GMNA-GM9111P-1998.pdf

vnd gfl gflql j l p engl 1 lq8 qunb37q tln31 54q sot i general motors engineering standards r materials and processes electrical standard reliability program for relays gm9111p lhble of contents 1 scope 2 referenced standards 3 general requirements 3 1 reference documents required 3 2 record retention 3 3 lot definition and sample selection 3 4 test data and forms 4 pre release requirements 4 1 design failure mode analysis 4 2 internal part approval requirements 4 3 design release and reliability demonstration tests 4 4 application nomograph 4 5 release data package 4 6 documentation and master sample submittals 5 process controls 5 1 frequency of checks 5 2 rework 5 3 equipment 5 4 process documentation 6 reliability audit test 6 1 30 cycle burn in 6 2 shift audit test 6 3 reliability audit data package 7 annual compliance audit 7 1 proccciurc 7 2 distribution 8 safety 9 general information appendix a glossary of terms figures 1a 1b 4 5 4 6 5 3 5 4a 5 4b 6 1 1 6 3 2a 6 3 2b method of control bathtub curve frequency of checks application nomograph release data package checklist relay curve produced on force displacement fixture process data checklist process data checklist action plan reliability audit data package checklist reliability audit data package june 1998 page 1 9111p copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs vnd gm gh ll llp engl 1998 w 900b379 ocll25 5 44b i general motors engineering standards i materials and processes electrical i standard reliability program for relays gmqlllp 1 scope this standard outlines reliability program requirements for relays the principles of establishing process controls and reliability tests are shown in figure 1a the fre quency and responsibility for these controls are outlined in figure 1b the major components of this reliability program are a general requirements section 3 b re released requirements section 4 c process controls section 5 d reliability audits section 6 e annual compliance audit section 7 principle of rellablllty control process controls reliability tests constant failure rate and wear out determined by figure 1a method of control bathtub curve 911lp june 1998 copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs vnd gm gm il l lp engl 1798 900b379 cio3254b 382 i general motors engineering standards i materials and processes electrical i standard reliability program for relays gm9111p i i fbhmnt rehbilii i lkrignrelea80 a rolkbilhy demonmdon tests effactdwto traportation s onp u 4 and maintauwm figure 16 frequency of checks 2 referenced standards gm9103p gm9110p gm9104p qs9000 3 general requirements 3 1 reference documents required 3 1 1 request for quote purchase order the purchase order and subsequent instructions or amendments may establish pro cedures for sample submissions or reliability test requirements which supplement the minimum requirements outlined by this standard for example cpc reliability specification document no 10076787 3 1 2 gm part drawing the part drawing shall be used for dimensional requirements the part drawing shall also include a circuit schematic and mating connector part number the cir cuit schematic identities the internal circuits for voltage drop isolation resistance and other circuit checks 3 1 3 gm test specification the test specification may or may not be integral with the part drawing the test specifica tion shall identity the following parameters a the applicable tests and the order in which the tests are to be performed for design release tests if dif ferent than specified in gm9103p b limits for release and reliability tests and the defti tions under which those limits apply if different than outlined herein c a functional definition for the device to be tested if specific make break sequences are required 3 1 4 materials and process standards gm9103p perform all tests under the conditions stated in gm9103p procedure for testing relays unless otherwise specified 3 1 5 quality system requirements are qs9000 other required procedures are failure mode effects analysis fmea the production part approval process ppap and other procedures contained in the advance product quality planning manual 3 2 record retention in the event of test failure appropriate action as outlined must be instituted a system for assuring due care shall be established to assure sorted material meets all part requirements adequate due care procedures include the establishment of a disposition of variance system which requires engineering manufacturing process industrial engineering and quality control representatives signatures on a document which specifically addresses the number of pieces affected the dimensional variance the effect on perfor mance corrective action and whether tevalidation is required such documents shall be maintained in a central file which is audited for compliance 0 copyright june 1998 general motors corpor mcbf of 1 failure per 10 million cycles at the resis tive load rating of the device note during reliability demonstration tests all contact sets must be operated at the resistive rated load identified by the relay drawing for the following reasons 1 the resistive current rating is the rating which is advertised by the relay manufacturer and often appears on the relay cover the resistive current rat ing is defined as the resistive load at which 100 000 cycles may be switched spst or sequentially switched spdt at a demonstrated reliability of 0 99 50 confidence level 2 individual part numbers may be used in a variety of load applications many applications arc made with out supplier input any reliability program for suppliers must recognize the need for standardization of test methods 3 resistor loads are commercially available and more reliable than actual loads especially when multiple test sequences are run on the same load 4 3 4 1 test duration shall be 100 000 cycles this cycle number was chosen as a best compromise between application cycles which range from 10 000 500 000 life cycles duty cycle shall be 1 s on 1 s off minimum 4 3 4 2 sample size shall be 170 relays this sample size was chosen in order to demonstrate an mcbf of one failure per 10 million cycles 50 confidence level using a one failure plan if more than one failure occurs consult gm engineering to determine if additional testing will be allowed minimum test stand capacity shall be 30 samples so that all testing can be completed within 6 weeks alternatively a sample size of 69 pieces may be used for a zero failure plan 4 3 4 3 other conditions power supply terminal voltage temperature profile wire size and test monitoring requirements shall be per gm9103p samples must meet test specification performance requirements before and after test 4 3 4 4 the shift reliability audit test fixture at the manu facturing location may be used for reliability demonstration tests shift audits may be suspended during this period 4 3 4 5 the mcbf of 1 failure per 10 million cycles set by this standard is independent of contact form spst spdt dpdt multiple coil relays 4 35 a formal report including test results and calibration sheets shall be compiled and included in the design release data package 4 4 application nomograph this standard cstab lishes a failure rate or reliability level at the resistive rated load and 100 000 cycles to use this standard the engineer applying a relay must choose a device with a current rating which will meet his individual cycle life and reliability require ments a specially prepared nomograph figure 4 5 has been developed using relationships found in mil hdbk 217e to simplify this decision 4 4 1 for example an engineer applying a relay for com pressor clutch knows the load is 3 amp inductive and must switch 500 000 cycles during the life expectancy of the vehi cle he has been told the reliability requirement for the relay is 0 984 by drawing a straight line from cycles 500 000 through reliability 0 984 the required load ratio is read from the inductor scale load ratio 0 25 the steady state applica tion load divided by the load ratio equals the resistive current rating needed load ratio operating load resistive rated load resistive rate load operating load load ratio 3 amp 0 25 12 amp since 12 amp ratings are not generally available the use of a 15 20 or 30 amp rated relay would meet the application requirements note do not exceed the maximum stress factors listed in the reliability nomograph figure 4 5 for each load type 4 5 release data package a data package includ ing test results signed by the director of engineering or his designate shall be maintained in a central engineering file which is periodically audited for compliance the data package shall be labeled gmpartno release data package and shall be made available upon request the contents of the package shall include the items required by the release data package checklist figure 4 6 an approval of the data package checklist shall signify that all conditions were fulfilled in the prescribed manner that all tests were completed without failure except where failures are allowed and that the design is now ready for production release 4 6 documentation and master sample submittals gm production part approval process ppap and pilot sample submission procedure gp 4 samples submitted for gm engineering validation or vehicle tests shall also include statistical distributions for the control characteristics listed below key control product characteristics 1 air gap 2 overtravel 3 contact force n o 4 contact force n c 5 resistance 6 pull in voltage 7 drop out voltage 8 millivolt drop n c 9 millivolt drop n o 10 pre travel if applicable 0 copyright june lw8 general motors c r ratm all rqhts r june 1998 page 5 9111p copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs vnd gh ghslllp engl lj978 m lllilb37 i 0032547 09ll m 1 general motors engineering standards 1 materials and processes electrical 1 standard reliability program for relays gmqlllp 4 6 1 the production part approval process pap shah not be used to submit requests for waivers deviations or change in any drawing feature consent for temporary waivers of non critical features approved in advance do not imply authoriza tion to waive any drawing or contractual requirements 4 6 2 running changes the following requirements must be met prior to incorporation of any changes in design material process location or subsupplier 1 written notification of the change must be submitted by the relay supplier to the designated gm purchasing representative notification must be early enough to allow for any revalidation testing that may be required the notification must included the fol lowing information a applicable gm part number b detailed description of the change e reason for change liming desired for the change test plan and or supporting documentation to revalidate the product revalidation testing if any must be completed a ppap resubmission may be requested by gm engi neering depending on the nature and magnitude of the change written approval for implementation must be given by gm purchasing a record of all changes must be maintained by the supplier engineering department the change record shall include items a through e above and the follow ing information a gm approval and data b actual incorporation date c outcome of mvalidation testing 9111p page 6 june 1996 copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs 00 gmslllp engl 1998 m 900b379 0012550 803 m i general motors engineering standards i materials and processes electrical i standard reliability program for relays gmqlllp cycles reliability load ratio 10 000 15 000 20 000 25 000 30 000 35 000 40 000 45 000 50 000 55 000 60 000 70 000 80 000 90 000 100 000 125 000 150 000 175 000 200 000 250 000 300 000 400 000 500 000 600 000 700 000 800 000 1 ooo ooo application nomograph 9998 9997 9996 9994 9992 999 lf 998 997 996 994 992 yc 99 98 96 94 i 92 9 8 7 6 1 5 4 2 3 bulb ind res 0125 05 7 075 1 ie5 2 e5 15 l 4 lo e 15 125 2 175 3 25 35 4 5 6 8 i 225 45 9 25 5 1 0 26 52 27 54 28 56 29 58 30 6 31 62 32 64 33 66 34 68 35 70 36 37 38 39 40 from mil hdbk 217e provided reliability at 100 000 cycles switching resistive load with stress factor 4 77 load ratio 1 0 is demonstrated to be 99 by test figure 4 5 application nomograph june 1998 page 7 9111p copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs vnd gm ghsll l p engl l 998 m 900b379 olll255 74t i general motors engineering standards i materials and processes electriqal i standard reliability program for relays gm9111 p data package no compiled by date complete the appropriate line os each item is filed 1 2 3 4 5 6 revision level and change date of gm port print revision level and change date of gm specification if separate from print date design foilure mode effects anolysis wos opproved dote model shop or production quality representotive signed a statement listing 011 piece part dimensional variances and or changes from normal production processes which occurred in the samples submitted for release testing report number and date covering the test results list of equipment ond next calibration due date for equipment used for design release tests report number and date covering the test results list of equipment and next colibrotion due date for equipment used for reliability demonstration tests i hove reviewed the release data package ond its contents and i certify thot the series of tests required by the gm port drawing were conducted using samples ond test equipment with proper traceability hoving conducted these tests there were no failures within the expected life of the product except where provisional opprovol is obtoined in writing from gm product engineering and is attached to this checklist director of engineering date 9111 005 6 98 figure 4 6 release data package checklist page 8 june 1998 copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs vnd gm gmsl l lp engl l l l8 m 900b37 7 0032552 b8b i general motors engineering standards i materials and processes electrical i standard reliability program for relays gm9111p 5 process controls process controls shall be implemented on all dimensions based on capability and criti cality adequate methods of control include use of variable or attribute gauges which have been approved for use by per forming gauge studies 5 1 frequency of checks table 1 lists minimum process control requirements and the frequency at which the checks must be performed measurement frequency for dimen sions is to be determined at the manufacturing location the burden of scrap and rework can be lessened by controlling part dimensions which in turn control the final assembly character istics listed in table 1 table 1 process compiled by dote complete the oppropriote box os each item is filed 1 revision level and change dote of design foilure mode effects analysis 2 dote simuloted reloys exhibiting defective performance ore due for colibrotion ond lost dote of calibration mo yr i hove reviewed annual copobility study results ond engineering drawings to determine the following control items exhibit copobility rotios less than 75 and ore centered obout the mean such that 99 7 of product is within print specifications x ond r charts ore mointoined for each control chorocteristic the following control items exhibit copobility ratios greoter thon 75 or ore not centered about the mean such thot 99 7 of product is within print specifications goals and plans for process improvement ore itemized on the bock of this form for each control chorocteristic 1 9 the generol requirements concerning internal part troceobility assignment of lot numbers ond onolyzing end of line rejects hove been met circle number where opplicoble 7 6 3 a z 9 7 6 3 a 4 9 5 yes no plont monoger dote figure 5 4a process data checklist 9111p page 12 june 1998 copyright general motors north america provided by ihs under license with gm licensee ihs employees 1111111001 user japan ihs not for resale 06 24 2008 00 54 34 mdtno reproduction or networking permitted without license from ihs i general motors engineering standards i materials and processes electrical i standard reliability program for relays gm9111p control chcracteristics 1 b 1 8 9c 9b i u 3111 543 5 94 figure 5 48 process data checklist 6 reliability audits 6 1 thirty 30 cycle burn in test these tests shall be conducted as indicated by table 1 b these tests are to be conducted under the test methods as follows a load on all contact sets to be minimum 1 amp resis tiveload 12 14v b ambient temperature to be 23 c duty cycle must allow for timing to verify make or break condition c total test duration to be 30 cycles minimum d the test shall be automatically monitored to assure that neither failure to make nor failure to break occur on any test cycle a policy regarding the maintenance of test connectors shah be established e tested relays may be shipped as new 6 1 1 thirty 30 cycle bum in test