1、 Specification for Testing Gas Discharge Light Source Subsystem SAE/USCAR-27 October 2007 ISBN: 978-0-7680-1976-6 _ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the Society of Automotive Engineers, Inc. (SAE) nor
2、 the United States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this docum
3、ent to determine whether or not it is applicable for their purposes. Copyright 2007 USCAR Printed in U.S.A. All rights reserved. QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SAE/USCAR-27 Issued 2007-10 SPECIFICATION
4、 FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM SUMMARY OF CONTENTS 1 SCOPE .3 2 SAFETY PRECAUTIONS3 2.1 HIGH VOLTAGE IDENTIFICATION/LABELING .4 3 REFERENCE STANDARDS.4 4 DIAGRAMS AND DEFINITIONS 6 4.1 APPENDICES.6 5 GENERAL REQUIREMENTS .6 5.1 RECORD RETENTION.6 5.2 SAMPLE DOCUMENTATION AND RETEN
5、TION.7 5.3 POWER SOURCES7 5.4 EQUIPMENT TOLERANCES .8 5.5 MEASUREMENT ACCURACY.8 5.6 TEST REPEATABILITY AND CALIBRATION.9 5.7 TEST DEFAULT CONDITIONS9 5.8 TEST SHARING WITHIN LIGHT SOURCE FAMILIES.9 5.9 TEST FAILURE PROCEDURE.10 5.10 CONTROL PLANS 10 5.11 RELIABILITY PROGRAMS AND METHODS 10 5.12 HAZ
6、ARDOUS MATERIAL RESTRICTION 11 6 ENVIRONMENTAL .13 6.1 TEMPERATURE SOAK13 6.2 THERMAL SHOCK IN AIR (TS)14 6.3 THERMAL SHOCK WATER .16 6.4 POWER TEMPERATURE CYCLE TEST. 18 6.5 SALT FOG/SPRAY.20 SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 2 - 6.6 HUMIDI
7、TY 21 6.7 ALTITUDE 27 6.8 DUST27 6.9 WATER SPRAY29 6.10 FLUID RESISTANCE 30 7 MECHANICAL 31 7.1 STEADY STATE LOADS (CRUSH)31 7.2 VIBRATION 32 7.3 MECHANICAL SHOCK.35 7.4 FREE FALL (DROP).35 8 ELECTRICAL36 8.1 JUMP START (OVER-VOLTAGE) AND REVERSE POLARITY.36 8.2 BATTERY VOLTAGE DROPOUT.37 8.3 SUPERI
8、MPOSED ALTERNATING VOLTAGE .38 8.4 SHORT CIRCUIT39 8.5 OPEN CIRCUIT 40 8.6 ISOLATION.41 8.7 INPUT CURRENT SURGE.42 8.8 STEADY STATE INPUT POWER.42 8.9 LEAKAGE CURRENT.43 8.10 ELECTROMAGNETIC COMPATIBILITY.43 8.11 AUTOMATIC RE-START / SYSTEM INTERLOCK44 8.12 REDUCED VOLTAGE OPERATION.45 8.13 NOISE .4
9、5 8.14 CONNECTOR TESTS.46 9 PHOTOMETRICS .46 9.1 LIFE / LUMEN / COLOR MAINTENANCE however, all interfaces, connectors and wiring must be exposed. SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 14 - 6.1.2 Procedure 1) Mount the GDLS on the fixture using t
10、he devices attachment points. No component of the GDLS shall come into contact with the chamber surfaces. 2) Power the GDLS for 1 minute at 13.5 Vdc. 3) Remove power from GDLS during temperature soak. 4) Set chamber settings to Tmaxand a maximum 50% relativity humidity and allow to stabilize. 5) Soa
11、k at Tmaxfor 96 hours. 6) At the end of the 96 hour soak, power the GDLS for 1 minute at 16.0 Vdc. 7) Remove power from GDLS. 8) Allow to cool to room temperature. 9) Lower the chamber temperature to Tmin. and allow to stabilize. 10) Soak at Tminfor 24 hours. 11) At the end of the 24 hour soak, powe
12、r the GDLS for 1 minute at 9.0 Vdc. 12) Remove power from GDLS. 13) Allow the chamber to reach room temperature. 14) Power the GDLS for 1 minute at 13.5 Vdc. 6.1.3 Acceptance Criteria 1) The GDLS shall not show any evidence of visible fractures, warpage or deformation. 2) The light source shall illu
13、minate continuously each time it is powered. 6.2 THERMAL SHOCK IN AIR (TS). 6.2.1 Purpose The GDLS shall be designed to withstand thermal stresses due to power cycling and rapid changes in ambient temperature without degradation in performance. The Discharge Light Source may be mounted in a lamp hou
14、sing or otherwise protected during this testing; however, all interfaces, connectors and wiring must be exposed. This is an accelerated test to evaluate failure mechanisms, which may be driven by mismatches in coefficients of thermal expansion. 6.2.2 Test and Measurement Apparatus 1. Environmental C
15、hamber (circulating air type) #1 TMin= -40 C 2. Environmental Chamber (circulating air type) #2 TMax= 105 C SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 15 - The environmental chambers shall be capable of maintaining the atmosphere at the appropriate t
16、emperature for the test in any region where the specimen is placed. The absolute humidity in the chambers shall not exceed 20 g/m3 The volume of the chambers and the air velocity shall be such that after insertion of the test specimens, the temperature within the chambers shall be within the specifi
17、ed tolerance after a time of not more than 10% of the exposure time. The air in the chambers shall be circulated. Air velocity measured close to the test specimen shall be not less than 2 m/s. 3. Power Source 4. GDLS Mounting Fixture The GDLS shall be tested using mounting or supports with low therm
18、al conduction, such that for practical purposes the specimen is thermally isolated. When testing several specimens simultaneously they shall be so placed that free circulation should be provided between specimens and between chamber surfaces. The Discharge Light Source may be mounted in a lamp housi
19、ng or otherwise protected during this testing; however, all interfaces, connectors and wiring must be exposed. 6.2.3 Procedure. Reference IEC 60068-2-14 Na. Upon agreement, this test can be performed during the development process without a case (or with a modified case). 1. Test Chamber #1 and #2 s
20、hall be stabilized to TMinand TMaxrespectively, prior to inserting test specimens. 2. The GDLS shall soak at TMinfor 10 minutes and then transferred to test chamber #2. 3. Transfer time between chambers shall not exceed 30 seconds. 4. The GDLS shall soak at TMaxfor 20 minutes. 5. Repeat steps 2 thro
21、ugh 4 for a minimum number of 300 cycles. (refer to Table Combined Thermal Shock / Power Temperature Cycling) 6. Lamp and ballast shall be energized once daily for 10 minutes at 105 C and once daily at 40 C for the last 2 minutes of the 10 minute soak. 7. Test shall be stopped if light source fails
22、to illuminate when energized. 6.2.4 Acceptance Criteria. The light source shall illuminate each time it is operated and at the completion of the test. SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 16 - 6.3 THERMAL SHOCK WATER 6.3.1 Purpose. To verify th
23、e GDLS functionality after exposure to sudden changes in temperature after a cold water splash on a hot system/component. The aim is to simulate driving through water in the wintertime. This applies to GDLS devices that lie in the splash area, (e.g. ballast mounted external to the lamp assembly). 6.
24、3.2 Test and Measurement Apparatus 1. Spray Chamber 2. Spray Nozzle (Reference ISO WD 16750-4 N142) Jet specification: Slot jet, see Figure 13. Width of jet slot: 1.2 mm Length of jet 220 mm Water flow: (1.00 to1.33) l/s 3. Test Fluid de-ionized water with 3% fine Arizona dust according to ISO 12103
25、-1; 5 % NaCI may be added 4. GDLS Mounting Fixture 1. GDLS mounted as in vehicle position, accommodating any ballast sealed connections and mounting surfaces. (Vehicle lamp assembly may be used) 2. Distance between the spray jet and the GDLS surfaces shall be 325mm +/- 25mm (water shall be applied o
26、ver the complete width of the exposed surfaces of the GDLS components) 6.3.3 Procedure 1. The GDLS is to be electrically connected as in the vehicle in the normal driving mode and continuously monitored. Any sealed connections on the ballast shall simulate vehicle interface. The GDLS light source sh
27、all be inside an enclosure such as a lamp assembly to shelter the arc tube from water. 2. Test cycle: Heat the GDLS exposed components to 105 C and hold this temperature for 30 min. Use a waterproof electrical connection. 3. Splash the hot GDLS exposed component with cold water from one direction wh
28、ile being in as-installed position. If the equipment is splashed from various directions in the vehicle, then these directions shall be taken into account. Provided that this is the case, a new GDLS may be used for each splash direction. The width of the splash directed at the GDLS shall always be g
29、reater than the width of the GDLS. If GDLS of considerable size are splashed that prove too big for one jet, several jets shall be arranged in a row to produce a line of splash impact on the GDLS. 4. Repeat the cycle. If the test is conducted with several GDLSs at the same time, a jet for splashing
30、shall be provided for each GDLS. 5. Number of cycles: 100 SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 17 - 6. Holding time at Tmax: 30 min 7. Transition duration: 20 s (For manual transition of GDLS between temperature storage and splashing) 8. Water
31、temperature: 0 C to +4 C 9. Splashing duration: 3 s 10. GDLS bulb to be energized at nominal voltage during the last 15 min at 105 C DUT325 25 mmSPLASH SLOT JETDUT Location with Respect to Slot JetDUT mounting according to as-installed condition in vehicle.Splash CycleOperating Type3.2ONONOFFOFFSpla
32、sh3s15(30 min cycle)SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 18 - 6.3.4 Acceptance Criteria The GDLS light source and ballast must operate during test and meet requirements of SAE J2009 (modified) pertinent sections for light up and luminous intens
33、ity after the test. 642111513198220R100101.2 0.05X10.56XFIGURE 13: Spray Nozzle Temperature Difference Cycle Time - min Number of Cycles Test Time Temperature Range Service Test n-PTC-Test Ther-mal ShockPower Temp Sam-ple Size nN-Test Ther-mal Shock Power Temp Days 70 145 1182 30 59 18 1329 300 729
34、36.1 70 145 1182 30 59 18 1329 564 201 20 70 145 1182 30 59 23 1176 300 576 29.9 (-40+105)C 70 145 1182 30 59 23 1176 488 200 18.4 Table: Combined Thermal Shock / Power Temperature Cycling 6.4 POWER TEMPERATURE CYCLE TEST. 6.4.1 Purpose. The purpose of this test is to determine if the GDLS is able t
35、o meet specification requirements when subjected to the power and temperature cycling stresses that cause failures related to mechanical attachments, integrated circuit dies, electro migration and solder creep. The number of combined thermal shock and power temperature cycles shall be determined fro
36、m the Table: Combined Thermal Shock / Power Temperature Cycling Any one row from table may be selected to meet the requirements of this section. Samples shall operate normally during and at the conclusion of testing. SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SU
37、BSYSTEM - 19 - 6.4.2 Procedure. The temperature cycle testing shall be performed according to IEC 60068-2-14 Nb. The input/ output cycling shall be scheduled such that the required minimum number of 1 life cycles, as shown in the following table, for each function is evenly distributed and achieved
38、during the total PTC test. The test parts shall be powered between points “A” and “B” of the Temperature Cycle Profile chart. The control instrumentation must be capable of synchronizing the GDLS on/off time with the chamber temperature transitions. Minimum Number of 1 Life Cycles (This table is to
39、be filled out by Engineering) Function Number of Cycles On / Off 200 minimum Temperature Range -40 C to 105 C Operating Type Normal operating mode with continuous monitoring. Temperature Transition Rate (3 2) C/min or modified with the approval of Engineering Dwell time after temperature stability i
40、n the chamber has been reached The time at -40 C should be 10min minimum. The time at 105 C should be 20 min minimum. Minimum number of thermal cycles 200 or the appropriate number to meet the 1 life usage cycles. Power on At the end of the cold soak Point “A” Power off At the end of the hot soak Po
41、int “B” Supply Voltage % of Operational Cycles Vlow10 Vnom80 Vhigh10 SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 20 - 1052 Hr. Minimum.Point “B”Point “A”-40Temperature (C)25Temperature (C)-4025Hours48105ChamberChamberTEMPERATURE CYCLE PROFILE Per SAE
42、J 2357 apply power at end of cold soak, turn off at end of hot soak. Transition rate to be 3 +/- 2 deg C/min. Change Device Internal Temp to Chamber Temperature. Figure 11: Power Temperature Cycle Profile Criteria. Any inputs/outputs in an incorrect state or any incorrect on vehicle messages shall b
43、e considered a nonconformance to specification requirements. 6.4.3 Purpose. This is an accelerated test to evaluate failure mechanisms, which may be driven by mismatches in coefficients of thermal expansion. 6.5 SALT FOG/SPRAY 6.5.1 Purpose This test is designed to show the GDLSs ability to withstan
44、d exposure to salt spray and fog as experienced in coastal regions and road salt environments. The Discharge Light Source (bulb) is presumed to be mounted within headlamp assembly. This specification assumes that the ballast is mounted external to lamp housing. 6.5.2 Test and Measurement Apparatus S
45、alt Spray Chamber per ASTM B117 SAE/USCAR-27 Issued 2007-10 SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM - 21 - 6.5.3 Procedure 1. The GDLS shall be set up in the “On Vehicle Position” such that they will not be exposed to dripping moisture. The vehicle interface connector and asso
46、ciated harness shall be connected to the parts at all times during this test with the opposite end of the harness kept outside the chamber or sealed off at the end. 2. The GDLS require four 30 minute salt-water applications during the ambient environment soak for each of the required test cycles. Ea
47、ch application should be spaced (1.5 0.01) hour apart. Each step shall be run immediately after the previous step. a) Ambient Environment Soak 8 hour at ambient room temperature with a relative humidity of (30 50) %. b) Humid Environment Soak 8 hour at a temperature of +49 C and a relative humidity
48、of (95100) %. c) Dry Environment Soak 8 hour at a temperature of +60 C and a relative humidity 30%. Note: One test cycle totals 24 hours 3. During 7thhour of Dry Environment soak apply power to the GDLS for 15 minutes. 4. Repeat steps 2 and 3 for a total of 10 test cycles. 5. After the final cycle,
49、verify function of the GDLS within 1 hour. The GDLS shall also be inspected for signs of corrosion. An external and connector cavity inspection is required at this time; an internal inspection is optional. The GDLS shall not be cleaned (? Typically rinsed with deionized water) prior to proceeding onto other tests in the test sequence. 6.5.4 Acceptance Criteria The acceptance criteria
