ES-YU5A-9034-AA-Stand-05-1992-Englisch.doc

engineering specificationpart name part numberengineering specification - pipe assembly, fuel tank filler es yu5a-9034-aaletfrletfrletfrrevisionsdrckreferencenoneprepared/approved byr. h. thompson / e. chrobakchecked bydetailed byconcurrence/approvalsignaturesdesign engineering supervisord. h. rothamelstaff tech. specialistm.j. harrigandesign engineering. managerm. w. soltispurchasings. m. dobbysupplier quality assistancer. w. flemingframe1of11rev newpdmay 19883947a1e(previous editions may not be used)engineering specificationframe11of11rev. let. newpart no. es yu5a-9034-aai. generalthis engineering specification describes the performance acceptance criteria for a steel and low permeation rubber fuel fill pipe assembly.this engineering is a supplement to the release drawing on the part, and all requirements herein must be met in addition to all other requirements of the part drawing.the engineering specification 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.preparation and submission of an acceptable control plan are the responsibility of the manufacturing source. control plan approval by the product engineering office and other activities according to qs-9000 is a prerequisite for the initial sample review and approval. the manufacturer will retain the original of the approved control plan and any later revisions per qs-9000 and provide a copy to the design responsible product engineering activity.ii. summary of production validation and in-process testsproduction validation (pv) tests are used to obtain an initial estimate of the process potential to produce parts that conform to engineering requirements, and to identify causal or predictive relationships between significant design and process characteristics (to be used for process control). these tests must be completed satisfactorily using initial parts from production tooling and processes before production part approval process (ppap) approval and authorization of production parts can be issued. sampling plans for pv testing must be included in the pre launch control plan.in-process (ip) are used to further understand the relationship between significant design and process characteristics and to establish a basis for continuing improvement. tests must be completed with production parts on an ongoing basis. sampling plans for ip testing and evaluation of the significant process characteristics must be included in the production control plan. when the process is found to be out of control or the test acceptance criteria are not met, the reaction plan approved in the control plan shall be invoked.the following table summarizes the various pv and ip tests and the acceptance parameters for each. they form the basis on which to develop a complete control plan for these and their related significant process characteristics. the control plan will include frequencies, sample sizes, and reaction plans. see ford quality system requirements, qs-9000, and advanced product quality planning and control plan, apqp.test for fuel fill pipe assembliestest test lower target upper acceptanceno. characteristic use limit value limit parameter pv ip a flange weld pv, ip 3000n see section v quality b cap retainer pv, ip 20n torque test c cap retainer pv, ip 2700n pull out test d restrictor door pv, ip see text opening test e restrictor door pv 5000 cycles fatigue test f1 assembly leak pv, ip (as req.) f2 assembly hydrocarbon losses in mini-shed pv, ip (as req.) g corrosion test pv see texth outer hose pull pv, ip fill - 2700n vent - 1200n i inner hose pull pv, ip 300n j internal pv, ip no 0.2 g/assy cleanliness contamination k electrical pv, ip 1x108 ohms conductivity l resistance to pv see text fuel m. fuel cap sealing compatibility pviii. test procedures and requirementsa. flange attachment quality1. test equipment requireda) fixture to hold fill pipe assembly by the flange at one end and the pipe at the other end.b) tensile test machine.2. test procedurea) cut pipe beneath flange in an appropriate place so that a tensile load can be applied through the center of the flangeb) load section into fixture.c) apply axial tensile load until the pipe and flange interface yields.d) record pipe/flange interface yield force.3. test requirementa) yield force at pipe/flange interface must exceed 3000 n.b. cap retainer torque test1. test equipment requireda) fixture to hold the fill pipe assembly at the flange.b) torque/displacement measuring device, with adapter to connect device to the retainer.2. test procedurea) install assembly in fixture.b) apply torque to the cap retainer until it yields.c) record yield force.3. test requirement a) yield force must exceed 20 nm.c. cap retainer pull out test1. test equipment requireda) fixture to hold pipe assemblyb) tensile load machine capable of 5000 n.c) adapter for applying axial load to the retainer2. test procedurea) load pipe assembly into fixtureb) apply axial load until retainer is pulled from the pipe.iii. cont.3. test requirementa) cap retainer must withstand a force of 2700 n, and: for retainers secured to the pipe assembly by welding or solder, no movement with respect to the pipe assembly. for retainers secured to the pipe assembly by crimping, or other means, slight movement is allowed provided that representative samples meet the requirements of leak tests iii. f1 and f2 after the pull test. d. door opening test1. test equipment requireda) nozzle, or simulated nozzle per sae j285a (with nozzle diameter appropriate for the fill pipe), which has a mass of 1.4 0.1 kg.2. test procedure a) hold barrel of nozzle vertical and directly above restrictor door such that it touches the door but does not displace it. b) release nozzle.3. test requirement a) restrictor door must not support the nozzle.e. restrictor door fatigue test 1. test equipment requireda) nozzle or simulated nozzle per sae j285a (with a nozzle od appropriate for the fill pipe).b) upper pipe assembly pipe assembly or the entire fill assembly.2. test procedure a) fully insert nozzle into assembly and completely remove it from the assembly.b) repeat step a) a minimum of 5000 times.3. test requirement a) -9b143- restrictor door must pass 5000 cycles without fatigue cracks or failure.b) after 5000 cycles the gap between the door and its mating surface of the restrictor body shall not exceed 2.5 mm. f1. assembly leak test1. test equipment a) a suitable device for applying an internal pressure to the applicable assembly and detecting a leak in the assembly.b) a test fixture enabling attachment of the filler pipe assembly in the manner representative of in-vehicle orientation and the fitting with fuel tank.c) the top end of the tested filler pipe shall be plugged with the latest-release compatible fuel cap, base p/n 9030 or 9k163, modified to block leaks through its valves.2. test procedurea) test in accordance with es yu5a-9000-aa fuel system component, assembly or module leak test 3. test requirementb) per es yu5a-9000-aa f2. assembly hydrocarbon losses in mini-shed (complete assembly)the purpose of this test is to verify and document that the fuel/vapor losses from these assemblies is in compliance with established permeation rates for use on vehicles intended to meet us tier 1 or more stringent or european stage 3 or more stringent evaporative emission regulations. this test does not apply to assemblies intended for use in vehicles for sale in marketplaces which do not have evaporative emission requirements.assemblies are defined as the end items delivered to the vehicle assembly plant. for the purposes of this test the fuel pipe and the hoses shall be connected to a fuel container duplicating in-vehicle assembly with the fuel tank.the top end of the tested filler pipe shall be plugged with the no-leak certified latest-release compatible fuel cap, base p/n 9030 or 9k163.1. test procedurea) per sae j1737 as applicable. b) testing is to be conducted in mini-shed to evaluate hydrocarbon losses when exposed to each of two fluids simulating standard gasoline and gasohol per sae j1681: test fluid c and test fluid ce10. soak and test in each fluid at both, 40oc and 60oc, constant temperatures. g. corrosion testin accordance with worldwide customer requirements (page 00.00-p-20) the fuel fill system shall function for 15 years in service in a high corrosion environment without a corrosion related failure.1. test equipmenta) see cetp 00.00-r-3112. test procedurea) 150 cycles of cetp 00.00-r-3113. test requirementsa) appearance: after 30 cycles, rust grade 6 or better per astm-d-610b) serviceability: after 120 cycles, all fasteners are removable without breaking or damaging other components.c) function: no loss of function due to corrosion after 150 cyclesfill system manufacturers are not expected to conduct this test. the manufacturer must support the design release activity with production level parts for the test and must make no changes to materials or processes that would degrade corrosion performance. parts must meet the requirements prior to psw approval.h. outer hose pull, (fill and vent hose)1. test equipment requireda) fixture to hold outer hose portion of fill pipeb) load generating device capable of 5000 n and a pull rate of 50 mm/minc) adapters for applying axial load to filler pipe and vent pipe, respectively.2. test procedurea) cut upper (steel) fill pipe assembly approximately 125 mm from hose end. for the vent hose pull test cut the assembly above the union of the vent and fill pipe such that the vent pipe remains with the fill pipe. do not shorten the hoses unless necessary: if the hose elongation exceeds the capability of the test device the hose may be shortened, but significant characteristics such as convolutions, bends, or changes in shape must not be eliminated. if it is necessary to eliminate significant hose characteristics to accommodate the test device, the manufacturer must submit a revised hose pull-off test plan and procedure for engineering approval.b) load cut-off fill pipe into fixturec) apply axial load to cut-off fill pipe assembly at a rate of 50 mm/min until separation occurs or the machine limit is reached.d) record load required to cause hose separationiii. cont.3. test requirements a) fill hose must not separate from fill pipe at a load less than 2700 nb) vent hose must not separate from vent pipe at a load less than 1120 nc) outer hoses, both fill and vent, must elongate 150% minimum at the above loadsi. internal hose pull-off test1. test equipment requireda) fixture to hold fill pipe assembly and outer hoseb) load generating device2. test procedurea) cut off inner fill hose at 240 mm from its connection at upper pipe assemblyb) load cut-off assembly into fixturec) apply axial load at a rate of 50 mm/min until separation occursd) record load required for separation3. test requirementa) inner hose must remain attached to the upper pipe assembly at 300 nj. internal cleanliness test1. test procedurea) perform test on completed assemblies selected at random from their shipping containers.b) the procedure used must remove all contaminants and foreign matter from the interior of the assembly. this includes barely attached slivers from pipe cutting and flash from molded parts which could break lose during shipping.c) the procedure must capture and weigh the removed materiald) each manufacturer must submit a description of the equipment and procedure he intends to use and receive engineering approval for each prior to ppap for the first part number they produce using a new or revised test procedure. no further approval is required for additional parts providing there are no changes to the procedure.2. test requirementa) 0.2 g max. foreign material per assemblyb) 0.1 g max foreign material per assembly if a group of assemblies are cleaned and the combined weight of the foreign matter is averaged.iii. cont.k. electrical conductivity1. test equipment requireda) mega-ohm meter capable of measuring 108 ohms at 500 volts.b) a steel tube having an od 10.5 mm larger than the id of the hose.2. test procedurea) insert steel tube into fill hose.b) measure resistance between the restrictor door and steel tube with a 500 v potential difference.3. test requirementsa) the resistance shall not exceed 1x108 ohms.l. fuel resistance test (for assemblies with elastomer or rubber seal between cap retainer and outer pipe)1. test equipmenta) environmental chamber capable of varying temperature between -40 and +95c.b) plenum of 1 liter volume configured to accept upper pipe containing cap retainer in nominal vehicle position. plenum must contain valving to maintain pressure between 10 kpa and -1.5 kpa.c) test fuels determined by the product engineering office and based on the vehicles market. all test fuel, except those containing cm15a or cm85a, must contain for plastics additives. test fuel are described in ford laboratory test method az105-022. test procedurea) install upper pipe assembly in fixture in nominal vehicle positionb) add 0.5l of first test fuel. c) place fixture in environmental chamber, pre-cooled to -40c, and stabilize for 1 hour.d) vary temperature between -40c and +65c over 10 hour according to the following schedule for 15 cycles: hold at -40c for 1 hour; increase temperature to +20c, hold for 3 hours; increase to +65c, hold for 2 hours; return to -40ce) at the end of 15 temperature cycles remove fuel and replace with fresh test fuel.f) invert fixture and repeat temperature for 5 cycles.3. test requirementsa) the upper pipe assembly must meet the requirements of b, c, and f after going sequentially through all tests fuels chosen.iii. cont.test m. fuel cap sealing compatibility1. test equipmenta) torque meter with a range of 2 n-m.b) torsion fixture capable of applying torque to the cap in clockwise direction. however, for fuel caps with ignition key lock, the fixture must be capable to apply torque in either direction. furthermore, the torque can be applied to partially inserted key (to prevent lock actuation) or a “dummy” key. c) column capable of applying 40 inches of water head pressure with the lower end capable of attaching the cut-off end of the fuel filler pipe with installed production sample of compatible fuel cap.d) production samples of a representative, latest release fuel cap, base part no. 9030 or 9k163.2. test procedurea) attach the cut-off end of the fuel filler pipe with the installed fuel cap to the base of the column. if applicable, lock the cap and remove the key.b) fill the column with 40 inches of water.c) attach the torsion fixture to the cap, apply 2 n-m clock-wise torque, hold it for at least 5sec. and inspect for presence of leaks.d) for the ignition key locking caps, repeat step c. in the counter-clockwise direction.e) for fuel caps with more than one possible orientati