1、 SAE/USCAR-33 Specification for Testing Automotive LED ModulesFebruary 2013ISBN: 978-0-7680- - 8038 4_ 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 Council for Au
2、tomotive 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 whether or not i
3、t is applicable for their purposes. Copyright 2013 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-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODUL
4、ES SUMMARY OF CONTENTS 1. SCOPE 3 2. SAFETY PRECAUTIONS . 3 3. REFERENCE STANDARDS . 3 4. DIAGRAMS AND DEFINITIONS . 5 4.1 APPENDICES . 5 5. GENERAL REQUIREMENTS . 5 5.1 RECORD RETENTION . 5 5.2 SAMPLE DOCUMENTATION AND RETENTION 6 5.3 POWER SOURCES 6 5.4 EQUIPMENT TOLERANCES . 7 5.5 MEASUREMENT ACC
5、URACY . 7 5.6 TEST REPEATABILITY AND CALIBRATION . 7 5.7 TEST DEFAULT CONDITIONS 8 5.8 TEST SHARING WITHIN LIGHT SOURCE FAMILIES 8 5.9 TEST FAILURE PROCEDURE . 8 5.10 CONTROL PLANS 8 5.11 RELIABILITY PROGRAMS AND METHODS . 8 5.12 HAZARDOUS MATERIAL RESTRICTION . 9 5.13 DOCUMENTATION 10 6. ANALYSIS .
6、 10 7. LED MODULE COMPONENTS 11 7.1 MODULE COMPONENTS 11 7.2 LUMEN / CHROMATICITY MAINTENANCE 11 7.3 LED BINNING . 12 7.4 LED OVERSTRESS TESTING . 12 8. LED MODULE ASSEMBLY TESTING 14 TEST SAMPLES . 14 ENVIRONMENTAL CONDITIONS 14 8.1 TEMPERATURE SOAK 14 8.2 THERMAL SHOCK IN AIR (TS). . 15 8.3 THERMA
7、L SHOCK WATER . 17 8.4 POWER TEMPERATURE CYCLE (PTC) TEST. . 20 8.5 SALT FOG/SPRAY . 22 SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES - 2 - 8.6 HUMIDITY . 24 8.7 ALTITUDE . 29 8.8 DUST. 29 8.9 WATER SPRAY 31 8.10 FLUID RESISTANCE 32 8.11 OUTGASSING 33 9. MECHANICAL . 3
8、4 9.1 STEADY STATE LOADS (CRUSH) 34 9.2 VIBRATION . 35 9.3 MECHANICAL SHOCK . 36 9.4 FREE FALL (DROP) . 37 10. ELECTRICAL 38 10.1 JUMP START (OVER-VOLTAGE) AND REVERSE POLARITY 38 10.2 BATTERY VOLTAGE DROPOUT. 39 10.3 SUPERIMPOSED ALTERNATING VOLTAGE . 40 10.4 SHORT CIRCUIT 41 10.5 OPEN CIRCUIT 42 1
9、0.6 ISOLATION . 42 10.7 INTENTIONALLY LEFT BLANK . 43 10.8 LEAKAGE CURRENT . 43 10.9 LOW POWER . 44 10.10 ELECTROMAGNETIC COMPATIBILITY 44 10.11 ELECTROSTATIC DISCHARGE 44 10.12 REDUCED VOLTAGE OPERATION 44 10.13 STARTING PROFILE 45 10.14 CONNECTOR TESTS 47 10.15 LAMP OUTAGE DETECTION 47 10.16 LIGHT
10、 OUTPUT TEMPERATURE COMPENSATION . 47 11. PHOTOMETRICS . 48 11.1 MODULE LUMINOUS INTENSITY MAINTENANCE ANALYSIS . 48 12. END OF LINE TESTING . 48 APPENDIX A: GLOSSARY . 49 APPENDIX B: FLUID SOURCES 50 APPENDIX C: TEST SEQUENCE 51 APPENDIX D: DESIGN GUIDELINES 52 APPENDIX E: ANNUAL TESTS 53 APPENDIX
11、F: REVISIONS . 54 SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES - 3 - 1. SCOPE This specification is a general level subsystem light source specification that establishes test requirements of Light Emitting Diode (LED) components and modules for use in automotive light
12、ing systems. The completed test data to this test specification is intended to be provided to the OEM by the Tier I lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved LED modules experiences a design, manufacturing or component change. This
13、document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. The LED module is defined as the LED devices and any electronics required to properly energize the LEDs using vehicle electrical power system along with any ass
14、ociated electrical wiring, connectors and thermal management system. Samples shall be tested as a subsystem and considered one test sample for the entire test sequence. A failure of any component in the test sample shall constitute a failure of the entire sample. If other manufactures components are
15、 intended to be approved for use in the LED modules, then those possible combinations of components shall be considered a new LED module and shall also be tested. Additional testing may be required by individual OEMs to meet specific EMC, quality, reliability and durability objectives. The following
16、 tests are to be performed under the following conditions: g120 New sample g120 Design or process change made to an existing module g120 Completion of one calendar year as noted in the “ANNUAL TESTS” Table shown in the Appendix. (Note: Production process control data, collected at a shorter interval
17、 per an approved control plan, may be substituted if approved by customers responsible engineer and purchasing representative.) 2. SAFETY PRECAUTIONS Reference IEC 62471. 3. REFERENCE STANDARDS In the event of a conflict between the text of this specification and the documents cited herein, the text
18、 of this specification takes precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. The latest issue of reference documents shall apply. SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES
19、 - 4 - g120 AEC Q101, AEC Q100, AEC Q200 g120 AIAG/APQP-2: Chrysler, Ford, and General Motors Advanced Product Quality Planning and Control Plan Reference Manual g120 AIAG/MSA-3: Measurement Systems Analysis Reference Manual g120 AIAG/FMEA-3: Potential Failure Mode and Effects Analysis Reference Man
20、ual (SAE J1739) g120 AIAG/PPAP-3: Chrysler, Ford, and General Motors Production Part Approval Process Manual g120 ASTM B117 (Standard Practice for Operating Salt Spray Fog Testing Apparatus) g120 Chrysler, Ford, and General Motors Quality System Requirements-TS-16949 Manual g120 AIAG Fundamental Sta
21、tistical Process Control Reference Manual g120 ASTM E595 - 07 Standard Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment g120 IEC 60068-2-1, Cold g120 IEC 60068-2-2 Ba, Dry Heat g120 IEC 60068-2-14 Na, Rapid Change of Temperature Wit
22、h Prescribed Time of Transition g120 IEC 60068-2-14 Nb, Change of Temperature with Specified Rate of Change g120 IEC 60068-2-27 Ea, Mechanical Shock g120 IEC 60068-2-32 Ed, Free Fall g120 IEC 60068-2-64, Vibration g120 IPC-A-610D Acceptability of Electronic Assemblies g120 ISO 16750-1 Road vehicles
23、Environmental conditions and testing for electrical and electronic equipment Part 1: General g120 ISO 16750-2 Road vehicles Environmental conditions and testing for electrical and electronic equipment Part 2: Electrical loads g120 ISO TC 22/SC 3/WG 13 N139 Road vehicles-Environmental conditions and
24、testing for electrical and electronic equipment Part 1: General g120 ISO TC 22/SC 3/WG 13 N140 Road vehicles-Environmental conditions and testing for electrical and electronic equipment Part 2: Electrical loads g120 ISO TC 22/SC 3/WG 13 N142 Road vehicles-Environmental conditions and testing for ele
25、ctrical and electronic equipment Part 3: Mechanical loads g120 ISO TC 22/SC 3/WG 13 N141 Road vehicles-Environmental conditions and testing for electrical and electronic equipment Part 4: Climatic loads g120 ISO 2575 Index M Electrical Functions in General and Electric Road Vehicles g120 SAE/USCAR 2
26、, Performance Standard for Automotive Electrical Connector Systems. g120 SAE/USCAR 12 Wiring Component Design Guidelines g120 SAE/USCAR 20 Field Correlated Life Test Supplement To SAE/USCAR-2 g120 SAE/USCAR 21 Performance Specification for Cable-To-Terminal Electrical Crimps g120 SAE/USCAR 34 Specif
27、ication for Testing Automotive Lamp Assemblies g120 SAE specification for LIN control SAE J2602 g120 SAE J575 Test Methods and Equipment for Lighting Devices and Components for Use on Vehicles Less Than 2032 mm in Overall Width g120 SAE J578 Color Specification g120 SAE J1128 Low Voltage Primary Cab
28、le g120 SAE J1330 Photometry Laboratory Accuracy Guidelines g120 SAE J1344 Marking of Plastic Parts g120 SAE J1383 Performance Requirements for Motor Vehicle Headlamps SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES - 5 - g120 SAE J1673 High Voltage Wiring Assembly Desig
29、n g120 SAE J1889 L.E.D. Signal and Marking Lighting Devices g120 SAE J2357 Application Guidelines for Electronically Driven and/or Controlled Exterior Automotive Lighting Equipment g120 SAE J2602 LIN Network for Vehicle Applications g120 SAE J2650 Performance Requirements for Light Emitting Diode (L
30、ED) Road Illumination Device Systems g120 SAE J2938 LED Light Source Tests and Requirements Standard g120 VDA 260 Marking Standard Federation of the Automobile Industry g120 Q7-K: Chrysler, Ford Motor Company and General Motors TS-16949 Supplier Quality Requirements *Copies of the AIAG Manuals can b
31、e obtained from AIAG (Automotive Industry Action Group) by calling (248) 358-3570 or by writing to AIAG, Dept. 77839, Post Office Box 77000, Detroit MI 48277-0839, Attn: Customer Service. 4. DIAGRAMS AND DEFINITIONS 4.1 APPENDICES Diagrams are provided at the end of this specification to clarify the
32、 details of the test procedures. A Glossary of Terms is also included in the Appendix. 5. GENERAL REQUIREMENTS 5.1 RECORD RETENTION Supplier must maintain a file for the storage of laboratory reports and calibration records, and establish a record retention policy concerning these records in accorda
33、nce with TS-16949 and PPAP requirements. These records need not follow a standard format, but must present the required data in an orderly, professional manner. The file must be made available to any and all customer personnel upon request, includingg127but not limited tog127representatives from the
34、 following areas: product engineering, purchasing, quality, and reliability. 5.1.1 Objectives of Record Retention Following are the main objectives for retention of test documents or records: 1. Retain records that will evidence compliance so that the supplier can appropriately respond when or if pr
35、oduct 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 audit or inspection. 2. Retain records as needed to assist in evidencing the exercise of “due care“ in matters relating to product co
36、mpliance, government requirements, or product liability. 3. Comply with statutory requirements for the maintenance and retention of specific records. SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES - 6 - 5.1.2 Retention Methods Methods of retention may include retention
37、of original documents, the use of film, or the use of electronic storage equipment. Records shall be stored so that they are accessible in a reasonable amount of time. Storage areas should provide adequate protection from unauthorized access, moisture, and fire. 5.2 SAMPLE DOCUMENTATION AND RETENTIO
38、N Engineering test samples must be identified by Industry Accepted Trade Number and manufacturers 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. (Reference TS-16949 and PPAP requiremen
39、ts) 5.2.1 Required Data Package Supplier must submit the data package for the appropriate level of submission to the customers responsible engineer and purchasing division for approval signatures. 5.2.1.1 PRODUCTION PROCESS APPROVAL The LED Module design shall be capable of meeting the requirements
40、of Automotive Industry Action Group (AIAG) document “Production Part Approval Process“ (PPAP). 5.2.2 Sample Retention Samples tested to attain part approval must be retained by the manufacturer for a period of time specified in the PPAP Manual. 5.3 POWER SOURCES Supplier must use voltage regulated D
41、C power sources for all tests to simulate an automotive battery and charging system. When Pulse Width Modulation (PWM) can be used to energize or control a function, the PWM supply shall be duplicated in each test. When vehicle electrical power system uses a Pulse Width Modulation (PWM) power supply
42、 to energize an LED module then the test must also use a PWM power supply of similar frequency and duty cycle. 5.3.1 Output Current The power source must be capable of supplying a continuous output current as required by the design loads, including inrush current. Where required to simulate automoti
43、ve inrush current conditions, an automotive battery or batteries with sufficient cold cranking amps may be connected in parallel with the power supply. SAE/USCAR-33 Issued 2013-02 SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES - 7 - 5.3.2 Output Voltage The power source must be capable of supplyin
44、g an output voltage that must not deviate more than 0.1 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 25 mV peak to peak. Power supplies used for photomet
45、ric measurements must conform to SAE J1330. 5.4 EQUIPMENT TOLERANCES Supplier must use test setups and equipment capable of measuring test parameters (nominal) within the limits found in Table 1. Table1: Equipment Tolerance Test Chamber Temperature/Humidity nominal g114 2 g113C Relative Humidity g11
46、4 5% Time nominal g114 0.5% Forces nominal g114 0.1 N Distances nominal g114 0.1 mm Voltages nominal g114 0.1 V MSCD nominal g114 2.0% NOTE: This table is not to be used for performance dependent variable (Refer to section Measurement Accuracy). 5.5 MEASUREMENT ACCURACY Meters and gauges used to ass
47、ess the performance dependent variable, as defined by the basic function of the test sample, must have a smallest unit of measure one order of magnitude less than the least significant digit specified. For example, even though a 0.6 mm and 0.60 mm wire might be the same diameter, calipers capable of
48、 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. 5.6 TEST REPEATABILITY AND CALIBRATION 5.6.1 Equipment Repeatability All measurement equipment used for product evaluation must be repeatable to within 10% of the part
49、tolerance according to Chrysler, Ford, and General Motors Measurement Systems Analysis Reference Manual. 5.6.2 Equipment Calibration Equipment re-calibration/re-certification timing is to be calculated based on the capability of any individual instrument to retain its “Manufacture Stated Accuracy“ between recall periods. However, this time shall not exceed one year. SAE/USCAR-33 Issued 2013-0
