GMW GMW16119-2013 Internal Heat Exchanger for Air Conditioning Systems Issue 4 English.pdf

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1、WORLDWIDEENGINEERINGSTANDARDSGeneral Specification GMW16119Internal Heat Exchanger for Air Conditioning Systems Copyright 2013 General Motors Company All Rights ReservedApril 2013 Page 1 of 191 IntroductionNote: Nothing in this standard supercedes applicable laws and regulations.Note: In the event o

2、f conflict between the English and domestic language, the English language shall takeprecedence.1.1 Scope. This standard establishes the minimum requirements for an internal heat exchanger (IHX)assembly to be used in R134a, GMW5038 and R1234yf, GMW16283 Air Conditioning (A/C) systems.1.1.1 Supplier

3、qualification shall be demonstrated for the IHX design before the supplier may bid on IHXbusiness. To obtain qualification, the suppliers IHX design shall meet all requirements of this specification andshall be approved by the General Motors Bill of Material (BOM) Family Owner (BFO).1.1.2 This stand

4、ard does not include the IHX validation requirements for: brazed/welded fittings, access ports,etc., (covered in GMW15787), Air Conditioning Refrigerant System Connections (covered in GMW15787),internal cleanliness (covered in GMW14319) or seal washers (covered in GMW15779). In addition, thisspecifi

5、cation does not include the validation requirements for larger assemblies containing an IHX. IHXproduction assembly parts shall be in accordance with metallic refrigerant lines GMW15773, and linescontaining elastomeric hose, or coupled hose assemblies shall fulfill GMW14319.1.2 Mission/Theme. The in

6、tent of this specification is to define the thermodynamic performance requirementsfor internal heat exchangers for use with R134a and R1234yf refrigerant.1.3 Classification. Not applicable.2 ReferencesNote: Only the latest approved standards are applicable unless otherwise specified.2.1 External Sta

7、ndards/Specifications.DIN 7716 ISO 130432.2 GM Standards/Specifications.9985752 GMW5038 GMW15773 GMW15787GMW3059 GMW14319 GMW15779 GMW16241GMW3116 GMW14655 GMW15786 GMW162833 Requirements3.1 System/Subsystem/Component/Part Definition. Not applicable.3.1.1 Appearance. Not applicable.3.1.2 Content.3.1

8、.2.1 Physical Content. A typical R134a or R1234yf internal heat exchanger assembly consists of a heatexchanger and line connectors (subassembly) or it is included as part of the body line set. This standardvalidates only the performance of the IHX design excluding terminations and/or transitions to

9、othercomponents (see paragraph 1.1 for related specifications).3.1.2.1.1 Liquid Refrigerant Volume. The IHX design shall have a minimized liquid volume to reduce theoverall amount of refrigerant in the (A/C) system.Copyright General Motors Company Provided by IHS under license with General Motors Co

10、mpanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16119 Copyright 2013 General Motors Company All Rights ReservedApril 2013 Page 2 of 19The maximal liquid volume for R1234yf refrigerant shall not exceed 35.5 cm3 for 500 mm c

11、enter line length ofthe liquid line as defined for IHX Type I (end blocks included) in Appendix A and for IHX Type II (IHX included)in Appendix B. No requirement is defined for an IHX for R-134a refrigerant.3.1.2.1.2 Type I: Coaxial Tube IHX. A coaxial tube IHX consists of the inner tube (suction li

12、ne) and the outertube, which contains the liquid refrigerant. Figure 1 shows the cross section of a typical coaxial tube IHXmanufactured by an extrusion process.Figure 1: Typical Coaxial IHX Profile3.1.2.1.2.1 Cross Section Deformation. The maximum allowed reduction of the cross section area bydefor

13、mation (e.g., bending) shall not exceed 20 % of the original area at minimum bend radius.3.1.2.1.2.2 Transitional End Blocks. The shape and size of the end blocks (feature used to separate coaxialconfiguration into separate liquid and suction pipes) is generally the suppliers design and shall be agr

14、eed to bythe BFO.3.1.2.1.3 Type II: Non-Coaxial Tube IHX. The design of a non-coaxial tube IHX shall allow the integration ofthe IHX in the vehicle body line without adding additional fittings or adding an additional amount of refrigerant(see paragraph 3.1.2.1.1) compared with a coaxial IHX. Figure

15、2 conceptually represents a non-coaxial tubeIHX design.Figure 2: Type II IHX integrated in Body Line3.1.2.2 Functional Content. The functional characteristics of the internal heat exchanger, such as theeffectiveness, the performance versus mass flow and the pressure drop, shall be optimized, validat

16、ed andreleased for specific GM applications.3.1.2.2.1 The design of the IHX shall prevent an accumulation of compressor lubricant to assure a goodlubricant circulation within the A/C system. See GMW16241 for further details.3.1.3 Ambient Environment. The internal heat exchanger shall be capable of w

17、ithstanding ambienttemperature variations from (-40 to +150) C (-40 to +250) F), (0 to 100) % relative humidity, and exposure toa severe corrosive environment.3.1.4 Interfaces. If the IHX is not integrated in the A/C body line as part of the assembly, the IHX joints shallutilize mini-block fittings

18、and seal washers to connect the IHX with the liquid line and the suction line.3.1.4.1 All joints and seals shall comply with GMW15779 and GMW15787 no deviations will be permitted.3.1.4.2 Soldered braze connections shall comply with GMW14655.3.1.5 Usage Definition. Internal heat exchangers as body li

19、ne part of assembly (POA), or as a singlecomponent for R134a or R1234yf refrigerant systems described by this specification, are used in passengerand light commercial vehicles.3.1.5.1 Noise and Vibration. The IHX shall not transmit nor generate any squeak and rattle, mechanical oracoustical Noise, V

20、ibration, Harshness (NVH) signatures that are perceptible to the vehicle occupants. Thisincludes, but is not limited to:Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORL

21、DWIDE ENGINEERING STANDARDS GMW16119 Copyright 2013 General Motors Company All Rights ReservedApril 2013 Page 3 of 19x IHX natural frequencies and resonances that are sympathetic to engine firing frequency or compressorfrequency.x Vibrations and resonance that are conducted through the steering whee

22、l, floor pan or seats.x Acoustic whistle/whine/gurgle/hiss sounds created by refrigerant flow that are observable at a distance of1 m from the IHX test sample.3.2 Product Characteristics.3.2.1 Performance Requirements.3.2.1.1 Test Conditions. All measuring variables as specified in this document sha

23、ll be determined correctlywith respect to its physical definition.3.2.1.1.1 If not otherwise required by the appropriate test paragraph, all tests shall be performed at roomtemperature (RT): RT (+23 5) C.3.2.1.1.2 A storage time of 24 h minimum is required after production of the test sample prior t

24、o running thefirst test. Between the tests, the samples shall be stored at RT with protective caps at each end, but withoutany kind of refrigerant charge.3.2.1.2 Supplier Qualification.3.2.1.2.1 IHX Type I (Coaxial Tube Type). The intent of this performance evaluation is to demonstrate that thesuppl

25、iers coaxial tube heat exchanger profile design fulfills the thermodynamic requirements for pressuredrop, heat exchange and effectiveness. Therefore, the IHX shall be tested in a test setup which represents atypical vehicle body line (see Appendix A). The suppliers IHX cross section design shall mee

26、t all of thequalification requirements and shall be approved by the General Motors IHX BFO prior to the supplier beingpermitted to bid on IHX business.3.2.1.2.2 IHX Type II (Non-Coaxial Type). The intent of this performance evaluation is to demonstrate that thesuppliers IHX design fulfills the therm

27、odynamic requirements for pressure drop, heat exchange andeffectiveness. Therefore, the IHX shall be tested in a test setup which represents a typical vehicle body line(see Appendix B). The suppliers IHX design shall meet all of the qualification requirements and shall beapproved by the General Moto

28、rs IHX BFO prior to the supplier being permitted to bid on IHX business.Table 1: Supplier Qualification TestsParagraph Test Number of Samples4.3.1 Heat Transfer 14.3.2 Pressure Drop 1 (same as paragraph 4.3.1)4.3.3 Effectiveness 1 (same as paragraph 4.3.2)3.2.1.2.3 Test Samples. The performance vali

29、dation tests shall be performed with a test sample according toAppendix A for a Type I IHX (coaxial tube) or Appendix B for a Type II IHX (non-coaxial tube design). The testsgiven in Table 1 shall all be performed with the same test sample. All coaxial IHX designs shall be formed inthe U-tube shape

30、shown in Appendix A, Figure A1.Other IHX designs, like plate type, shall have the test sample size and shape shown in Appendix B, Figure B1.All test samples shall be approved by the BFO prior to the tests. When the tests are successfully finished thetested samples shall be handed over to the BFO.The

31、 test conditions are the same regardless of the IHX technology.The materials and material suppliers used for the qualification samples shall be kept for the production parts. Achange of the material and/or of the material supplier shall be agreed by the GM Release Engineer.3.2.1.2.4 End Blocks. The

32、end blocks (see Figure 3) which join and split the suction line and the liquid linebefore and after the IHX (valid only for coaxial Type I) are part of the IHX evaluation. The design of theseblocks shall therefore be production intent and agreed by the responsible BFO.If the end blocks are no separa

33、te parts but integrated in the IHX they shall fulfill the following requirements:x The wall thickness of the forming areas shall be 80 % of the original wall thickness of the IHX.x No orange peel or micro cracks in the forming areas.Copyright General Motors Company Provided by IHS under license with

34、 General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16119 Copyright 2013 General Motors Company All Rights ReservedApril 2013 Page 4 of 19x The minimum radiuses shall not underrun 1.5 mmFigure 3: Samples of I

35、ntegrated and Separate End BlocksA End block (splitter) as integrated part of the IHXB Separate end blockFor all types of end blocks the supplier shall provide polished cut images of the end blocks for furtherinvestigation by the ITDC laboratory (see Figure 4). A detailed description of how the cut

36、images shall beprepared can be found in Appendix D.Figure 4: Samples of Good and Bad Preparation of Cut ImagesA Bad preparation, all brazing errors are filled with Aluminum particles produced during the preparationB Good preparation, same cut, all the brazings errors are visible3.2.1.2.5 Performance

37、 Requirements. The performance requirements for Heat Transfer, Pressure Drop andEffectiveness are given in Table 4, Table 5 and Table 6.3.2.1.3 Deviations from this Standard. Deviations from the requirements of this standard shall have priorwritten approval from the responsible GM IHX BFO. Such devi

38、ations shall be specified on componentdrawings, test certificates, reports, etc.3.2.2 Physical Characteristics. See paragraph 3.3.2.1.Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from I

39、HS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16119 Copyright 2013 General Motors Company All Rights ReservedApril 2013 Page 5 of 193.2.2.1 Dimensions and Capacity. See paragraph 3.3.2.1.3.2.2.2 Mass Properties. Not applicable.3.2.3 Reliability. Not applicable.3.2.4 Serviceability. Not applicable.3.2

40、.5 User System/Subsystem/Component/Part Interface. Not applicable.3.3 Design and Construction.3.3.1 Materials, Processes and Parts Selection Guidelines. See paragraph 3.3.2.1.3.3.1.1 Material Guidelines.3.3.1.1.1 Recycling Guidelines. Materials developed to this standard shall be optimized to provid

41、e maximumend-of-life cycle value utilizing the Recyclability Checklist and GM Recycling Design Guidelines. Recycledcontent shall be reported to the approving and procuring Materials Engineering department utilizing theRecycled Content Report Form. Reference the Recyclability/Recoverability Guideline

42、s to GMW3116.3.3.1.1.2 Material Compatibility. All materials which are used for outer surfaces of the IHX shall withstand allenvironmental influences normal for an engine compartment (e.g., engine oil, fuel, brake fluid) withoutdeterioration.The data sheet of these materials will be accepted as cert

43、ificate (proof of compliance).3.3.1.1.2.1 The inner surfaces of the IHX shall withstand the components of the refrigerant and the lubricantsgiven by R134a (GMW5038), R1234yf (GMW16283), Polyalkylene Glycol (PAG) Oil (9985752) and Polyolester(POE) Oil.3.3.1.2 Processes Guidelines. All production inte

44、rnal heat exchangers shall be manufactured using the samematerials and processes used to manufacture the originally approved samples. No change is permissiblewithout prior written approval from the responsible GM Release Engineer.3.3.1.3 Parts Guidelines. Not applicable.3.3.2 Design Guidelines and C

45、onstraints.3.3.2.1 Drawing Requirements. Internal heat exchangers shall meet the design specifications on the detaildrawings approved by GM.3.3.3 Identification and Marking. Not applicable.3.3.4 Workmanship. Not applicable.3.3.5 Interchangeability. Not applicable.3.4 Documentation.3.4.1 Failure Mode

46、 and Effects Analysis (FMEA). Detailed design and process FMEAs shall be submitted tothe GM Release Engineer and GM Validation Engineer, and they will be maintained as part of the records ofthe Design and Product Validation. The FMEAs shall be updated each time a change occurs. FMEAs shall besubmitt

47、ed with the GM Production Part Approval Process (PPAP) documentation.3.4.2 Product Validation. The Product Validation requirements for the IHX are described in GMW15773and/or GMW14319. Documentation shall be through the normal PPAP.3.4.3 Revalidation Requirements. Any change in design, material, or

48、processing from that previouslyapproved for production requires prior approval and revalidation as determined by the applicable GMValidation Engineer. Carryover designs may be revalidated for subsequent model year production using theresults of tests from previous months production.3.5 Support of Sy

49、stem/Subsystem/Component/Part After Sale. Not applicable.3.6 System/Subsystem/Component/Part Operator Training. Not applicable.3.7 System/Subsystem/Component/Part Characteristics. Not applicable.4 Validation4.1 General. The tests described in this section are only applicable for IHX supplier qualification. DesignValidation (DV) and Product Validation (PV) of IHX assemblies as part of a complete A/C body line arecovered by GMW15773 and/or GMW14319.C