GMW GMW14789-2012 Fixed Piston Air Conditioning Compressor Issue 2 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW14789 Fixed Piston Air Conditioning Compressor Copyright 2012 General Motors Company All Rights Reserved May 2012 Originating Department: North American Engineering Standards Page 1 of 25 1 Introduction Note: Nothing in this standard superced

2、es applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. Note: Unless otherwise stated as gage (G), pressures listed within the specification are absolute. 1.1 Scope. This specification establishes the m

3、inimum requirements for the air conditioning compressor to be used with refrigerant R134a unless otherwise specified. The functions, performance, reliability, and validation required of any compressor are defined in this document. This specification is for fixed piston compressors. All requirements

4、of this specification must be met in order to demonstrate design and production validation. 1.2 Mission/Theme. The compressor assembly accepts low pressure, low temperature refrigerant at an inlet port, compresses this refrigerant by a variety of mechanisms, and exhausts a high temperature, high pre

5、ssure refrigerant at an outlet port. Power to drive the compressor is supplied by a separate power source, such as the vehicle power plant. The compressor assembly must conform to all requirements in this specification, as well as, the approved engineering drawings. 1.3 Classification. Not applicabl

6、e. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASHRAE Standard 97 ASTM D1474-98 JIS Z8732 SAE/USCAR-2 ANSI S12.54 ISO 3744 JIS Z8733 ANSI S12.55 ISO 3745 SAE J639 2.2 GM Standards/Specifications. GMW3059 GMW3

7、191 GMW14477 GMW15760 GMW3097 GMW8758 GMW14483 GMW16044 GMW3103 GMW14156 GMW14872 GMW16241 GMW3116 GMW14157 GMW15272 GMW16290 GMW3172 GMW14264 GMW15758 2.3 Additional References. 52457600 Shipping Cap 52465700 Shipping Cap 52477000 Drawing 9986181 CG2051 GM1829 GM Best Practice HVACPTC-122 GM Best P

8、ractice HVACPTC-125 Note: The supplier shall work with the GM Design Release Engineer to comprehend these requirements. GM Part Number 12348526 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without lice

9、nse from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14789 Copyright 2012 General Motors Company All Rights Reserved May 2012 Page 2 of 25 GM Part Number 13505427 Statement of Requirements (SOR) Appendix B and Appendix C2 Subsystem Technical Specification (SSTS) Tyco Electronics 1-1703498-3 Tyco E

10、lectronics 963142-2 Tyco Electronics 967067-1 Tyco Electronics 1718760-3 Tyco Electronics 1718762-3 Vehicle Technical Specification (VTS) 3 Requirements 3.1 System/Subsystem/Component/Part Definition. 3.1.1 Appearance. 3.1.1.1 Color and Finish. Typical appearance is compressor body with a natural al

11、uminum finish and the clutch with a low gloss black finish to match with other underhood components. Deviations from this are permissible, but must be approved by the releasing GM engineering group. 3.1.2 Content. The following paragraphs specify the requirements for the physical and functional cont

12、ent of the Air Conditioning (A/C) compressor. 3.1.2.1 Physical Content. The physical content of the compressor includes the following: Inlet Port (Suction) Outlet Port (Discharge) Clutch/Pulley/Thermal Fuse Mounting Provisions High Pressure Relief Device Electrical Connector for Clutch High Temperat

13、ure Cut-out Switch (optional) High Pressure Cut-out Switch (optional) High Side Low-pressure Switch (optional) Shipping Caps Lubricant Thermal Protection Switch (TPS) 3.1.2.2 Functional Content. The A/C compressor is to provide the following functions: 3.1.2.2.1 The compressor circulates refrigerant

14、 in the A/C system. 3.1.2.2.2 The compressor affects pressure out of the evaporator. 3.1.2.2.3 The compressor provides high pressure and high temperature gas to the condenser. 3.1.2.2.4 High Pressure Relief Valve (HPRV). The compressor shall provide provisions for a high pressure relief device that

15、complies with SAE J639. 3.1.2.2.4.1 High Pressure Relief Valve Location. The pressure relief valve design and location must follow GM Best Practice HVACPTC-125: Location of the compressor high pressure relief valve. 3.1.3 Ambient Environment. The electrical components contained on the A/C compressor

16、 shall be able to withstand ambient air temperatures from -40 C to +125 C, with intermittent temperature requirements of +150 C for up to one hour of run time. The A/C compressor shall be able to withstand humidity of up to 100% within a 25 mm envelope around the compressor body and clutch without d

17、amage to function or appearance. As required, part or all, of the compressor may be used as a fixture device for component testing. Test according to GMW3172 with mounting location at the engine with high temperature load. Electrical Load Code Letter C Mechanical Load Code Letter A Copyright General

18、 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 GMW14789 Copyright 2012 General Motors Company All Rights Reserved May 2012 Page 3 of 25 Operating Temperatur

19、e Code Letter H Climatic Loads Code Letter B Chemical Loads Code Letter E Dust and Water Protection IP6K8 3.1.4 Interfaces. Not applicable. 3.1.5 Usage Definition. Not applicable. 3.2 Product Characteristics. 3.2.1 Performance Requirements. The paragraphs in this section specify the functional requi

20、rements for the A/C compressor. Data shall be submitted on compressors run sequentially through these performance tests for validation purposes at each stage of development. 3.2.1.1 Fixed Value Performance Tests. 3.2.1.1.1 Minimum Capacity and Coefficient of Performance (COP). Minimum requirements a

21、re defined in Table 1. Variation in random samples taken from production shall not exceed 10% total. Coefficient of Performance is defined as the capacity divided by the mechanical power consumption. Table 1: Capacity and COP Requirements Note Suction Pressure Discharge Pressure Capacity Type A Capa

22、city Type B Capacity Type C COP Type A COP Type B COP Type C rpm kPa kPa kW kW kW Idle Capacity 800 500 2000 4.2 5.6 6.6 2.5 2.3 2.1 Stable Capacity 2000 280 1600 5.3 6.6 7.9 2.2 2.0 1.8 Note: Compressor capacity Type (A, B, C) clarification for a given compressor is found in Appendix C2 (CTS except

23、ions document) or Appendix B (General Program Description) of the SOR, and is to be later documented in the drawing/UG information. 3.2.1.1.2 Maximum and Minimum Speed Definition. 3.2.1.1.2.1 Maximum Continuous RPM. Maximum continuous speed is defined per the durability test specification at conditi

24、on 10 of Table A1 in Appendix A. The compressor must run a minimum of 10 h at this condition at 9200 rpm (all compressor types). 3.2.1.1.2.2 Maximum Excursion RPM. Maximum excursion speed is defined per the durability test specification at condition 11 of Table A1 in Appendix A. The compressor must

25、run a minimum of 10 minutes at this condition at 11 000 rpm (all compressor types). 3.2.1.1.2.3 Minimum RPM. The compressor shall be capable of running at a minimum speed of 575 compressor rpm. 3.2.1.1.3 Maximum Oil Circulation Amount Allowed. The compressor must be able to maintain all durability r

26、equirements with oil circulation amounts in the actual system not to exceed 1.5% in the range of 1000 compressor rpm to 4000 compressor rpm. 3.2.1.1.4 Compressor Discharge Temperature Compliance. All compressor component material properties must be compliant to a continuous discharge refrigerant tem

27、perature of +140 C and an excursion temperature of +160 C. Excursion is defined as maximum of 5 minutes intermittent for 100 occasions. 3.2.1.1.5 High Pressure Relief Valve Function. The opening pressure of the pressure relief valve shall be between 3430 kPaG to 4140 kPaG. The closing pressure of th

28、e pressure relief valve shall be greater than 2750 kPaG. In cases, where the pressure relief valve is not required (it will be noted as such on the print), the maximum operating pressure of the system shall be considered to be 4500 kPaG for purposes of determining the burst pressure requirement in 3

29、.2.1.1.7.3. 3.2.1.1.6 Noise/Vibration. (Stakeholders: 0C Noise and Vibration, 30 HVAC however, data shall be submitted demonstrating this compressor characteristic. 3.2.1.2.2.8 Vibration Test. There shall be no loss in mounting boss torque, no fracture or cracking of the compressor housing, no damag

30、e to the pulley bearing, no loss in torque of the compressor assembly bolts, and no internal damage to bearings or bearing surfaces. 3.2.1.2.2.9 Thermal Cycle. The compressor shall withstand a minimum of 10 thermal cycles as defined in paragraph 4.3.1.2.9 and meet the post test performance and leaka

31、ge requirements 3.2.1.1.7.1.1 and 3.2.1.1.7.1.2 respectively. 3.2.1.2.2.10 Oil Migration. The compressor shall not fail when started after being subjected to 100 cycles of the test matrix shown in Table 11. Failure is defined in paragraph 3.2.1.2.1, any abnormal wear that exceeds the wear seen on te

32、ardowns after the customer usage test or having an oil quantity that is less than the supplier bogie for a given design (default will be to use 25 g if nothing is available from the supplier). 3.2.1.2.2.11 Compressor Discharge Temperature. When subjected to the conditions of Table 7, the stabilized

33、compressor discharge temperature shall not exceed +140 C (or supplier agreed value). 3.2.1.2.2.12 Start-Stop Durability. The compressor shall meet paragraph 3.2.1.2.1 after subjected to the conditions defined in paragraph 4.3.1.2.11. 3.2.1.2.2.13 Reverse Torque Durability. The compressor shaft, clut

34、ch driver, and attachment method (typically a bolt) shall not fail when subjected to loads 35 Nm. 3.2.2 Physical Characteristics. The required physical characteristics for the A/C compressor are specified in the design layouts. 3.2.2.1 Dimensions and Capacity. Not applicable. 3.2.2.2 Mass Properties

35、. The limit for the compressor assembly with clutch and specified lubricant charge is as follows in Table 3: Table 3: Mass Properties Type Maximum Mass with Lubricant and Clutch Type A 5.5 kg Type B 6.0 kg Type C 6.5 kg 3.2.2.3 Shipping Gas Charge. (If Applicable). Transport gas and pressure shall b

36、e helium (He) or nitrogen (N) at 160 kPaG (maximum). This charge may be required based on moisture requirement. 3.2.2.4 Mounting Port Location. Ports shall be located such that with the compressor mounted in vehicle position, lubricant will not run out of compressor when shipping caps are removed. P

37、ort location shall abide by GM Best Practice HVACPTC-122. 3.2.2.5 Compressor Mounting Attachments. All mounting bosses or A/C port mounting must be designed as to not have failures due to torque until after the attachment bolt/nut has broken by its failure torque. Load values that are to be used in

38、Finite Element Analyses (FEA) and Validation confirmations: Maximum load for a M8 that will guarantee the bolt is the failure mechanism: 32 kN Maximum load for a M10 that will guarantee the bolt is the failure mechanism: 65 kN The supplier shall design the compressor to comprehend these loads withou

39、t failure in mounting attachment castings or leaks at the fittings. Bolt “walking” on slots is likewise unacceptable. Whenever possible, validation using the actual attachment bolt arrangement should take place. Fastener bolts should be torque to failure followed by a confirmation of no damage to th

40、e compressor. Impressions in the casting that do not impact the compressors functional performance or create Noise, Vibration Harshness (NVH) issues are acceptable (i.e., Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networ

41、king permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14789 Copyright 2012 General Motors Company All Rights Reserved May 2012 Page 8 of 25 witness marks in the aluminum from the bolt head). The failure numbers need to be recorded for each attachment. Ninety-five percent

42、(95%) of the failure value will be utilized in leak testing validation 3.2.1.1.7 3.2.3 Reliability. 3.2.3.1 Reliability Evaluation Point. This standard, as written, provides a test exposure representing a reliability evaluation point (REP) of 10 years and 240 000 km (150 000 miles) of severe custome

43、r usage at the vehicle level. 3.2.3.2 Reliability Requirements. This standard as written supports demonstration of the required reliability of 97.0% or greater at a 50% confidence (R97C50) at the REP for the A/C Compressor. The supplier shall utilize “vehicle equivalent” laboratory test setups to si

44、mulate “in vehicle” orientations. If the orientation may be different from vehicle to vehicle, use the orientation which will provide the worst case loads, for all physical level Reliability demonstration testing. Note: If this compressor requires a reliability value other than R97C50, a different D

45、esign Validation (DV) Endurance test schedule will be required and must be agreed to by the GM Validation Engineer. Changing the Reliability requirement will affect Table 6, which should be updated to new requirements. Reference GMW14156 and GMW14157. The Reliability Demonstration is provided by the

46、 DV Endurance Tests. In contrast to DV, the Endurance. Tests specified for Product Validation, are intended to confirm conformance to the reliability demonstrated during DV. 3.2.3.3 Accelerated Test Methods. GM encourages the use of appropriate Accelerated Test Methods, wherever possible; for exampl

47、e, the use of accelerated stress testing to reduce test time. Reference GMW8758. GM Validation Engineering shall review and accept Reliability demonstration test plans prior to the supplier submitting the Analysis Development Validation (ADV) Test Plan for approval. 3.2.3.4. Design Level Requirement

48、s. 3.2.3.4.1 Approval Requirements. Approval shall be provided by the GM Design Responsible Engineer and the GM Validation Engineer. 3.2.3.4.2 Documentation. All test samples must be qualified dimensionally. All data points must be reported. For samples destructively tested, mode of failure must be

49、reported. All test specimens must be retained by the supplier for 1 year and be available for review by the GM HVAC Global Technology Engineer, if requested. Test Procedures referencing specific minimum test values, must be met by the -3 limit of the sample population tested. GM will document this approval using MATSPC. 3.2.3.4.3 Design Validation. Reference GMW15758. 3.2.4 Serviceability. The paragraphs in this section define the constraints and