GMKOREA EDS-T-5204-2008 ALTERNATOR.pdf

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1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards ALTERNATOR Do Not Use on New Programs. Being Replaced by GMW14036 EDS-T-5204 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8(Superceded) ALTERNATOR EDS-T-5204PAGE: 1/10 ISSUED DATE: 1990. 04. 24 REVISE

2、D DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW14036 1. PURPOSE This standard applies to alternating current generators (hereinafter called “alte

3、rnator“) to be used for GMDAT and aims at helping test personnel easily grasp and correctly conduct alternator test. 2. SCOPE This standard applies to alternators for 12V gasoline engine (with IC regulator) and those for diesel engines with an vacuum pump. When this standard is at odds with that of

4、drawing, the latter prevails. 3. INDICATING METHOD OF CAPACITY 3.1. Alternator output Its nominal output shall be the electric current value based on output mode of vehicle alternator. 3.2. Vacuum pump The vacuum pump shall be the one directly mounted to the back of an alternator. The theoretical ou

5、tput of alternator per rotation shall be the vacuum pump capacity. 4. APPEARANCE The appearance of alternators shall conform to drawings. 5. STRUCTURE AND DIMENSIONS 5.1. The alternator shall be of a structure that will ensure proper performance and prevent damage by intrusion of metal scraps throug

6、h cooling vents. 5.2. Its structure and dimensions shall conform to drawings. 6. TEST METHOD This test method shall conform to drawings and the SI Unit shall be used for measurement. 6.1. Performance test (See Fig 1) 6.1.1. As shown in the Appendix 1, install the alternator properly inside a bench w

7、hose temperature can be adjusted along with the velocity modulator and load resistance to measure the output current. 6.1.2. With the switch set to a proper position, set the alternator inlet air temperature and rpm to specific values and vary the load to fix the output voltage Vg according to DWG.

8、ALTERNATOR EDS-T-5204PAGE: 2/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology 6.1.3. When the output current values measured every 5 minute are the same for three times consecutively, the system is considered stabilized. Then determine this value as the

9、final output current. 6.1.4. Measure the output current for a specific time and plot the output curve. 6.1.5. The voltage drop in the cable between the alternator B+ terminal and the battery B+ terminal shall not exceed 0.6 V. 6.1.6. When the sensor terminal of the regulator is used, the voltage dro

10、p in the cable between the sensor line branch and battery B+ terminal shall not exceed 0.2 V. 6.1.7. The standard for temperature around ALT shall be the point 25mm away from SRE(supping end) cover. 6.2. Cold performance test 6.2.1. Ambient temperature : Perform the test in unstabilized condition. 6

11、.2.2. Allowable shortage of output to characteristic curve in the drawing : to be above the characteristic curve in the drawing. 6.2.3. Output terminal voltage : according to DWG(Full on condition) 6.2.4. Measure the output current according to the designated voltage/rpm. 6.3. Normal temperature per

12、formance test 6.3.1. Ambient temperature : +23 5K 6.3.2. Allowable shortage of output to characteristic curve in the drawing : to be above the characteristic curve in the drawing. 6.3.3. Output terminal voltage : according to DWG (Full on condition) 6.3.4. Measure the output current according to the

13、 designated voltage/rpm. 6.4. High temperature performance test 6.4.1. +90 2K 1) Allowable shortage of output to characteristic curve in the drawing : to be above the characteristic curve in the drawing 2) Output terminal voltage : according to DWG (Full on condition) 3) Measure the output current a

14、ccording to the designated voltage/rpm. 6.4.2. +105 2K 1) Allowable shortage of output to characteristic curve in the drawing : to be -2 A above the characteristic curve in the drawing at a temperature of +90 2K 2) Output terminal voltage : according to DWG (Full on condition) 3) Measure the output

15、current according to the designated voltage/rpm. ALTERNATOR EDS-T-5204PAGE: 3/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology 6.5. Output current test (voltage regulation) 6.5.1. Temperature 1) Alternator speed : 6500 RPM 2) Load current : about 50% of

16、rated output current A 3) Temperature : -40 +105 4) The output voltage shall be within the temperature compensation range indicated in the drawing. 6.5.2. Speed 1) Alternator speed : 2000 10000 RPM 2) Load current : 15 A 3) Temperature : +23 5K 4) The output voltage change shall be within 0.1 V.- 6.

17、5.3. Load 1) Alternator speed : 6500 RPM 2) Load current : about 5 95% of rated output current A 3) Temperature : +23 5K 4) The test shall be completed within one minute and the output voltage shall be within 0.3 V. 6.5.4. MULTI-FUNCTION TEST 1) Shall be applied to MULTI FUNCTION applied ALTERNATOR

18、only. 2) Shall satisfy DWG by checking any disorder in FUNCTION by performing separate test about MULTI FUNCTION specified in DWG. 7. ENVIRONMENT AND DURABILITY TEST 7.1. Humidity test 7.1.1. Connect all terminals of the alternator properly and fix the rotating axis. 7.1.2. Test time : 240 hours 7.1

19、.3. Test cycle 1) Raise test temperature and humidity to above +70 2K and 95% respectively within 2 hours. 2) Keep the above state (clause 7.1.3.1) for 6 hours. 3) While keeping test humidity at above 85%, lower temperature to below +27 for 16 hours. 7.1.4. Repeat the above cycle (clause 7.1.3) 10 t

20、imes. 7.1.5. Surface humidity of the alternator may be removed after test. 7.1.6. Perform performance test in clause 6.3 / 6.4 The resulting curve shall be above the output curve in the drawing. ALTERNATOR EDS-T-5204PAGE: 4/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO

21、 Auto & Technology 7.2. Shock test 7.2.1. Drop shock 1) Install a 50mm-thick plywood on the concrete or steel plate. 2) Drop the alternator from height of 300mm. 3) Repeat test for all sides of the alternator requiring test. 7.2.2. Bench shock : (See Fig 2) 1) Make the bench as in the Appendix 2 wit

22、h hard wood 2) Make a pivot at an edge of the bench 3) Fix one side of the alternator to the pivot 4) Raise the opposite side to make an angle of 45。and then drop it. 5) Repeat test for all sides of the alternator requiring test. 7.2.3. There shall be no external harmful defects after test. After pe

23、rformance test in clause 6.3 / 6.4, the result shall be above the output curve in the drawing. 7.3. Salt spray test 7.3.1. Connect all terminals of the alternator properly and fix the rotating axis. 7.3.2. Test time : 168 hours 7.3.3. Test temperature : +35 7.3.4. Salt content : 5% salt spray 7.3.5.

24、 Within one hour after the above test, rotate it at 6500 RPM for 10 minutes. 7.3.6. There shall be no external harmful defects within 24 hours after test. After performance test in clause 6.3 / 6.4 the result shall be above 90% of the output curve in the drawing. 7.4. MUDDY WATER SPLASH TEST 7.4.1.

25、Connect all terminals of the alternator properly and flow the current. 7.4.2. Test time : 30 hours 7.4.3. Test temperature : +70 2K 7.4.4. Test condition : according to Fig 3 7.4.5. Dust condition : 0.3%NaCl and 5% CLAY 7.4.6. After performance test in clause 6.3 / 6.4 the result shall be above the

26、output curve in the drawing. 7.5. Vibration test 7.5.1. Test temperature : ambient temperature ALTERNATOR EDS-T-5204PAGE: 5/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology 7.5.2. Test time : 100 hours 7.5.3. Apply vibration in one direction per time. 7.

27、5.4. Test time and frequency (X, Y, Z) Direction Time Frequency (Hz) Magnitude (G sqrd/Hz) Slope (dB/octave) Vertical 40 60 0.032 9.71 200 1.576 -108.61 220 0.050 -0.88 1000 0.032 Total spectral content = 10.6 Grms Horizontal 40 60 0.025 9.77 200 1.260 -132.02 220 0.019 -0.75 1000 0.013 Total spectr

28、al content = 8.7 Grms Axial 20 60 0.025 9.77 200 1.260 -132.02 220 0.019 -0.75 1000 0.013 Total spectral content = 8.7 Grms 7.5.5. There shall be no external harmful defects after test. After performance test in clause 6.3 / 6.4 the result shall be above 90% of the output curve in the drawing. 7.6.

29、Thermal cycle test 7.6.1. Cycle : 12000 RPM 8000 RPM 8000 RPM 12000 RPM 7.6.2. Cycle time : 20 seconds 7.6.3. Test time : 500 hours 7.6.4. Load current : 9095% of the rated output 7.6.5. Inlet air temperature cycle 1) Raise and lower temperature from -30 to +95 for an hour. 2) Cycle the ambient temp

30、erature from -30 or +95 once each hour insuring a minimum of three minutes of operation at each temperature extreme. 3) When temperature falls from 95 to -30, loading current shall be “0“. 7.6.6. There shall be no external harmful defects after test. After performance test in clause 6.3 / 6.4 the re

31、sult shall be above 90% of the output curve in the drawing. ALTERNATOR EDS-T-5204PAGE: 6/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology 7.7. Hot dwell test 7.7.1. Test temperature : 105 7.7.2. Alternator speed : 2500 3500 RPM 7.7.3. Loading current : 9

32、095% of rated current 7.7.4. Test time : 500 hours 7.7.5. There shall be no external harmful defects after test. After performance test in clause 6. the result shall be above 90% of the output curve in the drawing. 7.8. Noise test : (See Fig 4) 7.8.1. Stabilization 1) Stabilize the alternator at 300

33、0 rpm and 20A for 5 minutes. 2) Noise level of the driving part shall not exceed 50 dB. 7.8.2. Test method and spec. 1) RPM : 1000 15000 RPM 2) Load (A) : Full on condition load 3) Measure position : According to Fig 4 4) Development target (1) OVERALL LEVEL NOISE : 72dB Max.(1000 5000 RPM : peak le

34、vel 3dB PERMIT) 105Db Max.(15000 RPM) (2) MAX ORDER LEVEL NOISE : 70dB Max.(1000 6000 RPM) 88dB Max.( 15000 RPM) (3) The above development target is applied to component development. Mass production specification is separately established and managed by DWG considering the mass production character

35、and quality. Alternator Noise Target020406080100120100020003000400050006000700080009000100001100012000130001400015000Alternator Speed (rpm)SPL(dB)OverallMax. OrderALTERNATOR EDS-T-5204PAGE: 7/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology 7.9. High spe

36、ed acceleration test 7.9.1. Test temperature : normal temperature 7.9.2. Cycle : 18000 RPM 15000 RPM 15000 RPM 18000 RPM 7.9.3. Acceleration/deceleration rpm : 3000 5000 RPM 7.9.4. Cycle time : 15 seconds 7.9.5. Test time : 500 hours 7.9.6. Loading current : 9095% of rated current 7.9.7. There shall

37、 be no external harmful defects after test. After performance test in clause 6.3 / 6.4 the result shall be above 90% of the output curve in the drawing. 7.10. Total endurance 7.10.1. Test temperature : 85 105 7.10.2. Test temp : 500 hours 7.10.3. Test condition : According to Fig 5 7.10.4. There sha

38、ll be no external harmful defects after test. After performance test in clause 6.3 / 6.4 the result shall be above 90% of the output curve in the drawing. 7.11. EMC test After the performance test, conduct test according to EDS-5010, EDS-T-5011, EDS-T-5511, and EDS-T-5512, ALTERNATOR EDS-T-5204PAGE:

39、 8/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology No TEST ITEM TEST SAMPLE # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 261 PERFORMANCE 2 REGULATION 3 MUDDY WATER SPLASH 4 THERMAL CYCLE 5 HOT DWELL 6 H.S.A 7 TOTAL ENDURANCE 8 HUM

40、IDITY 9 SHOCK 10 SALT SPRAY 11 VIBRATION 12 NOISE 13 EMC 14 PERF. AFTER TEST Fig 1 ALTERNATOR EDS-T-5204PAGE: 9/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology Fig 2 Fig 3 3000rpmRPM RPM SPEED /TIME Min.Min.Min. Min. Sec.Load Load ALTERNATOR EDS-T-5204PAGE: 10/10 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 27 VERSION: 8 GM DAEWOO Auto & Technology Fig 4 Fig 5 2 Sec.1 Sec.1 Sec.11 Sec.3 Min. 3 Min. 1.5 Min. 1.5 Min. 1 Min.1 Min.