通用汽车电子部件GMW3172_EnvironmentalTestPlan_V13_22Jun2012.doc

XXXX company TPAN: xxxxXXX project SystemEnvironmental Test PlanVersion: 1.3 Component Environmental Test PlanComponent Name (no abbreviations):Revision Date:Revision Number:Rev. 1.3Component Part Number(s):Component Manufacturer:Drawing Number:Project:Prepared by (Supplier):Mounting Location in Vehicle:Approved by (Supplier):Kevin ZhouApproved by GM Responsible Engineer:Revision HistoryDateRevision Number + Description2012-3-10Rev. 1.0 Initial draft2012-4-27Rev. 1.1 Update of test items according to GM1829.2012-5-31Rev. 1.2 Update test paragraph 1.4, 1.5, 3.1, 3.2, 3.4, 3.5, 5.2, 5.32012-6-22Rev. 1.3 Update test paragraph 5.1.6 and 5.1.7; Exemptions update.This Test Plan is approved with the following corrections and/or added conditions:1 IntroductionThis Test Plan is completed by TTE and submitted to GM for approval by the ENV/DUR Expert.The environmental test plan is mainly for validation of XXXX project. Hereby, the EMC test is defined in a separate plan.1.1 PurposeThe Test Plan document describes validation methods and requirements to verify the design and production. The component operation and test procedures for all tests in the Test Plan documents are according to GMW3172-2010. It describes all test set-ups and the procedures to verify the environmental/durability robustness of the design.1.2 Environmental code letterAccording to the Component Technical Specification (CTS) or the Subsystem Technical Specification (SSTS),the GMW3172 Code Letters are defined as follows:Electrical LoadsMechanical LoadsTemperatureLoadsClimaticLoadsChemicalLoadsDust and WaterProtectioncomponentCCCDB/DIP5K2ECUZCCIFIP6K8IP6K9KSENSORThe Code Letter definitions are referenced in GMW3172 (August 2010).This Classification results in following Parameters:Umin = 9.0 0.1V Tmin = -403UA = 14.0 0.1VTmax = +85 3UB = 12.00.1VTPH = 953Umax =16.0 0.1VTRPS =9531.3 Parameter and Tolerance RequirementsParameterToleranceAmbient TemperatureSpec. 3 CRoom Temperature(+23 5) CTest TimeSpec. 0.5 %Room Ambient Relative Humidity(30.70) %Chamber HumiditySpec. 5 %VoltageSpec. 0.1 VCurrentSpec. 1 %ResistanceSpec. 10 %Random Acceleration (GRMS)Spec. 20 % (PSD deviations from applicable tables are not permitted)Acceleration (Mechanical Shock, G)Spec. 20 %FrequencySpec. 1 %ForceSpec. 10 %Distance (Excluding Dimensional Check)Spec. 5 %1.4 Test RequirementsIdentify any non-applicable activities in the following table as “N/A”.AnalysisDevelopment Number of samplesDesign Validation Number of samplesProduct Validation Number of samplesAnalysisElectricalNominal and Worst CasePerformance AnalysisShort/Open Circuit AnalysisMechanicalResonant Frequency AnalysisHigh Altitude ShippingPressure Effect AnalysisPlastic Snap Fit Fastener AnalysisCrush AnalysisTemperatureHigh Altitude Operation Overheating AnalysisThermal Fatigue AnalysisLead-Free Solder AnalysisDevelopmentElectricalJump Start3N/AReverse Polarity3N/AOver Voltage3N/AState Change Waveform Characterization3N/AGround Path Inductance Sensitivity3N/AElectromagnetic Compatibility(EMC)2N/AMechanicalHighly Accelerated Life Test(HALT)N/AN/ATemperatureN/AN/ATemperature MeasurementN/AN/AAnalysisDevelopment Number of samplesDesign Validation Number of samplesProduct Validation Number of samplesLow Temperature Wakeup3615ClimaticFrostN/AN/AHighly Accelerated Stress Test(HAST)N/AN/ADimensional246Design Validation (DV)ElectricalParasitic Current3N/APower Supply Interruptions3N/ABattery Voltage Dropout3N/ASinusoidal Superimposed Voltage3N/APulse Superimposed Voltage3N/AIntermittent Short Circuit to Battery and to Ground3N/AContinuous Short Circuit to Battery and to Ground3N/AGround Interconnect Short to BatteryN/AN/AOpen Circuit Single Line Interruption3N/AOpen Circuit Multiple Line Interruption3N/AGround OffsetN/AN/APower OffsetN/AN/ADiscrete Digital Input Voltage ThresholdN/AN/AOver Load All Circuits3N/AOver Load Fuse Protected CircuitsN/AN/AIsolation ResistanceN/AN/ACrank Pulse Capability andDurability3N/AMechanicalVibration With Thermal Cycling66Post Thermal Fatigue Vibration 18N/AMechanical Shock Pothole 6N/AAnalysisDevelopment Number of samplesDesign Validation Number of samplesProduct Validation Number of samplesMechanical Shock Collision6N/AMechanical Shock Closure SlamN/AN/ACrush For Housing Elbow Load3N/ACrush For Housing Foot LoadN/AN/AGMW3191 Connector Tests :Terminal Push-out Force3N/AGMW3191 Connector Tests: Connector-to-Connector Engagement Force3N/AGMW3191 Connector Tests: Locked Connector Disengagement Force3N/AGMW3191 Connector Tests: Unlocked Connector Disengagement Force3N/AConnector Installation Abuse Side Force3N/AConnector Installation Abuse Foot LoadN/AN/AFree Fall3N/AFretting Corrosion DegradationN/AN/AClimaticHigh Temperature Degradation6N/AThermal Shock Air-To-Air (TS)18N/APower Temperature Cycle(PTC)18N/AThermal Shock/Water SplashN/AN/AHumid Heat Cyclic (HHC)93Humid Heat Constant (HHCO)93Salt Mist3N/ASalt Spray3N/AEnclosureAnalysisDevelopment Number of samplesDesign Validation Number of samplesProduct Validation Number of samplesDust3N/AWater3N/ASeal33Water Freeze3N/ASugar Water Function ImpairmentN/AN/AProduct Validation (PV)Shipping VibrationN/ABy shippingcontainersAdditional ActivitiesAbrasion TestN/AN/ANote：Number of samples listed above represents both UPA and APA systemExemptions for UPA and APA system：#ItemReason1Mechanical Shock Closure SlamGMW3172 9.3.5This test is applied to components located in closure areas(door, trunk lid, hatchback, and hood). ECU is assembled in passenger compartment so that it is not needed. Sensor is assembled on bumper so that it is not needed.(Mechanical Code C)2 WaterGMW3172 9.5.2For sensor according to GMW3172, paragraph 9.5.3 seal is done so that it is not needed.3Ground OffsetGMW3172 9.2.11The ECU is no battery supply directly, but signal line connecting.4Power OffsetGMW3172 9.2.12The ECU is no battery supply directly, but signal line connecting.#ItemReason5Discrete Digital Input ThresholdVoltage GMW3172 9.2.13This test is applied to digital input and switch input interfaces with transmitters grounded locally without signal return to receiver. It can be replaced by Analysis at Hardware Design Review.6 Over Load Fuse Protected CircuitsGMW3172 9.2.15According to GMW3172, this test is applied for components containing internalcircuit protection features, such as a fuse or circuit breaker. Not contain fuse, circuit braker, etc. This sensor does not contain fuse, circuit bracker, etc so that it is not needed.7 Connector Installation Abuse Foot Load GMW3172 9.3.10ECU is located inside vehicle and will not experience foot loads during vehicle assembly or servicing.Sensor is assembled onto bumper which it wont experience foot loads during vehicle assembly or servicing.8Crush For Housing Foot LoadGMW3172 9.3.7 ECU is located inside vehicle and will not experience foot loads during vehicle assembly or servicing.Sensor is assembled onto bumper which it wont experience foot loads during vehicle assembly or servicing.9Fretting Corrosion DegradationGMW3172 Section 9.3.12According to GMW3172, this test is applied to components that have internalcontacts such as fuse holders, press fit connections, PCB-to-PCB connections, etc. The system does not have these components so that it is not needed.10Sugar Water Function ImpairmentGMW3172 9.5.5 According to GMW3172, this test is applicable to components with mechanical moving parts, such as knobs or buttons in passenger or trunk compartment. The system does not have these moving parts and is not located in the passenger or trunk compartments.(Chemical Code B-Cabin Unexposed)11Ground Interconnect Short to Battery GMW3172 9.2.8The PA system is connected without a ground pass-through.12Thermal Shock/Water SplashGMW3172 9.4.4This test is generally required for product that will operate hot, and may be splashed by water. So exclude the ECU and sensor( Climate ECU Code letter D, sensor Code letter I)1.5 Test Flows1.5.1 Analysis(N/A)1.5.2 Development(N/A)1.5.3 Design Validation (DV)(Refer to following flow chart )1.5.4 Product Validation (PV)(Refer to following flow chart)DV Flow Chart-passenger partDV Flow Chart-exteriorPV Flow Chart2 Component Description2.1 Component Family DescriptionThe ECU is optimized base on XXXX ECU, pin out definitions and mechanical structure requirements of GM. The sensors circuit is new design.Samples subjected to environmental tests are produced by formal mold and production line.The PA system of XXXX consists of Parking assist processing module (UPA, APA gen 1, APA gen 2), Bracket for PA processing module, PA sensors for rear and front and Retainer (Multiple styles). 2.2 Component Physical DescriptionFollow mechanical structure requirements of GM, Physical structure :ECU Appearance-Part location for reference Connector parallel the groundECU Appearance-Part location for referenceConnector parallel the groundXXXX Appearance-Part location for reference ZXZYConnector parallels the groundSENSOR Appearance-APAPart location for referenceZXYConnector parallels the groundPPPPPPDimension:(mm)ECU: ECU:XXXX: 25.30.543.60.5230.5280.5XXX: 25.30.543.60.5230.5280.52.3 Component Functional DescriptionFunction description here(rear range zone).xxxxxx(front range zone)xxxxx2.4 Operating TypesThe following table reflects the electrical operating type of GMW3172. Describe the I/O states for each Operating Type. Provide any additional clarification for component specific Electrical State as necessary.Operating Type Electrical State1No voltage is applied to the component.1.1Component is not connected to wiring harness.1.2 Component is connected to wiring harness.2The component is electrically connected with supply voltage UB (battery voltage, generator not active) as in a vehicle with all electrical connections made.2.1 Component functions are not activated (e.g., sleep mode, OFF mode).2.2 Component with electric operation and control in typical operating mode.3 The component is electrically operated with supply voltage UA (engine/generator active) with all electrical connections made.3.1Component functions are not activated (e.g., sleep mode, OFF mode).3.2 Components with electric operation and control in typical operating mode.2.5 Parking aid system interface and connector pin description:2.5.1 Hardware Interface 1Hardware Interface 22.5.2 Connector pin definition Pin definition here( To be continued)2.5.3 ECU Connector 1：ECU Connector- 2：Xxxx Connector-： 2.6 Functional Status Classification (FSC)The FSC defines the functional performance of the component.class Definition of FSC ClassAAll functions of the component perform as designed during and after the test.BAll functions of the component perform as designed during the test. However, one or more of them may go beyond the specified tolerance. All functions return automatically to within normal limits after the test. Memory functions shall remain FSC A.FSC A is also acceptable for components that are classified as FSC B.COne or more functions of the component do not perform as designed during the test but return automatically to normal operation after the test.FSC A or B are also acceptable for components that are classified as FSC C.DOne or more functions of the component do not perform as designed during the test and do not return to normal operation after the test until the component is reset by any “operator/use” action.FSC A, B, or C are also acceptable for components that are classified as FSC D.EOne or more functions of the component do not perform as designed during and after the test and cannot be returned to proper operation without repairing or replacing the component.FSC A, B, C, or D are also acceptable for components that are classified asFSC E.3 Performance Verification3.1 1-Point Functional/Parametric CheckApplicable Standard: GMW3172, paragraph 6.2Operating Type: 3.2Monitoring: Defined in procedureParameters: Room Temperature: 233; Unom=14V0.1VProcedure: 1 Connect the DUT with harness and place in temperature chamber. 2. Store the DUT at room temperature after the temperature stabilizes. 3. Check the DUT function at Troom=233 and Unom=14V0.1V 4 Above test is performed during or after tests as defined in this Component Environmental Test Plan.Result:3.2 5-Point Functional/Parametric CheckApplicable Standard: GMW3172, paragraph 6.1Operating Type: 3.2Monitoring: Defined in procedureParameters: Room Temperature: 233 Tmin=-403 Tmax=+853 Umin=9.0V0.1V Umax=16.0V0.1V Procedure: 1 The test is performed at five points as follow: . (Tmin, Umin);. (Tmin, Umax);. (Troom, Unom);. (Tmax, Umin);. (Tmax, Umax) 2 Connect the DUT to power and place in temperature chamber. 3. Reduce the temperature to Tmin=-403. Keep the DUT at the temperature more than 30 minutes after the temperature stabilizes. 4. Then check the DUT function at voltage Umin=9.0V0.1V and Umax=16.0V0.1V 5. Repeat the steps at Tmax=+853 with Umin and Umax. 6. Check the DUT function at Troom=233 and Unom=14V0.1V 7. Above steps are begin and after test flow. The performance shall satisfy the functional spec listed in before pages.8. Monitor via the tester of parameters of the distance & ring-time during test. The computer will display the values measured by the sensor in sequence and confirm OK/NG. Monitor the detection distance of sensors with tolerance 10% in room temperature and 25% in high and low temperature. The ring-time tolerance is 0.8ms2.6ms , , and monitor the detection distance of ECU with tolerance 10%.Criteria: Functional Status Classification shall be A during duration of mode 3.2. Result:3.3 Continuous MonitoringWhile at operating mode 3.2 phases, driver information outputs function will be checked by tester to verify whether the system working correctly or not. There will be two ways of monitoring based on test setup conditions: 1) Monitoring through the whole tests with a specialized-made testing tool: 1.1) When monitor the ECUs, simulating sensors will be used as input signal of detection1.2) When monitor sensors, the simulated distance of Obstacle will be adopted in order to simulate actual detection area distance. 1.3) All of ECUs shall be supplied and be sampled one by one. The sampling frequency is 1Hz. It is generally used to judge if ECUs have errors during the test by reading DTC state. 1.4) Monitored hardware I/O comprise SESNOR，UPA LED, SBSA LEDs, UPA SWITCH, APA SWITCH, which shall cause DTC state 2) Monitoring the parameters before tests, at intervals of tests and after tests by testing hardness and device. The parameters tested should be recorded to check the deviations against to specifications.3) Acceptance criteria: 3.1 ECU Testing SystemIt shall validate in the method of comparing object distance returned by tester with object distance set by sensor simulator ,and acceptable tolerance is within10%3.2 Sensor Testing System1. It shall validate in the method of comparing object distance checked by tester with actual object distance, and acceptable tolerance is within25% 2. Ring time range:8002600us Result: 3.4 Functional CyclingThe environment test is to simulate customer usage and some Functional Cycling will occur during test.1) During mode 3.2, a continues power supply will subject to DUT, which is to simulate real load when used on a vehicle.2) In PTC test, a 100 seconds Power ON and 20 seconds Power OFF will subject to DUT while temperature stable and rising phase.3) The DUT will be cycled betw