gme-拉索式换挡操纵系统设计规范_图文.doc

Cable Shift System for Manual Transmissions 拉索式手动换档操纵系统一般性要求1 Introduction 1 介绍1.1 Scope. This specification outlines the technical specifications required for the cable shift system of manual transmissions. This specification applies to the assembly, specially to the shift lever knobs, to the mechanism, to the shift and select cables and to the shift lever boot (where applicable). 1.1范围本技术规范概要性的描述了拉索式手动换档操纵系统的要求。包括操纵系统总成，尤其是换档手柄，操纵机构，换档换位拉索以及防尘罩（如果使用）Stipulation of the functional and durability require-ments placed on gearshift mechanisms is necessary in order to ensure the quality and service lifetime of the parts supplied. The requirements contained in this specification reflect those minimum values which are necessary in order to be able to carry out regular evaluation of conformity with design engineering targets. These requirements are to be looked upon as being an addition to validation tests, dimensional inspectionand ，and in process quality checks.为了确保质量和寿命，规定的功能和耐久性的要求是必要的。为了达到工程设计目标，以便定期检查各项产品设计的要求，设置各项最小值是必要的。这些要求作为除了验证测试，空间尺寸检查外，还应当进行过程质量控制。 In the context of technological progress changes to the cable shift system design are both inevitable and desirable, this document is not intended to limit the suppliers creativity. 操纵系统是不断完善的过程，本规范不应限制供应商的在零部件方面的创新。1.2 Mission / Theme. The cable shift system is the driver interface to the manual transmission and pro-vides the ability to select the desired gear position. The cable shift system is controlled by the driver mov-ing the shift lever knob to the desired gear. 1.2主题换档操纵系统是驾驶员的一个重要人际界面，为驾驶员提高选择到正确到位的装置，通过驾驶员运动手柄球头来达到控制档位的目的。2 References2参考文件2.1 Normative. 标准化要求DIN 50021 2.2 GM. GMI L-7B01D-9 GMN7000TP GMW3059 2.3 Additional. VDA 260 3 General Requirements 3一般要求3.1 Requirements to the Supplier of the Cable Shift System. The supplier of the cable shift system shall be a full service supplier with development, design and test capabilities. The supplier shall have testing facilities capable of performing and docu-menting all tests and validation requirements defined in this specification. The supplier shall validate the cable shift system according to section 5, and provide engineering support for the development, integration and application. The supplier shall have facilities to design, perform engineering analysis and maintain a drawing database. The drawings of the cable shift system shall be documented using the Unigraphics format. 3.1对供应商的基本要求供应商应具有开发、设计、试验一体的能力，具有能够测试本规范要求的一切要求的能力。具有能够满足本要求第5章的要求，能够为公司开发、集成、应用提供支撑。应具有设计、工程分析、基本的制图设备。制图要求用CATIA软件。3.2 Interfaces. 3.2接口aPart interfaces between shifter, cables (including grommet to vehicle), cable abutments and cable end fittings shall be designed to fit together per design specification. a 换档机构、拉索（包括与车身之间的连接）、拉索之间的接口、拉索接头的接口设计都应该在满足每一个技术要求的前提下进行一体化设计。bPart interfaces between shift lever knob, shift lever boot/cover, and gear lever itself shall be of appro-priate design. B 换档手柄、防尘罩（防尘盖）和换档机构本身之间的接口应该适当考虑。cShifter shall meet to floor pan specification shown in Appendix 1 and 2.C 换档机构应该满足地板安装的要求（按照附录1和2）dInterfaces between shift lever boot/cover, shifter and centre console shall be tailored to fit together per design specification. d 换档防尘罩（防尘盖）、换档机构与换档控制箱之间的接口配合应该严格考虑3.3 Installation Space. The installation space is de-fined in Appendix 2. The shifter shall be fully con-tained within this envelope with exception to the shift shaft which will extend upward out of the space.3.3安装空间要求安装空间按照附录2的要求。换档机构应该进行包络检查，手柄球的运动范围很有可能会超出安装底座的范围。3.4 Weight. 3.4重量1Shifter assembly: 1.5 kg（1）换档机构应小于1.5Kg 2Shift and select cable (assembly): 85 % (routing 90 with radius of 150 mm at room temperature with a force of 300 N). 拉索的效率应 85 %（室温下，300N的拉力，用150mm的曲率半径弯成90度进行测量）The free play in the cable shall be 0.6 mm (routing 90 with radius of 150 mm at room temperature with a force of 10 N). 拉索的无效行程应该小于 0.6 mm（室温下， 10 N的拉力，用150mm的曲率半径弯成90度进行测量）The cable cores shall be protected against environ-mental effects at transmission side. 变速器端的拉索接头应该具有防污染保护装置。The cable radius shall be 150 mm minimum. 拉索布置应该不小于150mm的曲率半径The cables shall be adjustable at the shifter side (range of adjustment: 6 mm) and the adjuster shall be activated from the top through the console opening. 拉索的调节机构应该位于换档操纵机构一端（调节行程： 6 mm），同时在将防尘罩打开的情况就能调节。The Pull-off load of select cable end fittings on transmission side shall be 1000 N minimum. The force is applied perpendicular to pin ball. 在变速器端的换位拉索接头与销子的拔出力最小为1000N。拔出力方向为拉索销的竖直方向。The Pull-off load of shift cable end fittings on trans-mission side shall be 1800 N minimum. The force is applied perpendicular to pin ball. 在变速器端的换档拉索接头与销子的拔出力最小为1800N，拔出力方向为拉索销的竖直方向。The abutments of the cables shall have a top load snap-in design at transmission and shift lever side, on the transmission side they shall have additional rotary symmetry. The Snap-in insertion of the abutment of the cables shall be 50 N maximum. The pull-off load shall be at shifter side 150 N minimum and on transmission side 400 N minimum. Easy removal with out tool shall be possible on shifter and transmission side.所有的拉索套管帽装配力最大为50N，换档器端拔出力最小为150N，变速器端最小为400N。同时在不使用工具的情况下能够轻松从支架上拆除。The cable end fittings shall be attach to ball pins on transmission side. The ball pins shall have a diameterof 10 mm h9拉索接头能很好装配到变速器的销子上，销子的直径应该为10 mm h9。The “snap-in” insertion of the cable end fittings to transmission pin ball shall be (75 20) N. The removalshall be 500 N minimum axial to pin ball.拉索接头与变速器端销子的最大装配力为(75 20) N.。销子轴向的拉索拔出力最小为500N。No free play is allowed in the connection of the cable end fittings to the ball pins on the transmission(Test: 9 N at cable end fittings, travel 0.05 mm maximum).拉索接头与拉索销之间的无效行程要求： 9 N作用于拉索接头上，行程不超过0.05mm。The colors of all visual cable and shifter parts were chosen under installation aspects. Different colors for shift and select are used for following parts拉索的外表应该进行颜色区分以便装配，这些零件为：:cable conduit护套 swivel tubes导向管 abutment on transmission side变速器端的套管帽 cover of adjuster调节机构的表面 The inliner material of both cables shall be PTFE.拉索内衬材料必须使用PTFE材料 The free play between adjuster and shift lever in shift direction shall be TBD and in select directionshall be TBD.调节机构与换档机构在换档方向和换位方向的无效行程应该进行计算。 Grommet fit to hole in the fire wall shall be (90 0.2) mm x (50 0.2) mm (Epsilon program).Thickness of sheet metal including coating shall be 0.886 mm minimum and 0.970 mm maximum4.5 Shift Lever Knob Requirements.4.5手柄球的要求The knob will be supplied as a part of the shifter assembly.手柄球应该作为换档操纵机构的一部分进行供货The knob shall have an additional metal insert.手柄球内部应该有一块金属块。The mass of the shifter lever knob shall be the biggest possible, under consideration of the shift lever knob design. 在换档手柄设计允许的前提下，应尽可能将换档手柄的质量设计尽可能的大。The leather of a leather shift lever knob shall be conform with TM 900500. 对有真皮要求的手柄球，应满足.的要求i。4.6 Shift Lever Boot Requirements. 4.6换档防尘罩的要求。The boot will be supplied as a part of the shifter as-sembly. 防尘罩应该作为换档操纵机构的一部分进行供货The boot material shall be conform with TM 343700. 防尘罩的材料应该满足.的要求The boot assembly shall be designed to fit into steel master peace of the center console according to the released 3D-data and to not wedge in the mechanik of the shifter. Off tool samples of the boot shall be tested and approved according to drive and bench test GMI L-7B01D-9 by product development. 工装样件的防尘罩应该经过路试和台架试验的验证。5 Testing 5试验5.1 Basic Requirements.5.1基本要求 5.1.1 Testing Responsibility. All lab / bench tests are the responsibility of the supplier. A statistically significant number of tests (3 parts minimum or five parts of one base design, 2 parts minimum of each version) are to be performed throughout each phase of development. GM may and will, at its discretion, perform some or all of the lab / bench tests. GM vehi-cle tests are also to be met as described in the SOR. Bench tests without shift lever knob. 5.1.1测试责任所有试验室和台架的准备都由供应商负责，每个开发试验阶段都应该具有一定数量的测试样件（至少3个或者基础设计5个，每个版本至少2个）台架试验可以不要求手柄球。5.1.2 Mounting of Test Specimen. If no other specific requirements are agreed upon, the position of the shifter shall simulate the vehicle installation conditions. 5.1.2试验样件的安装如果没有特别的同意和要求，安装位置应该模拟试车的安装条件。5.1.3 Load Application Point (LAP). In all tests the appropriate loads and / or movements are to be intro-duced at the load application point. The load applica-tion point is the largest radius of the shift lever knob. The load application point is simultaneously the mea-surement radius, i.e., the point where all the resulting displacements and / or deformations are to be deter-mined. 5.1.3加载点在所有的测试中，加载点或者运动点都是受力点，受力点为手柄球上的运动半径最大的点。受力点同时也是测量半径的点。5.1.4 Temperature Range (Part Temperature).Passenger Compartment: / (-30.+80) C Fahrzeuginnenraum: Engine Compartment: / Complete assembly of Base version / (-30.+120) C Motorraum: cable abutment / Basis Variante Short time -1 h: +140 C/ Kompletter Kurze Zeit -1 h: +140 C Zusammenbau der Hllenendstcke der Kabel Special HT version / Spezielle HT Variante (-30.+150) C Short time -1 h: +240 C/ Kurze Zeit -1 h: +240 C Assembly of end fitting / (-30.+120) C Zusammenbau Kabelseelenendstck Short time 1 h: +140 C/ Kurze Zeit -1 h: +140 C Cable conduit / (-30.+120) C Kabelummantelung Short time -1 h: +140 C/ Kurze Zeit -1 h: +140 C Grommet / TPE Grommet / (-30.+120) C Stirnwandabdichtung TPE Stirnwandab-Short time -1 h: +140 C/ dichtung Kurze Zeit -1 h: +140 C Silicone Grommet / (-30.+170) C Silikon Stirnwandab-Short time -1 h: +210 C/ dichtung Kurze Zeit -1 h: +210 C All testing to be performed at room temperature un-less otherwise specified. Note: Higher temperature resistance may be re-quired in certain local areas (e.g. cable conduit) pending the outcome of vehicle temperature testing. 5.1.5 Documentation. Each shifter is to be evalu-ated after completion of the test procedure and the results are to be recorded in the form of an test report. Such reports are in all cases forwarded to the appro-priate development department. Statistical methods may be used for evaluation purposes5.2 Static Load Test. 5.2.1 Free Play. Mount the shifter complete with ca-bles in the reference position in the test bench. Se-cure the cables at the transmission end fittings such that no movement is possible. Apply a load of 3 N at the LAP on the shifter asserted from the neutral position N in the operational planes (shift and se-lect) and also in both positive and negative directions. Free Play is the resulting displacement measured at the LAP. Requirement: ashift direction 4 mm (new parts) 8 mm (after durability testing according to para-graph 5.3.2) bselect direction 6 mm (new parts) 11 mm (after durability testing according to5.2.2 Elasticity. Mount the shifter complete with ca-bles in the reference position in the test bench with-out damping elements in transmission cable support bracket. Secure the cables end fittings such that no movement is possible. After application of a load of 3 N to eliminate free play, apply a load of 50 N at the LAP on the shift lever asserted from the neutral po-sition N in the operational planes (shift and select) and also in both positive and negative directions. The elasticity is the result of the displacement at the LAP (between 3 N and 50 N). Requirement: a shift direction 15 mm bselect direction 25 mm Final tuning in the car. 5.2.3 Efficiency test. Mount the shifter complete with cables in the reference position in a test bench. Simulate a load increasing from 80 N to 120 N at the LAP. Record the force required to operate (without engagement elements) at the LAP and the resulting force at the cable ends at the transmission end. Evaluation is to be carried out at 100 N. Effectiveness is to be calculated through use of the following formula: 5.2 Statische Belastungsprfung. 5.2.1 Spiel. Die Schaltbettigung komplett mit Ka-beln in Referenzposition auf den Prfstand montie-ren. Die Kabel an den Getriebeendstcken sichern, so dass keine Bewegung mglich ist. Eine Last von 3 N am LAP auf die Schaltbettigung von der Leer-laufposition N in den Operationsebenen (schalten und whlen) sowie in positiver und negativer Richtung wirken lassen. Das “Spiel” ist die resultierende Ver-schiebung, gemessen am LAP. Anforderung: aSchaltrichtung 4 mm (Neuteile) 8 mm (nach Dauerprfung gem Abschnitt 5.3.2) bWhlrichtung 6 mm (Neuteile) 11 mm (nach Dauerprfung gem Abschnitt 5.3.2) Anforderung: a Schaltrichtung 15 mm bWhlrichtung 80 % bselect plane 70 % 5.2.4 Friction. Mount the shifter complete with ca-bles in a test bench in the reference installation posi-tion. The load required to operate in the shift plane and the select plane is to be measured with loose ca-bles at the LAP. (Before measurement 10 movements in all shift and select planes are to be performed.) Requirement: aShift 6 N (new parts, without engagement ele-ment) 4 N (after durability testing according to para-graph 5.3.2, without engagement element) bSelect 8 N (new parts, without engagement element) 5 N (after durability testing according to para-graph 5.3.2, without engagement element) cSelect TBD (new parts, with engagement ele-ment) TBD (after durability testing according to para-graph 5.3.2, without engagement element) 5.2.5 Abuse Loads. Mount the shifter complete with cables in a test bench in the reference installation position. Secure the