fluctuations, then if stable, measure current for 10 s. Calculate the average current over the measured period.
In case of random current fluctuations this behavior shall be documented. Apply Umin to the component. T3 Operating Type 2. GMW OT 3. Variations T1 T2 T3 A 0. D 1s 28 s 7 s Criteria: Functional Status Classification shall be A after returning to Umin following each voltage drop and C elsewhere.
Procedure: 1 Set up the battery voltage dropout profile as shown in Figure Criteria: Functional Status Classification shall be as shown depending on the zone per Figure There shall be no inadvertent behavior during the transitions.
These voltage pulses will simulate a sudden high 5 Repeat steps 2 through 4 at T max. Functional Status Classification shall be 9. This test simulates loads with inrush current behavior such as motors, incandescent bulbs, or long wire harness resistive voltage drops modulated by PWM controlled high loads.
Figure Pulse Superimposed Voltage test setup Io output current capability 50 A Rise time Applicability: All components that have power supplied by the vehicle battery 12 V wiring system. Operating Type: Io Supply 3. Procedure: Refer to Figure Short circuit tests to supply and ground lines from the vehicle 12 V battery system are excluded from this test.
Additionally, monitor for overheating. Procedure: 1 Lower and stabilize the chamber temperature to Tmin. After completing the 60 cycles, perform any required re-initialization conditions and confirm the correct operation of the outputs with normal loads. Note: 6 Repeat steps 2 through 5 for short to ground condition. Criteria: Functional Status Classification shall be D. Fuse replacements are not permitted. For components with micro-controllers, the micro-controller must remain functional during the short circuit event.
Short circuit related trouble codes shall be stored in the micro-controller accordingly. Overheating is not permitted. Purpose: This test shall verify that the component will experience an open circuit of the ground passthrough trace in a safe manner. Applicability: pass-through. All components that have a ground Monitoring: Continuous Monitoring. A power supply with a current limitation set to 50 A if not otherwise specified shall be used. Connect the power supply ground to the component ground.
Keep this short circuit condition applied until the component temperature is stable. The short circuit duration is defaulted to 1 h, but may be shorter or longer depending on the protection design. View more articles gmw More Sectors Transportation. What is crank pulse capability and durability testing?
At Thermax, we are accredited to perform mechanical shock pothole testing gmw shipping vibration testing for this standard. Thermax is an accredited test laboratory, recognized by A2LA for gmw competence in testing and quality management.
Testing your vehicles with Element to ensure the safety of your product. For example, this applies to a stand-alone component gmw contains electrical content gmw as a Body Control Module. This test method verifies the robustness of the component together with the packaging during shipping.
This mechanical testing gmw concerned about the following mounting locations on a vehicle: Contact us today for assistance in meeting the requirements of your GMW Testing, or click here to complete a request for quote. The test duration is 24 hours per axis for all three axes. Click here to skip or gmw will close in gmw seconds. In addition to vibration testing, Element provides a range of dynamics testing including gmw, shock, drop, structural, fatigue and rotating load simulations.
Click here for more info. This Standard References Showing 10 of This section describes vibration testing combined with temperature, mechanical shock testing, and drop testing, etc. For the second time, you guys exceeded expectations. The test profile is random vibration over the frequency range of 10Hz to Hz with gmw acceleration of 1. Top Categories Terms of Use.
After testing has been completed the Crank Pulse plots are given to the customer to be analyzed and interpreted to ensure that their components are fit for purpose. Our Engaged Experts will help guide your GMW program to ensure the project gmw meets gmw needs.
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