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VW_80200_1_EN.pdf

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Group standard VW 80200-1 Issue 2013-10 Class. No.: 8LA10 Descriptors: add-on parts, engine, gearbox, vibration resistance, structural durability, vibrator table Add-On Parts Working Group Engine-Mounted Parts Preface The content of AK-LH 1 (Add-On Parts Working Group Performance Specification), subtitled “En‐ gine-Mounted Parts“, May 2013 issue, has been incorporated without revisions. The Performance Specification AK-LH 1 was developed by the “Performance Specification“ Work‐ ing Group of the automotive groups Audi AG, Bayerische Motoren Werke AG, Daimler AG, Por‐ sche AG, and Volkswagen AG. It supersedes Porsche Standard PTL 15500-1 and the cover sheet solution in Volkswagen Stand‐ ard VW 96370-1. Previous issues VW 80200-1: 2009-03 Changes The following changes have been made to VW 80200-1: 2009-03: – See the pages that follow (LH 1 for engine-mounted parts) Scope This standard serves to secure engine-mounted parts whose structural durability can be endan‐ gered by vibrational excitations of the engine. Description Engine-mounted parts as per VW 80200-1 1 2 Page 1 of 2. Pages that follow: LH 1 for engine-mounted parts, pages 1 to 30. Always use the latest version of this standard. This electronically generated standard is authentic and valid without signature. The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling. Numerical notation acc. to ISO/IEC Directives, Part 2. Technical responsibility The Standards department EGDB/3 Heiko Bade Tel.: +49 5361 9-23072 EGA2 Günter Weimert Tel.: +49 711 911-83946 EKDV/4 Wolfgang Tiefenbach EKDV Tel.: +49 5361 9-75357 Manfred Terlinden All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments. ? Volkswagen Aktiengesellschaft VWNORM-2012-05qPage 2 VW 80200-1: 2013-10 — empty page — WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 Always use the latest version of this standard. The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling. Numerical notation according to ISO/IEC Directives, Part 2. 0. Revision record and preface 2 1. Scope and aim 3 2. Definitions 4 3. Requirements for component measurements 6 3.1. Standardized reference point of base excitation, spatial axes 6 3.2. Measuring the component response 6 3.3. Measurement and evaluation procedure 7 4. Component tests 9 4.1. Requirements for the shaker and the test setup 9 4.2. Schematic flow chart 10 4.3. Testing when component resonances are known or easy to determine 11 4.3.1. Specification of the test level for fast testing, alternative test with stair-step method, flow chart. 11 4.3.2. Testing based on an available measurement 19 4.3.3. Testing based on a measurement on the predecessor engine 21 4.3.4. Testing without knowledge of the excitation 22 4.4. Testing without knowledge of the component resonances 25 4.4.1. Testing according to swept sine method with one or more sinusoidal excitations (multisine) 25 5. Confidentiality 30 All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group's Standards departments. ? Volkswagen AG AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 1 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 0. Revision record and preface July 2012: - Requirements for 2-cylinder and 3-cylinder engines added - Requirements for add-on parts on electric machines added Preface This Supply Specification (LV) version was prepared by representatives of automobile manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG, and Volkswagen AG in working group AK 5.2.18, also known as the “Add-On Parts“ working group. This Supply Specification is stored as an MS Word file in the Audi AG Standards department. No claim is made as to its completeness. The automobile manufacturers may demand additional tests with respect to the relevant state-of-the-art at any time. Since the individual automobile manufacturers may make changes if necessary, only the automobile manufacturers' in-house standards that are based on this LV must be used. Deviations from this Supply Specification are listed in the in-house standards on the cover sheet (in justified exceptional cases, deviations can be presented in italics in the text of the standard). If modifications of individual test sections are required in individual cases, these modifications must be agreed upon separately between the appropriate departments of the automobile manufacturer and of the supplier. For general development projects of the automobile manufacturers, test reports will be accepted as long as the tests were performed by an independent institute that is accredited as per DIN EN ISO/IEC 17025. Acceptance of the test reports does not automatically result in a release. Other test reports may be accepted at the discretion of the purchaser. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 2 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 1. Scope and aim The scope of the Performance Specification comprises specifications for the validation of engine-mounted parts whose structural durability may be endangered by vibrational excitations of the engine. Typical engine-mounted parts are heat shields, fuel lines, brackets with an add-on part, and engine-mounted sensors and actuators. Other causes of damage, such as pulsating internal pressure, thermally-induced fatigue, or reduction in strength due to material aging, are not covered. The Performance Specification provides test profiles for electromagnetic vibrator tables (“shakers”) and recommends working methods for ensuring strength. The aim of the Performance Specification is to establish a uniform procedure for qualification of components at the premises of the supplier or automobile manufacturer. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 3 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 Always use the latest version of this standard. 2. Definitions Swept sine test A test with sinusoidal excitation whose frequency cycles between a lower frequency limit and an upper frequency limit, with the objective of activating all resonances within this frequency range. Stair-step method The stair-step method is used to determine the mean value and the dispersion of the fatigue limit of a component. Random vibration profile, PSD spectrum A test with the aim of using a random vibration spectrum in order to obtain a wide frequency band for testing and, thus, possibly to excite all natural frequencies of the system to be tested simultaneously. In contrast to the fast Fourier transform (FFT) peak-hold spectrum, the power spectral density (PSD) represents the frequency band-normalized mean value of the square of the amplitudes over the frequency. This assumes a normal distribution of the amplitudes around the mean value during excitation. Base excitation The vibrational excitation that an engine-mounted part experiences at the contact point with the cylinder block and crankcase. If a particular component is installed by means of an additional bracket and not directly on the cylinder block and crankcase, the test setup must use the bracket, provided only the excitation functions in section 4.3.4 are available. If the base excitation is measured directly at the mounting point, this measurement can be used for the test. Logarithmic sweep Test sequence on a shaker in which the increase in the test frequency corresponds to the function ( ) T t o f t f 2 ? = AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 4 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 T is the time required to cover one octave, and f 0is the test's start frequency. The standard value for the increase is 1 octave/minute (T = 60 s). The logarithmic sweep applies equivalent cycles in each frequency interval of the same width ?f regardless of the frequency. For a given target number of load cycles within resonance width ?f, the test duration required can be calculated within the frequency interval [f 0 , f max ] by using the following formula: Hz f Hz f Hz f d cycles ber of loa Target num h ion Test durat ? ? ? = ) ln( ) ln( 3600 0 maxSample calculation: Test frequency of 80 Hz to 2 000 Hz, target number of load cycles of 2 000 000, assumed resonance width of 10 Hz: h ion Test durat 8 , 178 10 ) 80 ln( ) 2000 ln( * 600 . 3 000 . 000 . 2 = ? = FFT peak-hold spectrum Statistical evaluation of a signal within the frequency range in which an FFT window is moved with fixed interval length and, if applicable, with an overlap, versus a time signal. In this process, only the maximum value of each spectral line is recorded as the result. Hanning window Mathematical function for suppressing the FFT's leakage effect. Component response The response of the component to a given vibrational excitation. The absolute value of the transfer function is obtained by dividing the response by the excitation. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 5 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 3. Requirements for component measurements 3.1. Standardized reference point of base excitation, spatial axes By default, the base excitations are measured on the face of the cylinder block/crankcase or cylinder head in three spatial axes. The spatial axes are oriented at the structure of the engine. Measurements are taken in the running direction of the pistons, the crankshaft direction, and the transverse engine direction, in which all axes are positioned orthogonal to one another. For V engines, the bisecting line between the banks is used instead of the running direction of the pistons. For vehicles driven exclusively by electric motors, the excitation is measured in the area of both motor ends. For each spatial axis, the envelope must be formed on the basis of both spectra. Its application to areas with thin wall cross-sections must be avoided. The spatial axes are oriented based on the rotor's direction, the vehicle's vertical axis, and the direction of travel. If the rotor's direction coincides with one of the two latter axes, the third axis results from the other two. This Performance Specification does not cover wheel hub drives. Engine-mounted parts on hybrid drives are handled the same way as add-on parts on combustion engines. If a component that is mounted on a bracket or ancillary is to be tested, the base excitation of the specimen can also be measured directly and the test derived from the measurement. 3.2. Measuring the component response The component response must also be measured whenever possible. The axes of the vibration sensors must be oriented as described in section 3.1. The measurement of the component response enables resonances to be detected and non-linearities in the component response to be compensated for during the test. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 6 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 3.3. Measurement and evaluation procedure The base excitation and/or component response must be measured with a sampling rate greater than or equal to 8 kHz, but no less than 2,5 times the effective frequency. The maximum resonance frequency that is still capable of producing damage can be adopted as the effective frequency. If empirical values are not yet available, the appropriate value can be estimated by a numerical simulation. The measurement includes revving up at full throttle, as well as during deceleration, during which a speed ramp from idle speed to maximum-speed regulation over a period of no less than 120 seconds is measured. The frequency spectrum is evaluated as per the peak-hold method. In order to prepare the peak-hold spectrum as a test profile, the profile can be simplified or idealized using a polygonal chain, provided this simplified/idealized version approximates the profile conservatively. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG Document name: “Engine-Mounted Parts“ Working Group Performance Specification“ - 7 - WORKING GROUP PERFORMANCE SPECIFICATION May 2013 version AK5.2.18 Add-On Parts Working Group Engine-Mounted Parts AK-LH 1 The parameters for this are: Window function: Hanning Overlap: 50% to 90% Frequency resolution: 1 to 2 Hz Averaging: Peak-hold Amplitude correction: Yes (automatically included in some measuring systems) Bandwidth: 10 Hz to at least 1 600 Hz In order to comply with the required frequency resolution, the interval length of the Hanning window must be approximately equal to the numerical value of the sampling rate. AK-LH: Working Group Performance Specification Working group comprising staff members of the following companies: Audi AG, Bayerische Motoren Werke AG, Daimler A
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