SP100(SD)-SPDS-AIRBAG SYSTEM (LUXURY).doc

System Product Design SpecificationDoc.No.: SPDS-AIRBAG SYSTEM Doc.Rev.: 01Rev. Date: 2014.11.20Page 19 of 19In The Name of GodSystem Product Design SpecificationProj. NameProj. CodeModel YearVariantsAffectedVehicleAreaELECTRICALDocumentReferenceDoc. No.SPDS-AIRBAG SYSTEM ISSUE Date2014.12.25Doc. Rev01Rev. DateSystem/SubsSystemAIRBAG SYSTEM (LUXURY)InformationRefConfidentiality: This document is protected by copyright and may not be reproduced stored on database or duplicated by any means without the written consent of AIRIC. The information contained within this document may only be used for the purpose for which it is supplied. This document or any part thereof must not be disclosed to a third party without the prior written consent of AIRIC. Any contravention of our rights or misuse of this information may result in legal proceedings being issued against the offending party.DEPARTMENTNAMESIGNATUREDATECOMPILED BY(Engineer)CHECKED BY(Principal Engineer)APPROVED BY(Design Manager)INTEGRATION APPROVAL(Vehicle Engineer)SUPPLIER APPROVAL This document will be completed according to Q-I-MA-0019. CONTENTS SectionSubjectPage Ref1Introduction2Scope3Program Requirements3.1Markets & volumes3.2Base & Competitor Systems3.3Timing3.4Prototyping & Design development3.5Legal Requirements3.6Team Organization3.6.1Team membership, roles & responsibilities3.6.2Communications3.6.3Program Control3.7CAD Management3.8Design Validation3.8.1Parts Testing3.8.2System Testing3.8.3Vehicle Testing3.8.4Certification / Homologation3.8.5Material Tests3.8.6Geometric Tests3.8Geometric Tests3.9Technology Deployment3.10Product Features4Product Requirements4.1Attributes 4.1.1 Environmental Protection 4.1.2Appearance4.1.3Design for Manufacturing & Assembly 4.1.4Product Life Cycle4.1.5Variable Cost4.1.6Weight 4.1.7Packaging4.2Interface Diagrams4.3Function, quality & robustness4.4Design Assembly / Parts List4.5Operating Environment4.6 Service Requirements4.7Product Marking 4.8 Product Failure Mode Analysis ( DFMEA )4.9Reusability 5SUPPLIER REQUIREMENTS5.1General5.2Warranty 5.3 Material Handling 5.4Quality Assurance5.5Product / Process Failure Mode Analysis ( PFMEA ) 5.6Reusability 5.7Samples / Quality Conformance5.8Technical Date / Documentation6Glossary of Terms7Appendices8Issue History1. Introduction This Product Design Specifications (PDS) as part of a complete set has been compiled in order to identify all requirements for design, development & manufacture of the SP100 (SD) AIRBAG SYSTEM on vehicle line, as specified in:l Vehicle features list (Latest Issue)l Whole Vehicle PDS (Latest Issue)l Vehicle Target Book (Latest Issue)Suppliers may request information from these documents by contacting the AIRIC & SAIPA SP100 (SD) Program Manager. 2. Scopes This PDS covers all aspects controlling Design, Manufacturing and Quality requirements of the SP100 (SD) vehicle AIRBAG SYSTEM. Legal requirements included in this document are based on applicable current EEC, ECE and Iranian Safety Standards.Full documentation of required standards and norms will be provided to nominated suppliers by AIRIC.The latest issue of this PDS is to be taken as the definitive instruction.3. Program Requirements 3.1 Markets and VolumesSales markets, model life production volumes / rates and variant mix are detailed in the Whole Vehicle PDS, latest issue.The supplier must confirm manufacturing capability to support the stated production volumes / rates, with a maximum supply rate of AIRBAG SYSTEM per annual.The supplier must advise AIRIC of implications arising from any significant change in the stated volumes / supply rates.3.2 Base & Competitor Designs (current model year) Base design is: TBDCompetitor Designs are: TBD3.3 TimingThe SP100 (SD) Program Master Timing Plan is applicable and will be supplied on request to AIRIC SP100 (SD) Program Manager. Any revisions to the latest issue will be advised by AIRIC to the supplier, who must register immediately any concerns relating to conformance with this (and related) documents.The supplier must confirm capability to meet Program timing requirements and ensure the timely availability of suitable resources.Note: Supplier timing responsibilities detailed in the AIRIC Statement of Work3.4 Prototyping & Design DevelopmentThe supplier must supply all data / physical properties, samples etc., as specified in the AIRIC system DVP / Supply Agreement, and conforming to 3.3 above.3.5 Legal RequirementsThe SP100 (SD) vehicle AIRBAG SYSTEM must conform to the following legal standards, as a minimum:No.TestsStandards1ID system control SRS Warning Lamp78/316/EEC2Front offset Impact96/79/EC (ECE R94)3Protective Steering (DAB module Included)74/297/ EEC (ECE R12)4EMC (Airbag system included)72/245/EEC5Interior fittings (PAB& CAB module Included)74/60/EEC (ECE R21)3.6 Team Organization3.6.1 Team membership, roles & responsibilitiesSupplier representative (s) will be integrated in the AIRIC SP100 (SD) Program Team and fulfill their roles & responsibilities in line with AIRIC procedures and the Supply Agreement (Statement of Work).3.6.2 CommunicationsAll communications between relevant parties must be in electronic / written form, with circulation / archiving procedures to meet AIRIC requirements.3.6.3 Program ControlPlanning, monitoring progress, forecasting and open issue management must conform to AIRIC requirements.3.7 CAD ManagementThe supplier must comply with the AIRIC data management requirements for all CAD product / process data (including security & transfer).3.8 Design ValidationThe following tests are scheduled in a vehicle/system DVP (approved by AIRIC), and must completed for validation of the SP100 (SD) vehicle AIRBAG SYSTEM.3.8.1 Parts Tests3.8.1.1 DAB& PABTest ItemStandardModules (requirements & Test Procedures)ES 34143868Bags (requirements & Test Procedures) ISO 12097-2Inflator assemblies (requirements & Test Procedures)AK-LV 03(2009) High temperature light exposure ES 34143868Scratch resistance ES 34143868Odor test ES 34143868Determination of emission of organic compoundsAccording to supplier test reportCondensable consistence ( non-metallic parts)According to supplier test reportComponent test methods for electrical disturbances ISO 11452 Airbag cover material requirementsES 34143868FlammabilityFMVSS 302 3.8.1.2 ACU, CLOCK SPRING, COMBINATION SWITCHTest ItemStandardACUAccording to supplier test reportClock springQ-140000TF-001(2007)3.8.1.3 SAB& CABTest ItemStandardCurtain airbag (requirements & Test Procedures)TBDSide airbag (requirements & Test Procedures) TBD3.8.2 System tests3.8.2.1 The following IP system tests (PAB included)No.TestsStandard1Short-term Heat Resistance KES D-G008 (Hs-09,C)2Long-term Heat Resistance KES D-G008 (HL-I,04,C)3Repeating Cold-Heat Resistance KES D-G008 (Th-04,D,C)4Performance Other than Above (Except Abnormal Sound)KES D-C2035Noise test (Abnormal Sound) RENAULT: 32-04-858/BThese tests will be done by IP system integrator. (PAB module must fulfill the results as a component; PAB integrator will implement 3.8.1 tests as a reference.)3.8.2.2 The following seat system tests (SAB included)No.TestsStandard1 According to seat supplier requirements 23453.8.2.33.8.2.3 SLED tests Sled test_ FrontalSpeed (Km/h)PositionSafety PT beltDummy (2*H III)Temp. (o C)CommentTypePosition50 kph Full frontal 0Yes5%Front +23 RS Performance check and confirmation50 kph Full frontal 0Yes50%Middle+23RS Performance check and confirmation50 kph Full frontal 0Yes95%Rear +23RS Performance check and confirmation56 kph ODB40%OffsetYes50%Middle+23RS Performance check and confirmation64 kph ODB40%OffsetYes50%Middle+23RS Performance check and confirmation Sled test_ LateralSpeed (Km/h)PositionSafety PT beltDummy Temp. (o C)CommentTypePosition50 kph Lateral Yes1*WS-50%Middle +23 RS Performance check and confirmation50 kph LateralYes1*ES2-50%Front +23RS Performance check and confirmation50 kph LateralYes1*ES2-50%Rear +23RS Performance check and confirmation32kph Lateral pole Yes1*WS-50%Middle +23 RS Performance check and confirmation32kph Lateral pole Yes1*ES2-50%Front +23 RS Performance check and confirmation32kph Lateral pole Yes1*ES2-50%Rear +23 RS Performance check and confirmation3.8.3 Vehicle TestsNote: The below crash test Scenarios have been defined for the vehicle SP100_Sedan_Standard with one engine ( BM15), one transmission type (MT) and one fuel type (Petrol) so the test program and the number of vehicles may be changed if : There are some varieties in engines and transmission types. Fuel types ( Petrol/Bi-fuel) Variety of crash signals during the crash tests There are varieties in vehicle type (Sedan or Hatchback or ).3.8.3.1 Crash Test Scenarios Frontal crash tests _DV phaseConfigurationDummyDriver/PasDriver Passenger Remark DAB BeltPABBelt15kph AZTCrash1 x HIII-50%1. stage no fire2. stage no fire no fire1. stage no fire2. stage no fireno fireNo Fire20kph FFCrash1 x HIII-50%1. stage no fire2. stage no fire tbd ms1. stage no fire2. stage no firetbd msBP Threshold26kph FFCrash2 x HIII-50%1. stage tbd ms2. stage no firetbd ms1. stage tbd ms2. stage no firetbd ms1st StageThreshold35kph 30Crash2 x HIII-50%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd ms2nd StageThreshold50kph FFCrash2 x HIII-5%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd msEuro NCAPODB 64 kphCrash2 x HIII-50%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd msEuro NCAPConfigurationVehicle15kph AZTCrash#01LUX20kph FFCrash#02LUX+sun roof26kph FFCrash#03LUX+sun roof35kph 30Crash#01LUX50kph FFCrash#04LUX+sun roofODB 64 kphCrash#05LUX+sun roof Frontal crash tests _PV phaseConfigurationDummyDriver/PasDriver Passenger Remark DAB BeltPABBelt15kph AZTCrash1 x HIII-50%1. stage no fire2. stage no fire no fire1. stage no fire2. stage no fireno fireNo Fire20kph FFCrash1 x HIII-50%1. stage no fire2. stage no fire tbd ms1. stage no fire2. stage no firetbd msBP Threshold26kph FFCrash2 x HIII-50%1. stage tbd ms2. stage no firetbd ms1. stage tbd ms2. stage no firetbd ms1st StageThreshold35kph 30Crash2 x HIII-50%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd ms2nd StageThreshold50kph FFCrash2 x HIII-5%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd msEuro NCAPODB 64 kphCrash2 x HIII-50%1. stage tbd ms2. stage tbd mstbd ms1. stage tbd ms2. stage tbd mstbd msEuro NCAPConfigurationVehicle15kph AZTCrash#06LUX20kph FFCrash#07LUX+sun roof26kph FFCrash#08LUX+sun roof35kph 30Crash#06LUX50kph FFCrash#09LUX+sun roofODB 64 kphCrash#10LUX+sun roof Lateral crash tests _DV phaseConfigurationDummyDriver/PasDriver Passenger Remark SAB+ Curtain Belt SAB+ CurtainBelt13kph AEMDB side crash 1 x ES-2no fire no fireno fireno fire No Fire 30kph EEVC side crash 1 x ES-2tbd ms tbd msno firetbd msMust fire Threshold50kph AEMDB side crash1 x WS-50%tbd mstbd msno firetbd ms Euro NCAPPole 75 deg 32kph 1 x WS-50%no firetbd mstbd mstbd msEuro NCAPConfiguration Vehicle _ DV crash tests13kph AEMDB side crash#02 rightLUX+sun roof30kph EEVC side crash#03 left LUX+sun roof50kph AEMDB side crash#02 left LUX+sun roofPole 75 deg 32kph#03 rightLUX+sun roof Lateral crash tests _PV phaseConfigurationDummyDriver/PasDriver Passenger Remark SAB+ Curtain Belt SAB+ CurtainBelt13kph AEMDB side crash 1 x ES-2no fire no fireno fireno fire No Fire 30kph EEVC side crash 1 x ES-2tbd ms tbd msno firetbd msMust fire Threshold50kph AEMDB side crash1 x WS-50%tbd mstbd msno firetbd ms Euro NCAPPole 75 deg 32kph 1 x WS-50%no firetbd mstbd mstbd msEuro NCAPConfiguration Vehicle _ PV crash tests13kph AEMDB side crash#07 rightLUX+sun roof30kph EEVC side crash#08 right LUX+sun roof50kph AEMDB side crash#07 left LUX+sun roofPole 75 deg 32kph#08 left LUX+sun roof3.8.3.2 Rough Road Test ScenariosPOSTEST BrakedunbrakedKPH1Belgian-block-track X602Belgian-block-track X803Washboard Road X654Washboard Road X755Washboard Road X856Resonance Washboard Road Xtbd7Washboard Road X758Washboard Road with Resonance speed Xtbd9Torsion track X8010Cobble Stone track X7011Railroad Crossing X6012Railroad Crossing X6013Gravel Path X5014Gravel Path, start forward XMax.15Pothole RH wheels X4516Pothole LH wheels X5517Pothole X5018Pothole X6019Pothole X4520Ramp jump X7521Steel beam 80mm X5022Steel beam 80mm X4023Steel beam 100mm, 45 X4024Gravel heap X3025Deer impact (m=80kg) X7026Steel beam 140mm, 30, with steering X2527Bump, (flat cake) X9028Bump, (flat cake) X8029Step test (200mm, no overrun) X730Undercarriage test (1 inch overlap) X303.8.3.3 Frontal Misuse Test ScenariosPOSTEST1Seat adjustment driver occupied (move forward, rearward)2Seat adjustment driver empty (move forward, rearward)3Hammer Blow (HB) against seat rails4HB against tow hook5HB against axle suspension left6HB against axle suspension right7Door Slam (DS) front left8DS front and rear, right and left - Doors on both sides slammed simultaneously9DS front right - Locked striker10DS front left - Seat belt tongue outside B-pillar11DS front left - without door seal12HB against door latch13DS front and rear, right and left - Doors on both sides slammed simultaneously - without door seal14Fixation of belt fastener with pneumatic tool15Hood / bonnet slam16HB against door seal17HB against rocker fold (left)18HB against rocker fold (right)19HB against B-Pillar (left)20HB against B-Pillar (right)21HB against floor22HB against belt retractor23HB against Rocker from outside24HB against beam25HB near ECS position left26HB near ECS position right27HB against fixation screw of ECS left28HB against fixation screw of ECS right29HB against Tunnel near ECU - on vehicle floor30HB against bonnet latch31HB against wheelhouse32HB against frame rails3.8.3.4 Lateral Misuse Test ScenariosPOSTESTKPH1DS front left - Seat belt tongue outside B-pillar near SIS-2DS front right - Seat belt tongue outside B-pillar near SIS-3HB against rocker fold near SIS left-4HB against rocker fold near SIS right-5HB against B-Pillar near SIS left-6HB against B-Pillar near SIS right-7HB against floor near SIS left-8HB against floor near SIS right-9HB against belt fastener left-10HB against belt fastener right-11HB against fixation screw of SIS left-12HB against fixation screw of SIS right-13HB against Rocker near SIS left-14HB against Rocker near SIS right-15Pendulum, ball impactor on G-Sat position1516Pendulum, ball impactor on P-Sat position1517Pendulum, ball impactor on G-Sat position2018Pendulum, ball impactor on P-Sat position2019Pendulum, ball impactor on G-Sat position2520Pendulum, ball impactor on P-Sat position2521Foot kick (pendulum) on G-Sat position1522Foot kick (pendulum) on P-Sat position1523Foot kick (pendulum) on G-Sat position2024Foot kick (pendulum) on P-Sat position2025Bicycle impact on G-Sat position1526Bicycle impact on P-Sat position1527Bicycle impact on G-Sat position2028Bicycle impact on P-Sat position2029Bicycle impact on G-Sat position2530Bicycle impact on P-Sat position2531Shopping cart (m=50kg) on G-Sat position-32Shopping cart (m=50kg) on P-Sat position-33Door opening against obstacle-34Lateral sliding (90deg) on curb103.8.4. Certification / Homologation TestsRefer to section 3.5 l