GMW GMW15575-2013 General Specification for Vehicular Horns Issue 1 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW15575 General Specification for Vehicular Horns Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 1 of 38 Contents 1 Introduction. 5 1.1 Scope. 5 1.2 Mission/Theme. . 5 1.3 Classification. 5 2 References . 5 2.1 Externa

2、l Standards/Specifications. 5 2.2 GM Standards/Specifications. . 5 2.3 Additional References. 5 3 Test Preparation and Evaluation 6 3.1 Resources. 6 3.1.1 Calibration . 6 3.1.2 Alternatives. 6 3.1.3 Facilities 6 3.1.4 Equipment. 6 3.1.5 Test Vehicle/Test Piece. . 6 3.1.6 Test Time. . 6 3.1.7 Test Re

3、quired Information. . 6 3.1.8 Personnel/Skills. . 7 3.2 Preparation 7 3.3 Conditions. . 7 3.3.1 Environmental Conditions. 7 3.3.2 Test Conditions. 7 3.4 Instructions 7 3.5 Data . 7 3.6 Safety. 7 3.7 Documentation. . 7 3.7.1 Test Results. . 7 4 Requirements and Procedure 7 4.1 Regulatory Requirements

4、. . 7 4.1.1 United States. . 7 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 GMW15575 Copyright 2013 General Motors Company All Rights Res

5、erved June 2013 Page 2 of 38 4.1.2 Canada. 8 4.1.3 Europe, China, Indonesia, Confederation of Independent States (formerly Russia). 8 4.1.4 Japan. . 8 4.1.5 Gulf States. . 8 4.1.6 Brazil. 8 4.1.7 Taiwan 8 4.1.8 India. . 8 4.1.9 Republic of Korea . 8 4.2 Part Drawing Requirements. . 8 4.3 Pre-Release

6、 Requirements. 8 4.3.1 Design Failure Mode Effects Analysis (DFMEA). . 8 4.3.2 Process Failure Mode Effects Analysis (PFMEA) 8 4.3.3 Process Control Plan. . 8 4.4 Test Sample Performance and Failure Determination. . 9 4.5 Test Sample Size, Selection, Allocation, Identification and Disposition. . 9 4

7、.5.1 Test Sample Size. . 9 4.5.2 Test Sample Selection 9 4.5.3 Test Sample Allocation. 9 4.5.4 Test Sample Identification. . 9 4.5.5 Test Sample Disposition. 9 4.6 Functionality. . 9 4.7 Life Expectancy. 9 4.7.1 Electrical-Mechanical Horn Life Expectancy. . 9 4.7.2 Electronic Horn Life Expectancy. 1

8、0 4.8 Appearance. 10 4.9 Mechanical Requirements. 10 4.9.1 Mounting Orientation. 10 4.9.2 Mounting Torque. 10 4.9.3 Materials. 10 4.9.4 Bracket Attachment to Horn. . 10 4.9.5 Identification. . 10 4.9.6 Recyclability/Recoverability. . 10 4.10 Electrical and Audible Requirements. . 10 4.10.1 Polarity.

9、 10 4.10.2 Voltage Range. 10 4.10.3 Recommended Fusing and Wiring. 10 4.10.4 Terminations. . 11 4.10.5 Current Draw. 11 4.10.6 Readiness. 11 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license

10、 from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15575 Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 3 of 38 4.10.7 Parasitic Load. 11 4.10.8 Connection Sequence. . 11 4.10.9 Insulation Resistance. . 11 4.10.10 Electromagnetic Compatibility. . 11 4.10.11 Fundamental Fre

11、quency. 12 4.10.12 Sound Pressure Level and Harmonic Frequency Content. 12 4.10.13 Variability. . 12 4.10.14 Adjustments. . 12 4.11 Mechanical Validation Test Requirements. 12 4.11.1 Noise and Rattles. 12 4.11.2 Vibration. . 12 4.11.3 Shock. . 15 4.11.4 Drop. 15 4.11.5 Free Fall. . 15 4.12 Climatic.

12、 . 15 4.12.1 Temperature. 15 4.12.2 Low Temperature Wakeup. . 16 4.12.3 Seven (7) Point Functional Check. 17 4.12.4 High Temperature Degradation Electronic Horn Only. . 18 4.12.5 Thermal Shock. . 18 4.12.6 Humidity 20 4.12.7 Corrosion. . 22 4.12.8 Dust. 22 4.12.9 Frost. . 22 4.12.10 Water Impingemen

13、t. 23 4.12.11 Water Immersion. 23 4.12.12 Altitude. . 24 4.12.13 Dimensional. . 24 4.13 Additional Electrical Tests Electronic Horn 24 4.13.1 Battery Voltage Dropout Test. 24 4.13.2 Sinusoidal and Pulse Superimposed Test. . 25 4.13.3 Reverse Polarity. . 25 4.13.4 Overvoltage . 25 4.14 Horn Connector

14、 Test Requirements. . 26 4.14.1 Terminal Push-out Force. . 26 4.14.2 Connector Engagement Force. . 26 4.14.3 Locked Connector Disengage Force. . 26 4.14.4 Unlocked Connector Disengagement Force. 26 4.14.5 Connector Installation Abuse, Side Force. . 26 Copyright General Motors Company Provided by IHS

15、 under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15575 Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 4 of 38 4.15 Contaminants. . 27 4.16 Reliability/Durabilit

16、y Requirements. . 27 4.16.1 Combined Environmental Reliability Test (CERT). . 27 4.16.2 Durability Requirements. 28 4.16.3 Continuous Blow Requirements. 28 4.17 Serviceability and Service Parts Requirements. . 28 4.18 Quality Assurance. 28 4.18.1 Quality Assurance Requirements. 28 4.18.2 Process Con

17、trol. . 28 4.18.3 Reliability Re-Certification. 28 4.18.4 Quality Control Audits. 29 4.18.5 Audit Test Failures. . 29 4.18.6 Audit Documentation. . 29 5 Provisions for Shipping 29 5.1 Shipping . 29 5.2 Packaging. . 29 5.3 Lot Control. 29 6 Notes 29 6.1 Glossary. 29 6.2 Acronyms, Abbreviations, and S

18、ymbols. . 30 7 Additional Paragraphs 31 7.1 All parts or systems supplied to this specification must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. . 31 8 Coding System . 31 9 Release and Revisions 31 Appendix A 32 A1.1 Severe Usage Regions. 32 A1.1.1 Backgr

19、ound. . 32 A1.1.2 Observations. . 32 A1.1.3 Electrical, Mechanical and Audible Requirements. 32 Appendix B 33 Appendix C 35 Appendix D 37 D1 GMW15575 Horn Test Plan Report 37 D1.1 Instructions. . 38 D1.2 Report Outline. 38 Copyright General Motors Company Provided by IHS under license with General M

20、otors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15575 Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 5 of 38 1 Introduction Note: Nothing in this specification supercedes applicable laws a

21、nd regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This specification covers the requirements for horns for installation in General Motors Company (GM) vehicles. This document should be referenced on, and i

22、s thus an extension of engineering parts drawings covering these products. 1.2 Mission/Theme. The horn subsystem is required on all vehicles. Its purpose includes one or more of the following: An alerting device to be used by the operator of the vehicle to alert persons outside the vehicle to the ve

23、hicles position or motion. An annunciating device to inform the operator of the vehicle to some condition, or change of condition of the vehicle, e.g., alarm enabled. An alerting device for the purpose of warning away intruders, or for providing an audible vehicle locator. Although not a primary mis

24、sion of the horn, it is recognized that it is also used as a celebratory noise maker, e.g., parades, wedding processions, and should be capable of not being damaged by a reasonable amount of such usage. An alarm device for an anti-theft system. 1.3 Classification. Electrical-Mechanical and Electroni

25、c classes of horns are covered by this specification. Acoustic amplification may be provided by a trumpet-type projector, whether straight or curved. Unless otherwise specified, the requirements of this specification apply equally to horns of both classes. This specification does not cover horn or h

26、orn assemblies that use air, or compressed air, to generate the sound, except by specific reference from another document. Paragraph 6.1 Glossary has horn definitions. Note: The horn is not a safety device. It is not so classified in any known regulation, world-wide. The horn is a sound signaling de

27、vice. It is often referred to as a “warning“ device, but in the context alerting people around the vehicle, as described in Paragraph 1.2 Mission/Theme. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. AIAG DFMEA

28、GB 15742-2001 ISO 16750-2 USCAR 150-S-003-1-C01 AIAG PFMEA GSO 99 ISO 16750-4 AIAG PPAP IEC 60068-2-1 ISO TS/16949 CONTRAN 35/98 IEC 60068-2-27 KMVSS 53 ECE R28 IEC 60068-2-30 KNVCA 38 EEC 70/388 IEC 60068-2-38 SAE J377 FMVSS 302 IEC 60068-2-64 USCAR 150-S-002-1-A01 2.2 GM Standards/Specifications.

29、GMW3059 GMW3103 GMW3431 GMW15725 GMW3091 GMW3116 GMW14872 GMW3097 GMW3191 GMW15357 2.3 Additional References. GP10 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

30、 ENGINEERING STANDARDS GMW15575 Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 6 of 38 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2 Altern

31、atives. Alternative test facilities and equipment may also be used. However, all measuring variables, as specified in this specification, shall be determined correctly with respect to their physical definition. 3.1.3 Facilities. All data based on laboratory testing shall be from a laboratory accredi

32、ted to GM standards. See General Procedure (GP) 10 in Paragraph 2.3 Additional References. Documents verifying accreditation shall be available for inspection. 3.1.4 Equipment. When not otherwise specified, the test equipment requirements of SAE J377 4.1.1 On-Vehicle Test Equipment Defaults and 4.2.

33、1 Component Level Test Equipment Defaults shall be used. 3.1.5 Test Vehicle/Test Piece. 3.1.5.1 Production Part Approval. The Production Part Approval Process (PPAP) shall be completed in accordance with and in the format prescribed by the joint industry standard, PPAP, published by Automotive Indus

34、try Action Group (AIAG), or its successor document. The default submission level shall be used unless otherwise specified by the purchasing documents. 3.1.5.1.1 Part Approval Submission. Where sample submission is required for appearance or dimensional verification, GM sample submission procedures a

35、s outlined in the AIAG PPAP or subsequent publications shall be followed. 3.1.5.1.2 Visual Inspection and Dissection. The part shall be visually inspected for defects in appearance, manufacture, or assembly. Rattles, tightness of attachments, smoothness of operation, and workmanship shall be include

36、d in the inspection. Dimensions, mass, and finishes as specified in this specification and the applicable GM drawings are to be checked. Refer to Paragraph 4.12.13 Dimensional. 3.1.6 Test Time. 3.1.6.1 Electrical Mechanical Horn Calendar time: 67 days Test hours: 1150 hours Coordination hours: 24 ho

37、urs 3.1.6.2 Electronic Horn Calendar time: 86 days Test hours: 1466 hours Coordination hours: 24 hours 3.1.7 Test Required Information. 3.1.7.1 Development Tests. Development tests are tests used to evaluate specific areas of design. They are a tool for evaluating original designs, design alternativ

38、es, proposed improvements, cost reduction proposals, or for field problem analysis. Development tests may be severe. Development tests often accelerate testing by exaggerating specific environments. Failures under a development test are expected. Such failure does not necessarily indicate inadequacy

39、 of design. Any failures must, however, be evaluated and the results and any actions documented. 3.1.7.2 Validation Tests. All horns must be validated at the component and system levels prior to their release for vehicle level testing. Validation tests are those tests required to demonstrate that th

40、e horn or horn system can meet the requirements of Section 4 for the life of the horn. These component validation, or design release tests, must be satisfactorily completed before authorization for start of production and before quantities are made exhibiting a GM logo or part number. Copyright Gene

41、ral 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 GMW15575 Copyright 2013 General Motors Company All Rights Reserved June 2013 Page 7 of 38 3.1.7.3 Reliabil

42、ity/Durability Tests. Sample sizes, specification parameters to be monitored, and test sequence shall be determined by the test plan developed under Paragraph 4.3.5 Mandatory Detailed Test Plan. Where new parts differ from parts previously tested and fully qualified under this specification, by deta

43、ils that affect only styling, re-testing may be waived by the purchase agreements. 3.1.7.4 Test Content and Sequence. Figure B1 Test Matrix for Electrical-Mechanical Horn and Figure B2 Test Matrix for Electronic Horn, in Appendix B, gives the sample size and test sequence to be used for validation.

44、Where basic horns are validated as separate items, the test schedule for assemblies consisting of those validated basic horns together with brackets and/or jumper harnesses may be abbreviated by the GM Development/Validation Engineer to include only those parameters related to the added bracket(s) a

45、nd/or harness(es). 3.1.8 Personnel/Skills. General familiarity with laboratory equipment, e.g., electrical measurement equipment, like voltage and resistance meters, hot/cold chambers, etc. Familiarity with sound pressure measuring equipment. 3.2 Preparation. As specified by the required tests. 3.3

46、Conditions. 3.3.1 Environmental Conditions. When not otherwise specified, the test environment of SAE J377 4.1.2 On-Vehicle Test Environment Defaults, and 4.2.2 Component Level Test Environment Defaults shall be used. 3.3.2 Test Conditions. Deviations from the requirements of this specification shal

47、l have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.4 Instructions. All tests must be accomplished in accordance with the procedures and methods outlined in this or referenced documents unless otherwise specified. Specific forms sha

48、ll be used where required. 3.5 Data. All original data shall be retained with the master file copy of any final laboratory or test report. Comments, if included, are to be based on fact, and should not include opinions. 3.6 Safety. This specification may involve hazardous materials, operations, and

49、equipment. This specification does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this specification 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 specification shall be tested fo