保险丝盒测试标准(中文)

CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 1 of 24TITLE:JB Validation SpecificationCURRENT RELEASEGeely Lear China Project Lead Mech Mngr Lab Engr AuthorNAME M. Desabille N. Medallo Hector Uy Mary Rose PoroSIGNATURECOPY:REVISION HISTORYISSUE CHANGE DESCRIPTION DATE AUTHOR0001020304Initial releaseChange per Lear SpecificationAdded some tests per Lear Wuhans direction11/07/0711/22/0712/21/07M. PoroM. PoroM. PoroLear Automotive Services (Netherlands) B.V.COVER PAGECONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 2 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.TABLE OF CONTENTS 目录COVER PAGE1TABLE OF CONTENTS 目录 21.0 PURPOSE 目的 32.0 PRODUCT DESCRIPTION 产品描述 .34.2.2 Power Dissipation 功率耗散 .54.2.3 135% Short Circuit Test 135%短路测试 64.2.4 135% Fuse Load Test 135%保险丝负载测试 74.2.5 Dielectric Test 绝缘测试 84.2.6 Insulation Resistance Test 绝缘阻抗测试 .84.2.7 Temperature Rise 温升测试 .94.3 Environmental Tests 环境测试 .104.3.1 Thermal Shock Resistance Test 耐热冲击测试 .104.3.2 Low Temperature Exposure Test 低温暴露测试 .114.3.3 High Temperature Exposure Test 高温暴露测试 124.3.4 Perform Humidity Temperature Cycle Test 温湿循环测试 124.3.5 Dust Test 灰尘测试 .144.3.6 Salt Spray Test 盐雾试验 154.3.7 Water Test 防水测试 .164.3.8 Multiple Environment Compatibility Test 复合环境能力测试 .174.3.9 Dew Condensation Test 结露测试 184.4 Mechanical Tests 机械测试 .194.4.1 Terminal Insertion Test 端子插入测试 .194.4.2 Terminal Retention Test 端子保持力 204.4.3 Component Insertion / Removal Test 组件插入/拔出力测试 214.4.4 Connector Pull Test 连接器拉脱测试 214.4.5 Perform Drop Test 跌落测试 224.4.6 Vibration Test 振动测试 .234.4.7 Detaching Force of Upper Cover Test 测试上盖分离力 .244.4.8 Holding Force of Cover Test 盖子保持力测试 254.4.9 Bolt/Nut Tightening Torque 螺栓/螺母拧紧扭矩 264.5 Chemical or Fluid Tests 化学或液体测试 .274.6 Thermal Test 端子测试 284.6.1 Thermal Mapping 热分布测试 285.0 APPENDICES 附录 295.1 Appendix A Voltage Drop Test Lead Location and Set-up.29附录 A-电压跌落测试引线布局和装置 .295.2 Appendix B Geely JB DV/PV Reliability Test Profile30附录 B-吉利 JB DV/PV 可靠性测试框图 .30CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 3 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.1.0 PURPOSE 目的This test method for Electrical Junction Boxes (JB) , aims at assuring standardizing its product validation. This is intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking and in-process controls and should in no way adversely influence other inspection operations.2.0 PRODUCT DESCRIPTION 产品描述This specification is written for Engine Junction Box. The specification defines test procedures, minimum performance requirements and an acceptance criterion for the said box used in automotive vehicles. This Engineering Specification is also an extension to the released drawings on JB or a supplement and the requirements herein must be met in addition to all other requirements of the part drawing. It is also intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking, and in-process controls, and should no way adversely influence to other inspection operations. 3.0 TEST MATRIX 测试矩阵See Appendix B.见附录 B4.0 TEST ITEM PLAN 测试项目计划4.1 Inspection 检查4.1.1 Visual Check 可视化检查Test item 测试项目 Standard 标准 Test Item No. Quality RankVisual Check 可视化检查 SGEP-07-00023-00 4.1.1 CPurpose 目的 A visual check is performed to inspect the component for possible damage that may have occurred during an environmental test. Use appropriate physical and/or visual techniques and aids such as microscope etc. There shall be no visible distortion in the assemblies. 进行目视检查是为了检查零件在环境测试阶段可能出现的损伤。使用合适的物理或目视工具和辅助工具，如：显微镜等。Test Condition 测试条件 Inspect the module housing and connector pin for any damage or unusual condition that could have been caused by environmental stress or module handling. Things to look for are listed below. Notify the Test and/or Design Engineer of any anomalies that could affect module performance. Visual checks shall be performed when required, or immediately after and at two (2) hours and/or 24 hours following the environmental test, as appropriate, and/or as specified. 检查模块外壳和连接器引脚上的任何损伤或环境应力/模块处理造成的特殊条件。下面列出了检查项目。必须给测试/ 设计工程师告知可能影响模块性能的异常。当有要求时，必须在环境测试后的 2 小时和/或 24 小时立即进行目视检查。CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 4 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.Confirmation 确认 Conduct a visual inspect to look for the following defects: 目视检查以下缺陷： Warping or cracking of housing. 外壳翘曲或裂化 Gaps of 1 mm on closing line or hinges. 闭合线或者铰接处 1mm 间隙 Bent connector pins. 接插件端子弯曲。 Excessive corrosion of connector pins. 接插件端子过度腐蚀。 There shall be no plastic flow or terminal fusing. 不应有塑胶流纹或者端子熔化。 Audible rattles upon “hand” shaking of module. 用手晃动模组不应有响声。 Dripping of liquid (water and other) out of housing. 不应有液体从外壳流出。 Foul odor and/or smoke emanating from module. 不应有臭味或者烟尘从模组发出。 Visible changes in color, gloss and surface structure. 色泽和表面结构变化。 Corrosion. 腐蚀。 Other defects. 其它缺陷。 Etc. 等等。lf one or more defects are detected; the occurrence shall be reported to the responsible engineer who will evaluate the importance of the defect/s found.如果检测到一个或多个缺陷，需报告给负责的工程师，他将评估缺陷的重要性。Notes 备注 Do not open the module housing to conduct this inspection.检查时不打开模块的外壳4.2 Electrical Tests 电气测试4.2.1 Voltage Drop 电压降Test item 测试项目 Standard 标准 Test Item No. Quality RankVoltage Drop Test 电压降测试 SGEP-07-00023-00 4.2.1Purpose 目的 To check if there is an excessive resistance in high amperage circuits and to check whether there is a good connection or bad.检查高电流电路中是否有过多电阻，检查连接是否完好。Test Condition 测试条件 The unit shall be considered as a black box. Voltage drop shall be measured at LOAD CURRENT from the end of a wire 75 mm long connected to the INPUT of a function, and to the end of a wire 75 mm long connected to the OUTPUT of the same function. Fuses and relays shall be replaced by shunts. The voltage drops of the shunts may be subtracted from the total voltage drop. In the event of non-removable switching CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 5 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.elements (such as FETs and soldered relays), a value specified by the component supplier will be subtracted from the value of the circuit. 在连接到输入功能端的 75 毫米长的线末端，和连接到输出相同功能端的 75 毫米长的线末端的负载电流处测量电压降。用分流器替换保险丝和继电器。分流器的电压降需要从总电压降中减去。在非移动的开关元件（如：FETs 和固态继电器）的情况下，从电路电压降值减去零件供应商指定的值。Special conditions:特殊条件Temperature 温度 +23C2C.Operating condition: At normal load current specified in Normal Load Cycle 工作条件：额定负载循环指定的额定负载电流。Refer to Appendix A for the test diagram. 测试框图见附录 A。Confirmation 确认 After each test the maximum voltage drop for each circuit shall be less than:每个测试后确认每个电路的最大压降必须小于： - 20 mV/A for currents lower than 10 A 低于 10A 的电路：20 mV/A- 15 mV/A for currents between 10 A and 20 A 10A 和 20A 之间的电路：15 mV/A- 10 mV/A for current higher than 20 A 大于 20A 的电路： 10 mV/ANotes 4.2.2 Power Dissipation 功率耗散Test item 测试项目 Standard 标准 Test Item No. Quality RankPower Dissipation 功率耗散 SGEP-07-00023-00 4.2.2Purpose 目的 This test checks how much power is dissipated as the box is in operation. 检测工作中保险丝盒的连接是否完好Test Condition 测试条件 1.Before and after the test, measure and record the voltage drop from input to output, 1. Before and after the test, measure and record the voltage drop from input to output, then subtract the voltage drop of the fuse, relay, wires, buss bars and other components at rated current (see Appendix A, Figure 4, for more detail).测试前和测试CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 6 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.后，测量并记录额定电流条件下输入端与输出端之间的压降，并减去保险丝、继电器、母线棒和其他零件的电压降。2. Secure the JB in vehicle position / orientation.将保险丝盒固定在汽车的位置和方向上 。3. Ensure that each space in the JB is filled with the appropriate component (fuse, relay, , module, etc.). Every terminal shall be mated to its corresponding mating terminal and connector.确保保险丝盒上每个空位都装配了合适的零件（保险丝、继电器、模块等）。每个端子必须与其配对的端子和连接器配合。4. Remove and reinstall all components (fuse, relay, etc.) 10 times.拔出和插入所有零件10 次（保险丝、继电器等）。5. Conduct test at 125C 3C (engine compartment mounted). 在 125C 3C 下进行测试。6. Apply max vehicle steady state load current to each component in the JB simultaneously, 45 minutes and 15 minutes OFF for 300 hours. Apply vehicle intermittent load current to each component, the last 5 minutes of each 45-minute ON cycle.给保险丝盒上的零件砸在最大汽车稳态负载电流，同时保持 45 分钟打开，然后 15分钟断开，总计 300 小时。给每个零件加载间歇汽车电流，每 45 分钟 ON 的最后 5 分钟。Note the increase in temperature above the ambient throughout the JB.注明保险丝盒上高于环境温度的温度增加值。Confirmation 确认 1. The voltage drop before the test shall be less than or equal to : (number of crimps x 0.5mV/Amp) + (number of terminal interfaces x 1.0mV/Amp). 测试前电压降应该小于或者等于(压接数量 x 0.5mV/Amp) + (端子接口数量 x 1.0mV/Amp)2. The voltage drop after test completion shall be less than or equal to: (number of crimps x 1.0 mV/Amp) + (number of terminal interfaces x 2.0 mV/Amp). 测试后电压降应该小于或者等于(压接数量 x 1.0mV/Amp) + (端子接口数量 x 2.0mV/Amp)3. The temperature of the JB shall not increase above the ambient temperature by more than 50C max and/or the JB temperature shall never exceed its material deflection temperature at 460kPa (66 psi).保险丝盒增加的温度不能超过环境温度的最大 50以上，或者保险丝盒的温度不能超过 460kPa (66 psi)下材料的变形温度。4. There shall be no visible distortion in the assemblies.总成零件上不能有可见的变形。Notes 4.2.3 135% Short Circuit Test 135%短路测试Test item 测试项目 Standard 标准 Test Item No. Quality Rank135% Short Circuit Test135%短路测试 SGEP-07-00023-00 4.2.3CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 7 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.Purpose 目的 With the fuses removed, the box is tested with 135% current load to check if there is no terminal fusing.保险丝去拔出后，给保险丝盒加载 135%的电流负载以检查端子是否熔断。Test Condition 测试条件 1. Secure the JB in vehicle position / orientation.将保险丝盒固定在汽车方位。2. Ensure that each space in the JB is filled with the appropriate fuse and .确保保险丝盒上每个空位都装配了合适的保险丝和。3. Remove all relay and modules and replace with shunts to complete the circuit.将继电器和模块从保险丝盒中拔出，并用分流器替换之，组成电路。4. Apply 110% load (wire rated current of input/output mated circuit) at 13.5 volt for 15 minutes followed by 135% load for 60 minutes to each circuit not protected by a fuse/ within the JB one at a time (example: pass through circuit, body harness to engine harness).在 13.5V 下给每个无保险丝保护的电路加载 110%的负载 15 分钟，然后加载135%负载 60 分钟Confirmation 确认 There shall be no plastic flow or terminal fusing. 不应该有塑胶流纹和端子熔化。Notes 4.2.4 135% Fuse Load Test 135%保险丝负载测试Test item 测试项目 Standard 标准 Test Item No. Quality Rank135% Fuse Load Test 135%保险丝负载测试 SGEP-07-00023-00 4.2.4Purpose 目的 This test checks if each fuse can withstand the 135% of the rated load of the circuit.检查保险丝能否承受 135%的电路额定负载。Test Condition 测试条件 1. Secure the JB in vehicle position / orientation.将保险丝盒固定在汽车方位Ensure that each space in the JB is filled with the appropriate component (fuse, relay, , module, etc.) Every terminal shall be mated to its corresponding mating terminal and connector. 确保保险丝盒上每个空位都装配了合适的零件（保险丝、继电器、模块等）。每个端子必须与其配对的端子和连接器配合。2. Apply 110% load (rated value of fuse) at 13.5 volt for 15 minutes followed by 135% CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 8 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.load to each fuse until failure. Repeat 4 more times with each fuse location. This test shall be done for each fuse position one at a time. 在 13.5V 下给每个保险丝加载110%的负载 15 分钟，然后加载 135%的负载直到失效。每一个保险丝位置重复 4 次。每个保险丝位置每次测试一个。Confirmation 确认 There shall be no plastic flow or terminal fusing. 不应该有塑胶流纹和端子熔化Notes 4.2.5 Dielectric Test 绝缘测试Test item 测试项目 Standard 标准 Test Item No. Quality RankDielectric Test 绝缘测试 SGEP-07-00023-00 4.2.5Purpose 目的 High rated voltage is applied for a specified time to determine the capability of insulating materials to withstand breakdown.在指定的时间内加载高额定电压，以确定绝缘材料承受破坏的能力。Test Condition 测试条件 1. Apply 500 V AC, 60 or 50 Hz for two (2) minutes between any two conductive parts designed to operate at different potentials.给任意两个导电零件之间加载 500V 交流电，60 或 50 Hz 2 分钟。2. Determine the leakage current. 确定漏电流。Confirmation 确认 The leakage current shall not exceed 1 mA. 漏电流不超过 1mANotes 4.2.6 Insulation Resistance Test 绝缘阻抗测试CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 9 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.Test item 测试项目 Standard 标准 Test Item No. Quality RankInsulation Resistance Test 绝缘阻抗测试 SGEP-07-00023-00 4.2.6Purpose 目的 This test measures the total resistance of the box itself to determine the long time stability of its plastics over time.测量保险丝盒的总电阻，以确定塑料材料的长期稳定性。Test Condition 测试条件 Apply 500 V DC for 1 minute and measure the insulation resistance between the closest connecting segments and to the outside surfaces of the housing.加载 500V 直流电 1 分钟，测量最近的连接片与外壳外表面之间的绝缘电阻。Confirmation 确认 The insulation resistance shall not be less than 100 MOhm. 绝缘阻抗不得小于 100 MOhm.Notes 4.2.7 Temperature Rise 温升测试Test item 测试项目 Standard 标准 Test Item No. Quality RankTemperature Rise 温升测试 SGEP-07-00023-00 4.2.7Purpose 目的 To check and measure the temperature rise 检查和测量温升Test Condition 测试条件 Fit the prescribed components such as electric wire, fuse, relay and unit to the box properly. Apply an actual load continuous current to every component installed in the box. Measure the finally settled temperature when the temperature at the terminal crimp becomes saturated.被保险丝盒安装好合适的零件如电线、保险丝、继电器。给保险丝盒上的每一个零件加载实际持续电流。端子上的温度稳定后测量最终确定的温度值。Confirmation Temperature rise guaranteed temperature for terminal use Ambient temperature温升 端子使用-环境温度的保证温度CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 10 of 24TITLE:JB Validation SpecificationLear Automotive Services (Netherlands) B.V.Terminal Storage:端子存储108-18013-JPT 2.8 端子 (-40C to +130C)108-18025-SPT 6.3 端子 (-40C to +130C)108-18047-MPT 9.5 端子 (-40C to +130C)The ambient temperature is 90 C 环境温度是 90Notes 4.3 Environmental Tests 环境测试4.3.1 Thermal Shock Resistance Test 耐热冲击测试Test item 测试项目 Standard Test Item No. Quality RankThermal Shock Resistance Test 耐热冲击测试 SGEP-07-00023-00 4.3.1Purpose 目的 With this test, the box is tested against sudden thermal changes.测试保险丝盒能否承受热骤变Test Condition 测试条件 1. Before and after the test, measure and record the voltage drop from input to output, then subtract the voltage drop of the fuse, relay, wires, buss bars and other components (see Appendix A, Figure 4, for more detail).测试前和测试后，测量并记录输入端到输出端的压降，然后减去保险丝、继电器、母线棒和其他零件的电压降（详见附录 A，图 4）2. Remove and reinstall all component (fuses, relay, etc.) 10 times each. 拔出和插入所有零件 10 次（保险丝、继电器等）。3. Transfer the JBs to a cold chamber stabilized at -40C 3C. Expose the JBs at this temperature for 30 minutes.将保险丝盒置于-40C 3C 的冷温箱中，暴露 30 分钟。4. Immediately following cold temperature exposure in Step 1 above, transfer the JBs to a hot chamber stabilized at 125C 3C, 30 minutes (for engine compartment mounted only).冷温暴露后，将保险丝盒放入 125C 3C 的温箱中，暴露 30 分钟。5. Repeat the above for 36 cycles for all non-printed circuit board JB.在非 PCB 的保险丝盒上重复上述步骤 36 次。Confirmation 确认 1. The voltage drop before the test shallb e less than or equal to: (number of crimps x 0.5 mV/Amp) + (number of terminal interfaces x 1.0 mV/Amp). 测试前电压降应该小于或者CONFIDENTIAL: This document is property of LEAR. It cannot be reproduced, delivered or disclosed to third parties without prior consent from LEAR CorporationAuthor: Mary Rose A. PoroDate : 21 Dec 2007SPEC GROUP No ISSUE File: JB_Product_Validation_SpecificationSGE P 07-00023 02 Page : 11 of 24TITLE:JB Validation SpecificationLea