1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW16633 Exhaust Gas Heat Recovery Unit Validation Tests Copyright 2011 General Motors Company All Rights Reserved August 2011 Originating Department: GME Specification Center Page 1 of 9 1 Introduction Note: Nothing in this standard supercedes
2、applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. The intent of this standard is to define a set of validation tests for an Exhaust Gas Heat Recovery Unit (EGHR) which are not covered by o
3、ther existing GM Test Procedures. This standard includes EGHR which are located directly at a close coupled catalytic converter (CC-EGHR) and EGHR which are installed in an under floor position (UF-EGHR). It is applicable for all Exhaust Gas Heat Recovery Systems for cars and light commercial vehicl
4、es. 1.2 Mission/Theme. This standard establishes the minimum requirements for the validation of an EGHR. All requirements of this specification must be met in order to demonstrate design validation (DV) and product validation (PV). It does not cover all necessary functional or validation tests which
5、 are described in the corresponding SSTS for the EGHR. For a complete validation of the EGHR refer to the “Validation Cross Reference Index for EGHR” as described in the SSTS “Exhaust Gas Heat Recovery Unit” (Appendix C3 of the Exhaust SSTS). 1.3 Classification. Not applicable. 2 References Note: On
6、ly the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GM6277M GMW3059 GMW15261 2.3 Additional References. EGHR-SSTS, Appendix C3 of Exhaust SSTS 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 C
7、alibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with res
8、pect to their physical definition. Usage of alternative facilities needs the prior approval by the General Motors Design Release Engineer (DRE) and the General Motors Validation Engineer. 3.1.3 Facilities. 3.1.3.1 Burst pressure test bench with a maximum pressure of 3 MPa. 3.1.3.2 Climate chamber wh
9、ich can be cooled down to -30 C capable to contain the EGHR. 3.1.4 Equipment. 3.1.4.1 Instrumentation and recording equipment for the documentation of all test parameters. Details can be found in the appropriate test description. Copyright General Motors Company Provided by IHS under license with Ge
10、neral Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16633 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 2 of 9 3.1.4.2 Controllable hot gas source (fuel burner) with a maximum mass f
11、low of 540 kg/h at +1000 C Note: The above required values are worst case values. They can be lowered based on the requirements given by the program specific EGHR SSTS. 3.1.4.3 Controllable coolant loop with a coolant flow of 25 l/minute at +100 C. 3.1.4.4 Air blower capable to deliver fresh air at
12、room temperature (RT ) (+23 5) C) at the same mass flow like the hot gas source. 3.1.4.5 A control device capable to switch the actuator automatically between “Non-Recovery Mode” and “Recovery Mode”. A full actuator cycle (switching from “Non-Recovery Mode” to “Recovery Mode” and back to “Non-Recove
13、ry Mode”) shall be completed within a maximal time of 3 s. Note: Only necessary for an EGHR with non-thermostatic actuator. 3.1.4.6 Electromagnetic or hydraulic shaker with a minimum acceleration of 8 G (78.5 m/s) and a minimum frequency of 200 Hz. 3.1.5 Test Vehicle/Test Piece. EGHR test samples eq
14、uipped with interfaces (exhaust pipe flanges, coolant connectors) according to the release drawing. 3.1.6 Test Time. Calendar time: (60 to 220) days (depending on actuator technology) Test hours: (1100 to 5000) h (depending on actuator technology) Coordination hours: 30 h 3.1.7 Test Required Informa
15、tion. Not applicable. 3.1.8 Personnel/Skills. Not applicable. 3.2 Preparation. As described in the appropriate test description. 3.3 Conditions. 3.3.1 Environmental Conditions. Unless otherwise required by the appropriate test, all tests shall be performed at (+23 5) C, together with the exhaust sys
16、tems connectors and the fluid loop connectors. The connectors shall be assembled with the nominal torque given by the release drawing. 3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, tes
17、t certificates, reports, etc. 3.4 Instructions. Not applicable. 3.5 Data. Not applicable. 3.6 Safety. This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the u
18、ser of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 3.7 Documentation. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and a
19、pproved by the responsible GM Department prior to the start of delivery of production level components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole
20、 responsibility of the supplier to provide the customer, unsolicited, with documentation of any change or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of d
21、elivery of the modified or changed product. In some cases, a shorter test can be agreed to between the responsible GM department and the supplier. 3.7.1 Test Results. The test results shall be compiled to a test report which contains the following sections: 3.7.1.1 Test Piece Description. Part name
22、and/or number, development state, date of manufacture, drawing number and drawing state. 3.7.1.2 Summary of Test results. Documentation of individual test results, target values, rating of test results (OK, NOK) and deviations from the test procedure, if necessary. Test incidents shall be documented
23、 additionally with pictures. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16633 Copyright 2011 General Motors Company All Rights Reser
24、ved August 2011 Page 3 of 9 3.7.1.3 Test Description. Description and pictures of test setup. Calibration of test equipment. 4 Requirements and Procedure 4.1 Maximum Exhaust Gas Pressure Test. The EGHR shall withstand high pressure on the exhaust gas side for short term (in case of misfiring or simi
25、lar). 4.1.1 Preparation. Cap one end of the exhaust path of the EGHR sample and connect the other end to a burst test fixture. The fixture shall have a pressure gage, pressure source and use water or hydraulic oil as pressure medium. The test set up shall allow venting of all air and is to be enclos
26、ed in a suitable chamber to prevent injury in case a component shall burst. 4.1.2 Procedure. Apply ten (10) pressure cycles in Recovery Mode between 0 MPa and 3 MPa with a cycle time of 3 s according to Figure 1. Switch to Non-Recovery Mode and apply another ten (10) pressure cycles. A leakage test
27、according to GMW15261 shall be performed without heat treatment at end of the test. Figure 1: Maximum Exhaust Gas Pressure Test 1 Pressure 2 Maximum test pressure = 3 MPa rel. 3 Minimum test pressure = 0 MPa, rel. 4 Time to increase / decrease pressure = 1 s 5 Time to hold pressure = 0.5 s 6 Test Ti
28、me 4.1.3 Acceptance Requirements. 4.1.3.1 No cracks or damage in base material or weld area. 4.1.3.2 The EGHR test sample shall fulfill the exhaust gas leakage requirements of the EGHR-SSTS. 4.2 Operating Durability in High Temperature Gas Environment. The EGHR shall be functional at high exhaust ga
29、s temperatures. Depending on the installed actuator technology the following different test procedures shall be used. 4.2.1 Preparation. Set up the EGHR sample(s) on a test bench which contains the following components: x A controllable hot gas source (fuel burner) capable to deliver a mass flow of
30、540 kg/h (150 g/s) at a minimum temperature of +1000 C. Note: The above required values are worst case values. They can be lowered based on the requirements give by the program specific EGHR-SSTS. x A controllable coolant loop capable to deliver a minimum coolant flow of 25 l/minute at +100 C. The c
31、oolant shall be a mixture of 60 % water and 40 % antifreeze according to GM6277M. For EGHRs with an electrical or vacuum operated actuator the following additional equipment is necessary: x An air blower capable to deliver fresh air at (+23 5) C at the same mass flow like the hot gas source. x A con
32、trol device capable to switch the actuator automatically between “Non-Recovery Mode” and “Recovery Mode”. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEER
33、ING STANDARDS GMW16633 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 4 of 9 4.2.2 Procedure. 4.2.2.1 Thermostatic Actuator - Coolant Temperature Variation. 4.2.2.1.1 Set the exhaust gas mass flow to a value 25 % below the maximal value for the Heat Recovery Mode which is
34、 defined by the EGHR-SSTS. Note: This prevents the systems to switch to the Non-Recovery Mode by an implemented passive override function. 4.2.2.1.2 Set the coolant volume flow to 25 l/minute and vary the coolant inlet temperature from -10 K to +10 K around the temperature where the thermostatic act
35、uator starts to switch from Recovery Mode to Non-Recovery Mode. The thermostatic actuator shall switch from Recovery Mode (fully closed) to Non-Recovery Mode (fully open) and back to Recovery Mode during the coolant temperature variation (= 1 cycle). 4.2.2.1.3 Run the required number of cycles at th
36、e exhaust gas temperature specified in the thermostatic actuator durability section of the EGHR-SSTS. 4.2.2.1.4 Perform a leakage test according to GMW15261 without heat treatment at end of the test. 4.2.2.2 Electrical or Vacuum Actuator Gas Temperature Variation. 4.2.2.2.1 The test conditions for n
37、on-thermostatic actuators are described in the appropriate actuator durability section of the EGHR-SSTS. 4.2.2.2.2 Set the coolant volume flow to 25 l/minute at the coolant inlet temperature of the EGHR as specified by the EGHR-SSTS. Set the exhaust gas mass flow and temperature to the values given
38、by the EGHR-SSTS. See Figure 2 for details of the test setup. Figure 2: Gas Temperature Variation Test Setup 1 EGHR Test Sample 2 Hot Gas Source (Fuel Burner) 3 Coolant Loop Control Unit 4 Fresh air blower 5 Valve to switch between exhaust gas and fresh air 4.2.2.2.3 Run the required number of actua
39、tor cycles for electrical or vacuum operated actuators which are specified in the actuator durability section of the EGHR-SSTS. 4.2.2.2.4 When the EHGR housing temperature has reached the maximum value specified by the EGHR-SSTS, switch the test setup from hot exhaust gas to fresh air at (+23 5) C w
40、ith the same mass flow like the exhaust gas. Stay in the fresh air position until the minimum EGHR housing temperature given by the EGHR-SSTS has been reached and switch back to the exhaust gas position. 4.2.2.2.5 Monitor and record the actuator temperature during the whole test. 4.2.2.2.6 Perform a
41、 leakage test according to GMW15261 without heat treatment at end of the test. 4.2.2.3 Exhaust Gas Mass Flow Variation. This test shall only be performed if an override function by exhaust gas mass flow (passive override) is implemented. 4.2.2.3.1 Set the coolant volume flow to 25 l/minute at +40 C
42、at the coolant inlet of the EGHR to prevent a switching of the mode by coolant temperature. Vary the exhaust gas mass flow from -50 kg/h to +50 kg/h (-14 g/s to +14 g/s) around the point where the override mechanism starts to switch from Recovery Mode to Non-Recovery Mode. This value is defined by t
43、he EGHR-SSTS. 4.2.2.3.2 Run the test at the exhaust gas temperature specified by the EGHR-SSTS for the “Parasitic Heat Rejection” conditions. The required number of cycles for the override mechanism is specified in the actuator durability section of Appendix C3 of the Exhaust SSTS. Copyright General
44、 Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16633 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 5 of 9 4.2.3 Acceptance R
45、equirements. x No jamming of actuator or mode switch mechanism during or at the end of the test. x The EGHR test sample shall fulfill the exhaust gas leakage requirements of the EGHR-SSTS. x The actuator temperature shall not exceed the maximum value specified by the EGHR-SSTS. Note: This requiremen
46、t only applies for non-thermostatic actuators. x An implemented passive override mechanism shall open at the exhaust gas mass flow within a range of 3 % specified the EGHR-SSTS at the end of the test. 4.3 Operating Durability with Vibration. The EGHR shall be functional at high vibration impact when
47、 the actuator switches the mode under gas pressure. 4.3.1 Preparation. 4.3.1.1 Set up the EGHR sample on a test bench which contains the following components: x An air blower capable to deliver fresh air at (+23 5) C with a mass flow of 180 kg/h (50 g/s). x A controllable coolant loop capable to del
48、iver a minimum coolant flow of 25 l/minute at +100 C. The coolant shall be a mixture of 60 % water and 40 % antifreeze according to GM6277M. x An electromagnetic or hydraulic shaker with a minimum acceleration of 8 G (78.5 m/s) and a minimum frequency of 200 Hz. 4.3.1.2 For EGHRs with an electrical
49、or vacuum operated actuator the following additional equipment is necessary: x A control device capable to switch the actuator automatically between “Non-Recovery Mode” and “Recovery Mode”. A full actuator cycle (switching from “Non-Recovery Mode” to “Recovery Mode” and back to “Non-Recovery Mode”) shall be completed within three (3) seconds. Install the EGHR sample on the shaker and connect it with the coolant loop and the h
