GMW GMW16186-2012 Externally Controlled Variable Displacement Piston A C Compressor Issue 1 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW16186 Externally Controlled Variable Displacement Piston A/C Compressor Copyright 2012 General Motors Company All Rights Reserved July 2012 Originating Department: North American Engineering Standards Page 1 of 29 1 Introduction Note: Nothing

2、 in this standard supercedes 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, pressures listed within the specification are absolute. 1.1 Scope. This specifica

3、tion establishes the minimum requirements for the air conditioning compressor to be used with refrigerant R134a and R1234yf unless otherwise specified. The functions, performance, reliability, and validation required of any compressor are defined in this document. This specification is for externall

4、y controlled variable capacity compressors with a clutch. All requirements 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 refrig

5、erant by a variety of mechanisms, and exhausts a high temperature, high pressure 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 we

6、ll as, the approved engineering drawings. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ANSI S12.54 ASTM D1474-98 JIS Z8732 SAE/USCAR-2 ANSI S12.55 ISO 3744 JIS Z8733 ASHRAE

7、Standard 97 ISO 3745 SAE J639 2.2 GM Standards/Specifications. GMW3059 GMW3191 GMW14477 GMW15760 GMW3097 GMW8758 GMW14483 GMW15862 GMW3103 GMW14156 GMW14872 GMW16044 GMW3116 GMW14157 GMW15272 GMW16241 GMW3172 GMW14264 GMW15758 GMW16290 2.3 Additional References. 9986181 52457600 (Shipping Cap) 52465

8、700 (Shipping Cap) 52477000 (Drawing) Artemis Sound Quality Software CG3010 GM1829 GM Best Practice (The supplier shall work with the GM responsible engineer to comprehend these requirements) Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo r

9、eproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16186 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page 2 of 29 GM Best Practice Heating, Ventilation, Air Conditioning, Powertrain Cooling (HVACPTC-122) GM Best Practice HVA

10、CPTC-125 GM Component Verification and Traceability Procedure GM Drafting Guidelines GM Part Number 12348526 GM 13505427 (Tyco 1-1703498-3) for the clutch GM 13505428 (Tyco 2-1703498-3) for the control valve Interface Control Document (ICD) Statement of Requirements (SOR) Appendix B, C2 and G2 3 Req

11、uirements 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 aluminum finish and the clutch with a low gloss black finish to match with other underhood components. Deviations from this are permissible, but

12、must be approved by the releasing GM engineering group. 3.1.2 Content. The following paragraphs specify the requirements for the physical and functional content of the Air Conditioning (A/C) compressor. 3.1.2.1 Physical Content. The physical content of the compressor includes the following: Inlet Po

13、rt (Suction) Outlet Port (Discharge) Clutch/Pulley/Thermal Fuse Mounting Provisions High Pressure Relief Device Electrical Connector for Clutch High Temperature Cut-Out Switch (Optional) High Pressure Cut-Out Switch (Optional) High Side Low-Pressure Switch (Optional) Shipping Caps Lubricant Thermal

14、Protection Switch (TPS) Discharge Shut Off Valve Control Valve Device. Electric Connector for Control Valve. 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 in the A/C system. 3.1.2.2.2 The compressor affects press

15、ure 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 complies with SAE J639. 3.1.2.2.4.1 High Pressure Relief V

16、alve Location. The pressure relief valve design and location must follow GM Best Practice HVACPTC-125: Location of the compressor high pressure relief valve. 3.1.2.2.5 The control valve controls compressor displacement to meet system needs. 3.1.2.2.6 Thermal Protection Switch. Under extreme compress

17、or temperatures the switch will disengage the clutch mechanism. The switch specification (set point, hysteresis, location) must be agreed to by supplier and GM engineering. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or netw

18、orking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16186 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page 3 of 29 3.1.3 Ambient Environment. The electrical components contained on the A/C compressor shall be able to withstand ambient air tempe

19、ratures from -40 to 125 C, with intermittent temperature requirements of 150 C for up to one (1) h 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 damage to function or appearance. As required, pa

20、rt 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 Operating Temperature Code Letter H Climatic Loads Code Letter B

21、Chemical Loads Code Letter E Dust and Water Protection Code Letters 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 requirements for the A/C compressor.

22、Data shall be submitted on compressors run sequentially through these performance tests for validation purposes at each stage of development. Displacement size for a given compressor shall be defined in SOR Appendix B (General Program Description) or SOR Appendix C2 (Component Technical Specificatio

23、n (CTS) Exceptions Document) of the SOR Document. Table 1 defines the size range. Table 1: Compressor Sizing Size Code Displacement (cc/rev) A1 100 to 110 A2 110 to 125 B1 135 to 145 B2 160 to 175 C 180 to 200 Note: cc/rev = Cubic Centimeters per Revolution 3.2.1.1 Variable Value Performance Tests.

24、3.2.1.1.1 Minimum Refrigerant Mass Flow Rate and Maximum Power Consumption. The minimum mass flow rate and maximum power consumption requirements are to be met per the conditions defined in Table 2 (where x = compressor displacement cc/rev). The resulting compressor refrigerant discharge temperature

25、 must not exceed its associated requirement. Variation in random samples, taken from production, shall not exceed 10% total. Power consumption is defined as the measurement of mechanical torque applied to achieve the reported refrigerant mass flow rate. Copyright General Motors Company Provided by I

26、HS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16186 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page 4 of 29 Table 2: Mass Flow and Power Consumption Require

27、ments Conditions Result Compressor min-1 Suction Pressure (kPa abs) Suction Temperature (Degree C) Discharge Pressure (kPa abs) Minimum Reference Mass Flow (kg/h) Maximum Power Consumption (kW) Maximum Discharge Temperature (Degree C) 850 420 20 2000 137*(x/170) 1.6*(x/170) 90 1600 375 16 1600 242*(

28、x/170) 2.8*(x/170) 85 2600 340 13 1600 326*(x/170) 4.8*(x/170) 95 5000 300 10 1800 421*(x/170) 8.2*(x/170) 115 Note: abs = absolute, (*) = multiplier symbol 3.2.1.1.2 Maximum and Minimum Speed Definition. 3.2.1.1.2.1 Maximum Continuous Revolutions per Minute (min-1 (RPM). Maximum continuous speed is

29、 defined per the durability test specification at condition ten (10) of Table A1 in Appendix A. The compressor must run a minimum of 10 h at this condition at 9000 min-1 (9000 rpm) (all compressor types). 3.2.1.1.2.2 Maximum Excursion RPM. Maximum excursion speed is defined per the durability test s

30、pecification at condition 11 of Table A1 in Appendix A. The compressor must run a minimum of 10 minutes at this condition at 10 500 min-1 (10 500 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 min-1 (575 compresso

31、r rpm). 3.2.1.1.2.4 Minimum Compressor Displacement. The minimum displacement of the compressor shall be 4000 ppm) and two aging temperature/time settings (190 C/24 h and 175 C/14 days). The resulting Total Acid Number shall be less than 3.0 and the ASTM International (ASTM) color less than 2.5. If

32、the color requirement is not met following Standard 97, this requirement must be met with oil evaluated from a post customer usage test as defined in 4.3.1.2.2. 3.7.1.3.3 Other Refrigerant Lubricants. GM Global Service Oil Denso N-D-12 Sanden SP-A1 Mitsubishi PAG46 Idemitsu PS-D1 Visteon 4D46XG Delp

33、hi PS-D1 Valeo VC100YF Denso N-D-8 Sanden SP 10/15 Mitsubishi Sun 56 PAG Idemitsu-Daphne PS Delphi UCON488, 897 Valeo/Zexel 100PG or 200PG KDAC ISU105 3.7.1.3.3.1 GM Service Oil. Not applicable. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleN

34、o reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16186 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page 15 of 29 3.7.1.3.4 Refrigerant Lubricant Compatibility with Desiccants. Refrigerant lubricant must be compatible wi

35、th desiccant UOP XH7 and XH9. 3.7.1.3.5 Manufacturing Tolerance for Lubricants. The oil amount in the compressor shall be 10 cm3 from the value identified on approved final drawing. 3.7.1.3.6 Moisture/Contamination of Oil. Levels of moisture up to 2000 ppm in the compressor oil must not affect the c

36、ompressor durability. Moisture content of the oil shall not exceed 1000 ppm when tested as received at the GM assembly plant. Note: This may require an alternate in-transient cap to meet the parts per million (ppm) requirement and still meet our assembly plants pull off requirements. 3.7.1.4 Clutch

37、and Pulley Assembly. 3.7.1.4.1 Clutch Assembly. 3.7.1.4.1.1 Current Draw. Current draw requirements are defined in Table 8. Table 8: Current Draw Maximum Current Instantaneous at 20 C Ambient 4.0 A At 12.0 V Continuous at 93 C Ambient 3.0 A Note: The clutch coil shall withstand a grounding voltage o

38、f 550 V for one second without damage. 3.7.1.4.1.2 Air Conditioning Clutch Cycling. As a design guide, the A/C clutch shall be capable of a total of 500 000 cycles in actual vehicle usage. The clutch shall be capable of running at 4 cycles per minute continuously and 6 cycles per minute intermittent

39、 with minimum off time of 5 s. 3.7.1.4.1.3 Air Conditioning Clutch Slippage. When tested with typical A/C system components for the application or on a calorimeter, the A/C clutch requirements shall not slip at 7.5 V at the 845 compressor min-1 (845 compressor rpm) capacity point conditions in 3.2.1

40、.1.1. 3.7.1.4.1.4 Over-Voltage Test. The A/C compressor clutch shall not be damaged when tested for over-voltage per GMW3172 (electrical code C). 3.7.1.4.1.5 Torque Capability. The minimum static transmission torque at 4.0 A, for the Type B compressor at 53 Nm, for type A compressors at 35 Nm, and f

41、or type C compressors at 65 Nm. A modified value based upon individual designs may be allowed. In this case, it must be shown that the proposal is not A-typical of the industry applications of similar designs. Note: These requirements assume a burnished clutch. 3.7.1.4.1.6 Temperature Capability. Th

42、e clutch assembly shall be capable of a maximum operating temperature for 1 h continuous loading of +150 C. 3.7.1.4.1.7 Thermal Fuse for Belt Protection (specific to application). Installation shall be inside the magnetic clutch stator. Switch-off temperature in as received condition shall be 184 5

43、C (this value may change based on compressor supplier specific design requirements). The minimum switch-off-temperature during lifetime shall be 165 C. Switch off time at 3000 min-1 (3000 rpm) and F = 2000 N. There shall be no seizure of the clutch bearing and the belt drive shall remain intact. The

44、 maximum current consumption at the critical temperature (maximum voltage and critical coil resistance) shall not exceed 3.0 A without thermal fuse, or 4.0 A with thermal fuse. A functional test of the thermal fuse shall be performed on 100% of compressors at the end of the production line. 3.7.1.4.

45、1.8 Diode. Unless specifically called out on the engineering drawing, a diode must be integrated into the clutch coil. The diode design must enable the compressor to meet GMW3097. A functional test of the diode shall be performed on 100% of compressors at the end of the production line. 3.7.1.4.2 Pu

46、lley Requirements. 3.7.1.4.2.1 Pulley Run-out. Axial and radial run-out of the rotor-face and poly-vee pulley groove shall not exceed 0.25 mm Total Indicated Run-out (TIR) from the compressor bearing surface. 3.7.1.4.2.2 Static Pulley Balance. Total static pulley assembly imbalance shall not exceed

47、180 g/mm. 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 GMW16186 Copyright 2012 General Motors Company All Rights Reserved July 2012 Page

48、16 of 29 3.7.1.4.2.3 Impact on Belt Wear. The pulley finish must not impact belt wear by confirming any paint/coating passes a pencil hardness test at number two (2) (alternately pass Knoop hardness of six (6) per ASTM D1474-98). 3.7.1.4.2.4 Pulley Groove Design. The pulley groove and flange must me

49、et the profile dimensioning template and meet the pulley specification GMW16290. 4 Validation 4.1 General. 4.1.1 Product Validation. Reference GMW15758 (ADV Process Development and Validation Terminology). 4.1.1.1 Test Samples. Production test samples must be produced on production representative equipment including the effects of manufacturing-i