SAE J 2932-2017 Air Disc Brake Actuator Test Requirements.pdf

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1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this p

3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497

4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/J2932_201712 SURFACE VEHICLE RECOMMENDED PRACTICE J2932 DEC2017 Issued 2014-09 Revised 2017-12

5、Superseding J2932 SEP2014 Air Disc Brake Actuator Test Requirements RATIONALE This update is to include T18 and T1X/24 air disc brake actuators with a 57.1 mm (2.25 inch) rated stroke that are in the market place. Formerly these actuators were covered by SAE J1469 FEB 2009 and SAE J2318 NOV2008. How

6、ever, this document was updated to exclude air disc brake actuators which are direct caliper face mounted. (SAE J1469 FEB 2017 and beyond) Therefore this revision includes these sizes with the same stroke and test requirements from SAE J2318 NOV2008. TABLE OF CONTENTS 1. SCOPE 2 1.1 Purpose . 2 2. R

7、EFERENCES 2 2.1 Applicable Documents 2 2.1.1 SAE Publications . 2 2.1.2 U.S. Government Publications 2 2.1.3 DIN Publications 2 3. DEFINITIONS . 2 4. LEAK RATE - PARKING AND SERVICE CHAMBERS 2 5. RELEASE AND HOLD-OFF PRESSURE PARKING CHAMBER . 3 6. MINIMUM PRESSURE RESPONSE - SERVICE CHAMBERS . 3 Ta

8、ble 1 Leak rate parking chamber, service chamber and caliper flange seal . 3 Table 2 Diaphragm parking chamber force output stroke(1) (nominal forces given, tolerance 10%) . 4 Table 3 Service chamber force output stroke (for reference purposes only) 5 Table 4 Low temperature leak rate parking chambe

9、r and service chamber 5 SAE INTERNATIONAL J2932 DEC2017 Page 2 of 8 1. SCOPE This document provides test performance requirements for air disc brake actuators for service and combination service parking brake actuators with respect to function, durability and environmental performance when tested ac

10、cording to SAE J2902. 1.1 Purpose This SAE document provides recommended uniform minimum requirements for air disc brake actuators used in brake systems for truck, truck-tractor, bus and trailer applications. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this speci

11、fication to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA

12、), www.sae.org. SAE J2902 Air Disc Brake Actuator Test Procedure, Truck-Tractor, Bus and Trailer 2.1.2 U.S. Government Publications Copies of these documents are available online at http:/quicksearch.dla.mil. Federal Motor Vehicle Safety Standard 121 Air Brake Systems, 49 Code of Federal Regulations

13、 Parts 571.121. 2.1.3 DIN Publications Available from the Standardization Committee of Motor Vehicles (FAKRA) in the DIN German Institute for Standardization. DIN 74060-3 2002 Compressed Air Brakes, Pneumatic Cylinder, Part 3 Diaphragm Cylinder, Characteristic Data for Disc Brakes 3. DEFINITIONS 3.1

14、 Reference SAE J2902, Section 3. 4. LEAK RATE - PARKING AND SERVICE CHAMBERS 4.1 Reference SAE J2902 Test Procedure 4 SAE INTERNATIONAL J2932 DEC2017 Page 3 of 8 4.2 For allowable leak rate, see Table 1. Table 1 - Leak rate parking chamber, service chamber and caliper flange seal 5. RELEASE AND HOLD

15、-OFF PRESSURE PARKING CHAMBER 5.1 Reference SAE J2902 Test Procedure 5 5.2 Hold-off pressure (pressure decreasing) is typically measured at 5 mm (0.20 inch) stroke of the parking chamber from the actuator zero stroke position. A maximum target hold-off pressure of 483 kPa (70 psig) will in most appl

16、ications, ensure the brakes do not drag. This requirement may vary depending on a vehicle air brake system, which may allow higher hold-off pressure or require lower hold-off pressure. A low hold-off pressure is preferred to ensure brakes do not drag. 6. MINIMUM PRESSURE RESPONSE - SERVICE CHAMBERS

17、6.1 Reference SAE J2902 Test Procedure 6. 6.2 The response pressure is to be measured, recorded and made available upon customer request. 6.2.1 Measured response pressure shall be no greater than 0.34 bar (5 psig). Chamber Tested Maximum Allowable Leakage Rate (Calculated) Alternate Test Procedure M

18、aximum Allowable Pressure Change Applicable SAE J2902 Test Procedure Parking Chamber 23 cc/min (1.40 in3/min) 4.1.2 10.34 kPa (1.5 psig) 4.1.3 Service Chamber 23 cc/min (1.40 in3/min) 4.2.2 10.34 kPa (1.5 psig) 4.2.3 Caliper Flange Seal 0.7 kPa (0.1 psig) 4.3.2 SAE INTERNATIONAL J2932 DEC2017 Page 4

19、 of 8 7. FORCE OUTPUT AND STROKE PARKING AND SERVICE CHAMBERS 7.1 Parking Chamber, reference SAE J2902 Test Procedure 7.1. 7.1.1 Parking force output for the most common diaphragm actuated air disc brake parking chambers are given in Table 2 for reference purposes only. Force values given are nomina

20、l 10%. Various application differences may require other spring forces by size (type). Parking chamber force output is measured for a new complete combination actuator assembly after the power spring has been fully caged for 24 hours. Test procedures other than SAE J2902 may require the spring to be

21、 caged for a longer period. The forces given in Table 2 are only applicable to the test procedure in SAE J2902. Some parking chamber sizes may be offered with various parking forces to accommodate different applications and customer requirements; only the most common diaphragm parking chamber forces

22、 are given in Table 2. Table 2 - Diaphragm parking chamber force output stroke(1) (nominal forces given, tolerance 10%) Size Rated Stroke mm (Inches) Units 33% of Rated Stroke 90% of Rated Stroke Max Min Min 24 57.2 (2.25) N (lbf) 5413 (1217) 3975 (894) +1335 N (+300 lbf) 24 63.5(2.50) N (lbf) 5371

23、(1207) 3363 (756) 30 N (lbf) 6297 (1416) 4244 (954) (1) Table 2 For Reference Only 7.2 Service Chamber, reference SAE J2902 Test Procedure 7.2. 7.2.1 Service chamber force outputs versus stroke at applied air pressures are given in Table 3. SAE INTERNATIONAL J2932 DEC2017 Page 5 of 8 Table 3 - Servi

24、ce chamber force output stroke (for reference purposes only) Type/Size Nominal Rated Stroke mm (Inches) Nominal Force Pressure N (lbf) 1.38 bar (20 PSIG) 4.14 bar (60 PSIG) 6.59 bar (100 PSIG) 8.96 bar (130 PSIG) 10* 57.2 (2.25) 523 (118) 2182 (490) 3654 (821) 5076 (1141) 12 841 (189) 2856 642) 4857

25、 (1092) 6344 (1426) 14 865 (189) 3410 (767) 5820 (1309) 7598 (1708) 15* 897 (202) 3486 (784) 5785 (1300) 8012 (1801) 16 890 (200) 3963 (891) 6784 (1525) 8853 (1990) 18 1141 (257) 4219 (948) 6959 (1563) 9593 (2157) 18* 63.5 (2.50) 1141 (257) 4219 (948) 6959 (1563) 9593 (2157) 20 1323 (298) 4693 (1055

26、) 8082 (1817) 10644 (2393) 22 1507 (339) 5185 (1166) 8865 (1993) 11573 (2602) 24 1690 (380) 5677 (1276) 9648 (2169) 12501 (2810) 27* 1909 (429) 6524 (1467) 10621 (2388) 14591 (3280) 30 2235 (503) 7340 (1650) 12411 (2790) 16196 (3641) Max Tol: 33-90% Nom. Rated Stroke +10% +5% +5% +5% Min Tol: 33-67%

27、 Nom. Rated Stroke -15% -5% -5% -5% Min Tol: 90% Nom. Rated Stroke -30% -15% -15% -15% Minimum tolerance is a linear progression from the minimum value at 67% of nominal rated stroke to the minimum value at 90% of rated stroke. *These are considered in-between sizes and are not commonly used. Force

28、output values for these sizes are derived from German standard DIN 74060-3 2002. 8. LOW TEMPERATURE LEAKAGE - PARKING AND SERVICE CHAMBERS 8.1 Reference SAE J2902 Test Procedure 8. 8.2 Allowable leakage is shown in Table 4 for test performed at -40 C/F. Arctic leakage testing at -54 C 1 C (-65 F 2 F

29、) is an optional test and requirements shall be agreed to with the vehicle manufacture or customer. Table 4 - Low temperature leak rate parking chamber and service chamber Chamber Tested Maximum Allowable Leakage Rate (Calculated) Alternate Test Procedure Maximum Allowable Pressure Change Applicable

30、 SAE J2902 Test Procedure Parking Chamber 30 cc/min (1.83 in3/min) 8.1.2 13.79 kPa (2.0 psig) 8.1.3 Service Chamber 30 cc/min (1.83 in3/min) 8.2.2 13.79 kPa (2.0 psig) 8.2.3 SAE INTERNATIONAL J2932 DEC2017 Page 6 of 8 9. LOW TEMPERATURE MAX RELEASE AND HOLD-OFF - PARKING CHAMBER 9.1 Reference SAE J2

31、902 Test Procedure 9. 9.2 Optional test, only if required by vehicle manufacturer or customer, requirements same as Section 5. 10. LOW TEMPERATURE FORCE OUTPUT - PARKING CHAMBER 10.1 Reference SAE J2902 Test Procedure 10. 10.2 Optional test, only if required by vehicle manufacturer or customer, requ

32、irements same as 7.1. 11. LOW TEMPERATURE OPERATIONAL TESTS - SERVICE CHAMBER 11.1 Low Temperature Service Return Test 11.1.1 Reference SAE J2902 Test Procedure 11.1. 11.1.2 The service chamber diaphragm shall return to within 6.4 mm (0.25 inch) of zero stroke position within 60 seconds without assi

33、stance. 11.2 Low Temperature Minimum Response Test, Service Chamber 11.2.1 Reference SAE J2902 Test Procedure 11.2. 11.2.2 Same as Section 6. 11.3 Brittle failure check: Upon disassembly (after completion of Section 18 Vibration Test, Test Unit A) there shall be no evidence of cracking or brittle fa

34、ilure of the diaphragm or the caliper flange seal boot. 12. CHAMBER VOLUME - SERVICE CHAMBERS 12.1 Service Chamber, reference SAE J2902 Test Procedure 12.1. Service chamber volumes should be in compliance with Federal Motor Vehicle Safety Standard 121 section 5.1.2.1 for trucks and buses and section

35、 5.2.2.1 for trailers which references Table V “Brake Chamber Rated Volumes”. 13. CORROSION RESISTANCE - PARKING AND SERVICE CHAMBER 13.1 Reference SAE J2902 Test Procedure 13. 13.2 After assemblies have been air dried, they shall meet the following minimum requirements: 13.2.1 Output Force for a Pa

36、rking Chamber of a Combination Actuator, same as Section 7.1. 13.2.2 Leakage Parking Chamber: Same as Section 8, Table 4. 13.2.3 Leakage Service Chamber: Same as Section 8, Table 4. 13.2.4 Leakage Caliper Flange Pushrod Boot Seal: Same as Section 4, Table 1. 13.2.5 Mechanical Back-Off Release Mechan

37、ism: Same as Section 14. SAE INTERNATIONAL J2932 DEC2017 Page 7 of 8 14. MECHANICAL BACK-OFF RELEASE MECHANISM 14.1 Reference SAE J2902 Test Procedure 14.3. 14.2 The running torque of the release mechanism shall not be greater than 67,8 Nm (50 lb-ft) during the manual caging cycle (manual spring com

38、pression cycle) for the power spring for two applications. 14.3 No evidence of galling of the threads of any internal or external threaded parts is permitted. 15. ELEVATED TEMPERATURE CYCLE TEST PARKING AND SERVICE CHAMBERS 15.1 Parking Chamber, reference SAE J2902 Test Procedure 15.1. 15.1.1 Leakag

39、e Same as Section 8, Table 4. 15.2 Service Chamber, reference SAE J2902 Test Procedure 15.2. 15.2.1 Leakage Same as Section 8, Table 4. 15.3 There shall be no component failure. 16. CYCLE TEST - PARKING AND SERVICE CHAMBERS 16.1 Parking Chamber, reference SAE J2902 Test Procedure 16.1. 16.1.1 Test a

40、ssemblies must complete 200000 cycles. 16.1.2 After completion of cycle testing, the assemblies shall meet the following requirements: 16.1.2.1 Leakage Parking Chamber Same as Section 8, Table 4. 16.1.2.2 Force Output Record for reporting and reference only. 16.1.2.3 Maximum Release and Hold-Off Pre

41、ssure Same as Section 5. 16.1.2.4 There shall be no component failure. 16.2 Service Chamber, reference SAE J2902 Test Procedure 16.2. 16.2.1 Test assemblies must complete 1000 high pressure cycles and 1000000 durability cycles. 16.2.2 After completion of cycle testing, the assemblies shall meet the

42、following requirements: 16.2.2.1 Leakage Service Chamber Same as Section 8, Table 4. 16.2.2.2 Leakage Caliper Flange Seal Pushrod Boot Same as Section 4, Table 1. 16.2.2.3 There shall be no component failure. 17. PROOF PRESSURE TEST PARKING AND SERVICE CHAMBER 17.1 Parking Chamber, reference SAE J29

43、02 Test Procedure 17.1. 17.1.1 Leakage Same as Section 8, Table 4. SAE INTERNATIONAL J2932 DEC2017 Page 8 of 8 17.2 Service Chamber, reference SAE J2902 Test Procedure 17.2. 17.2.1 Leakage Same as Section 8, Table 4. 17.2.2 No structural failure is permitted in the assembly. 18. VIBRATION TEST 18.1

44、Reference SAE J2902 Test Procedure 18. 18.1.1 Parking Chamber 18.1.1.1 Leakage Same as Section 8, Table 4. 18.1.1.2 No structural failure as detected by a 10% change in output frequency is acceptable. 18.1.2 Service Chamber 18.1.3 Service brake actuator vibration testing is optional. Requirements fo

45、r service brake actuator vibration testing should be agreed to with the vehicle manufacturer or customer. 18.1.4 Service Chamber as a portion of a combination actuator. 18.1.4.1 Leakage Service Chamber Same as Section 8, Table 4. 18.1.4.2 Leakage Caliper Flange Seal Pushrod Boot Same as Section 4, T

46、able 1. 18.1.4.3 No structural failure as detected by a 10% change in output frequency is acceptable. 19. NOTES 19.1 Revision Indicator A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to

47、 the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE SAE TRUCK AND BUS BRAKE ACTUATOR COMMITTEE OF THE SAE TRUCK AND BUS BRAKE AND ADVANCED DRIVER ASSISTANCE STEERING COMMITTEE