1、Specification for Testing AutomotiveMiniature Bulbs SAE/USCAR-3 Revision 3 December 2009 ISBN: 978-0-7680-3395-3 _ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United States Co
2、uncil 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 document to determine whet
3、her or not it is applicable for their purposes.Copyright 2009 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-3 REVISION 3 Issued August 1997 Revised 2009-12 SPECI
4、FICATION FOR TESTING AUTOMOTIVE MINIATURE BULBS SUMMARY OF CONTENTS 1. SCOPE* 32. REFERENCE STANDARDS . 43. GENERAL REQUIREMENTS . 43.1 Record Retention 43.2 Sample Documentations and Retention* 43.3 Power Sources 53.4 Equipment Tolerances 53.5 Measurement Accuracy 63.6 Test Repeatability and Calibr
5、ation 63.7 Test Default Conditions* . 63.8 Test Sharing Within Bulb Families 63.9 Test Failure Procedure . 63.10 Control Plans* . 73.11 Reliability Programs and Methods 73.12 Hazardous Material Restriction . 74. PHYSICAL PERFORMANCE . 74.1 Physical Dimensions . 74.2 Mean Spherical Candela . 84.3 Ext
6、ernal Visual Examination . 84.4 Crush Strength 94.5 Thermal Shock 104.6 Bayonet Base Retention . 104.7 Pin Removal 114.8 Wedge Base Retention . 114.9 Lead Wire Bend 124.10 Lead Wire Pull . 124.11 Color* 134.12 Color Maintenance and Coating Durability* 144.13 Color Chemical Resistance* . 154.14 Reson
7、ant Frequency* . 164.15 Aged Resonant Frequency . 174.16 Salt Spray 184.17 Wire Loop Pull . 184.18 Outgassing/Heat . 18SAE/USCAR-3 REVISION 3 Revised 2009-12 SPECIFICATION FOR TESTINGAUTOMOTIVE MINIATURE BULBS - 2 - 5. DURABILITY . 195.1 Laboratory Life* . 195.2 Accelerated Life* . 205.3 Luminous In
8、tensity Maintenance* . 205.4 Vibration Durability*. 215.5 Shock 225.6 Aged Vibration Durability 226. QUALITY/RELIABILITY PROGRAMS 236.1 Reliability Growth 236.2 Ongoing Quality Improvements 236.3 Quality/Reliability Improvement 247. REPORT REQUIREMENTS . 247.1 Calibration Sheets . 247.2 Data Require
9、ments . 24APPENDIX A GLOSSARY OF TERMS* . 25APPENDIX B GRAPHICS, CHARTS, ETC. 27APPENDIX C REVISIONS . 44Figure B1 Filament Orientation 27Figure B2 Crush Test Fixtures . 28Figure B3 Pin Removal Test Fixture (B-1, B-2, And C-2 Base Types) . 29Figure B4 Pin Removal Test Plate (B-1, B-2, And C-2 Base T
10、ypes) 30Figure B5 Wedge Base Retention Fixture . 31Figure B6 Point Color 32Figure B7 Resonant Frequency Test . 33Figure B8 Shock Tester (Side View) . 34Figure B9 Shock Tester (Top View) 35Figure B10 Shock Tester - S-8 Wedge Base Lamp Mounting Detail 36Figure B11 Shock Tester Cam 37Figure B12 Shock T
11、ester Detection Circuit . 38Figure B13 Shock Tester Counter Circuit 39Figure B14 Bulb Versus Function Cross Reference Table . 40Figure B15 Heat Test Enclosures 41Figure B16 Normal Probability Plot . 42Figure B17 Weibull Life Plot 43SAE/USCAR-3 REVISION 3 Revised 2009-12 SPECIFICATION FOR TESTINGAUTO
12、MOTIVE MINIATURE BULBS - 3 - 1. SCOPE* The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling applications. The following tests shall be run whenever the following occurs: New bulb design Design or
13、process change made to an existing bulb, which could affect the outcome of the test. The completion of one calendar year as noted in the following Test Schedule Table. Process control data is acceptable.Test Schedule Table Test Title YearlyPhysical Dimensions X Mean Spherical Candela X External Visu
14、al Examination X Crush X Thermal Shock X Bayonet Base Retention X Pin Removal X Wedge Base Retention X Lead Wire Bend X Lead Wire Pull X Natural Amber Color X Coated Amber Color Integrated Color Visual Color Point Color Color Maintenance and Coating Durability Amber Coating Chemical Resistance XXXRe
15、sonant Frequency Aged Resonant Frequency Salt Spray Wire Loop Pull X Outgassing/Heat Laboratory Life Accelerated Life X Luminous Intensity Maintenance X Vibration Durability Shock Aged Vibration Durability SAE/USCAR-3 REVISION 3 Revised 2009-12 SPECIFICATION FOR TESTINGAUTOMOTIVE MINIATURE BULBS - 4
16、 - 2. REFERENCE STANDARDS Chrysler, Ford, and General Motors Advanced Product Quality Planning and Control Plan Reference Manual Measurement Systems Analysis Reference Manual (AIAG) SAE J1739, Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Ana
17、lysis in Manufacturing and Assembly Processes (Process FMEA) Chrysler, Ford, and General Motors Production Part Approval Process Manual ANSI (C78.390) ASTM B 117 (Standard Practice for Operating Salt Spray Fog Testing Apparatus) Chrysler, Ford, and General Motors Quality System RequirementsQS-9000 M
18、anual SAE J573, Miniature Lamp Bulbs SAE J1330, Photometry Laboratory Accuracy Guidelines SAE J578, Color Specification Unless otherwise specified or required by law, suppliers should use the most recent versions of any applicable reference documents or standards.3. GENERAL REQUIREMENTS 3.1 Record R
19、etention Supplier must maintain a file for the storage of laboratory reports and calibration records, and establish a record retention policy concerning these records. These records need not follow a standard format but must present the required data in an orderly professional manner. The file must
20、be made available to any and all PPAP approver personnel upon request, includingbut not limited to representatives from the following functions: product engineering, purchasing, quality, and reliability.3.1.1 Objectives of Record Retention The following are the main objectives for retention of test
21、documents or records: 1. Retain records that will evidence compliance so that the supplier can appropriately respond when or if product compliance is challenged. Files must exist for the storage of all laboratory records, data, and calibration records. The files must be available at any time for aud
22、it or inspection. 2. Retain records as needed to assist in evidencing the exercise of “due care” in matters relating to product compliance, government requirements, or product liability. 3. Comply with statutory requirements for the maintenance and retention of specific records. 3.1.2 Retention Meth
23、ods Methods of retention may include retention of original documents, the use of film, or electronic storage equipment. Store records so that they are accessible in a reasonable amount of time. Storage areas should provide adequate protection from unauthorized access, moisture, and fire. 3.2 Sample
24、Documentations and Retention* Engineering test samples must be identified by ANSI Trade Number and serial number unless otherwise noted. Documentation must identify the type of test performed and describe special tests that are not a part of this specification.3.2.1 Required Data Package Supplier mu
25、st submit the data package for the appropriate level of submission to the PPAP approvers responsible engineer and purchasing division for approval signatures. SAE/USCAR-3 REVISION 3 Revised 2009-12 SPECIFICATION FOR TESTINGAUTOMOTIVE MINIATURE BULBS - 5 - 3.2.2 Sample Selection Test bulbs referenced
26、 in this specification are to be selected from the same “Test Lot“. The minimum “Test Lot” is defined as one hour of production. Test bulbs are to be subjected to production intent processing, including final packaging. NOTE: A test sample size of 10 would consist of one sample piece being removed f
27、rom the test lot, every six minutes of production, for a one- hour production run. It is important that the test samples be identified as to location, within the test lot, throughout all testing.3.2.3 Sample Retention Samples tested to attain part approval must be retained by the bulb manufacturer f
28、or a period of time specified in the PPAP Manual. 3.3 Power Sources Supplier must use voltage regulated direct current (DC) power sources for all tests to simulate an automotive battery and charging system. 3.3.1 Output Current The power source must be capable of supplying a continuous output curren
29、t as required by the design loads, including inrush current. Where required to simulate automotive inrush current conditions, an automotive battery or batteries with sufficient cold cranking amps may be connected in parallel with the power supply.3.3.2 Output Voltage The power source must be capable
30、 of supplying an output voltage that must not deviate more than 1.0 volt from the nominal setting over the entire load range (including surges). The power source must recover 63% of its maximum excursion within 5.0 milliseconds. Ripple voltage must not exceed 300 mV peak to peak.Power supplies used
31、for photometric measurements must conform to SAE J1330. 3.4 Equipment Tolerances Supplier must use test setups and equipment capable of measuring test parameters (expressed in nominals) within the limits found in the Equipment Tolerances Table. Equipment Tolerances Table Test Chamber Temperature nom
32、inal 3CTime nominal 0.5% Forces nominal 0.01 N Distances nominal 0.01 mm Voltages nominal 0.01 V for photometrics nominal 0.1 V for all other tests Mean Spherical Candela nominal 2.0% NOTE: Not to be used for performance dependent variable (see Measurement Accuracy section). SAE/USCAR-3 REVISION 3 R
33、evised 2009-12 SPECIFICATION FOR TESTINGAUTOMOTIVE MINIATURE BULBS - 6 - 3.5 Measurement Accuracy Meters and gages used to assess the performance dependent variable, as defined by the basic function of the test sample, must be capable of measuring to one count less than the specified value. For exam
34、ple, even though a 0.1 mm and 0.10 mm wire might be the same diameter, calipers capable of 0.01 mm resolution may be used to measure the first wire, but a micrometer with 0.001 mm resolution is needed for the second wire. 3.6 Test Repeatability and Calibration 3.6.1 Equipment Repeatability All measu
35、rement equipment used for product evaluation must be repeatable to within 20% of the part tolerance according to Chrysler, Ford, and General Motors Measurement Systems Analysis Reference Manual (AIAG).3.6.2 Equipment Calibration Equipment used for measurement or verification of measurement must be p
36、eriodically calibrated to known standards. Calibration interval must be consistent with industry practices but may not be more than 18 months. 3.6.3 Laboratory Masters Bulbs which are traceable to known standards are laboratory masters. Each supplier must use laboratory masters for comparison measur
37、ements, calibration of test equipment, and for evaluating long-term drift in test equipment. 3.7 Test Default Conditions* When specific test conditions are not given, the following basic conditions apply: Test the bulb with the base and filament parallel to the direction of excitation as shown in fi
38、gure Filament Orientation. Perform tests or measurements at the following ambient conditions:Room Temperature 20C Atmospheric Pressure 650 800 mm Mercury Conduct tests or measurements using the bulbs design voltage as published by the American National Standards Institute, Inc., (ANSI) in Special Re
39、port 25, ANSI Assigned Miniature Lamp Codes. Season the bulbs for 1% of the average life, 10 hours maximum at design voltage, or an equivalent period at a higher (forced) voltage as defined in Accelerated Life section. Note the seasoning method used on the test report. Whenever bulbs are operated at
40、 higher than design voltages, switch them on at their design voltage for at least 50 milliseconds and then step up to the appropriate design voltage. This will limit the inrush current to the design level. 3.8 Test Sharing Within Bulb Families The results of tests performed on one bulb type may, in
41、some cases, be used to indicate the capability of another bulb type within the same bulb family. For example, a crush test performed on a clear, S-8 wedge bulb type may be used as a demonstration of the glass strength of all clear, S-8 wedge bulb types made by the same process from the same glass fr
42、om the same source. Sound judgment must guide this practice. Bulbs within the same bulb family that share components such as glass envelopes, lead wires, filaments, bases, fill gases, etc., may be able to share test results. The PPAP approver will be the final authority on whether this surrogate dat
43、a may be used. 3.9 Test Failure Procedure Should a test fail, contact the requesting party to determine if the test is to be continued to gain additional product experience or if testing is to be suspended. When contact cannot be immediately made, stop the test until the requesting party can be cont
44、acted. SAE/USCAR-3 REVISION 3 Revised 2009-12 SPECIFICATION FOR TESTINGAUTOMOTIVE MINIATURE BULBS - 7 - 3.10 Control Plans* Supplier must maintain a control plan, consistent with Chrysler, Ford, and General Motors Advanced Product Quality Planning and Control Plan Reference Manual, for each bulb typ
45、e (or bulb family), that contains appropriate controls to ensure that all the significant/critical characteristics covered by the tests in this specification are met. 3.11 Reliability Programs and Methods 3.11.1 Reliability Growth and Ongoing Quality Improvements Bulb suppliers must establish and im
46、plement a plan to improve demonstrated product quality and reliability. They must establish procedures for analyzing and correcting end-of-line defects and predominant failure modes identified by the field return program. True reliability growth occurs when design changes to the bulb or manufacturin
47、g process are made to eliminate the failure modes. 3.11.2 Notification of Process Changes Suppliers must notify the PPAP approver of manufacturing process, material, or design changes to determine if resubmission for PPAP approval is required. 3.11.3 Quality/Reliability Improvement Tools Suppliers m
48、ust use appropriate methods to improve the quality and reliability of their products in accordance with QS-9000. Examples of such methods are Field Return Programs, Design Failure Mode Effects Analysis (DFMEA), Process Failure Mode Effects Analysis (PFMEA), and Fault Tree Analysis (FTA) or Fishbone
49、Diagrams. Further information on these methods is available from the Automotive Industry Action Group (AIAG). 3.12 Hazardous Material Restriction Any regulated substance that is identified by any federal, state, provincial, or local government unit or automotive manufacturer, shall not be used in the manufacturing process of any bulb.Any bulb manufacturer that is currently supplying
