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VW_80200_2_EN.pdf

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Add-On Parts Team Body-Mounted Parts Preface The content of AK-LH 1 (Team Performance Specifications for Add-On Parts) with subtitle “Body- Mounted Parts“, October 2008 issue, has been incorporated without revisions. LH 1 was developed by the “Performance Specifications“ Team of the automobile companies Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, and Volkswagen AG. Scope This standard applies to body-mounted parts in passenger cars of all model series. 1 Group Standard VW 80200-2 Issue 2009-03 Class. No.: 8DA0 Descriptors: add-on parts, bracket, vibrator table, vibration resistance, structural durability Page 1 of 1. Following pages: LH1 Body-Mounted Parts Page 1 to 12. Check standard for current issue prior to usage. 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 shall govern. Numerical notation acc. to ISO practice. Technical responsibility Standards Department EGDB/1 Jens Lucas Tel.: +49 5361 9 34971 EKTC/4 Wolfgang Tiefenbach EKTC Tel.: +49 5361 9 75357 Manfred Terlinden Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the B2B supplier platform www.vwgroupsupply.com. ? Volkswagen Aktiengesellschaft VWNORM-2008-12f-patch1 TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 1 - 0. Revision record ..........................................................................................................................2 1. Scope and aim ............................................................................................................................3 2. General information ..................................................................................................................4 3. Definitions...................................................................................................................................5 4. Test requirement........................................................................................................................7 4.1 General information.........................................................................................................7 4.2 Test.....................................................................................................................................7 4.2.1 Setup ...............................................................................................................................7 4.2.2 Sequence .........................................................................................................................7 4.2.3 Test spectra ....................................................................................................................7 4.2.4 Parameters....................................................................................................................10 4.2.5 Number of specimens ..................................................................................................10 4.3 Requirement....................................................................................................................10 5. Superimposition of temperature profile ................................................................................11 6. Changes to the component ......................................................................................................12 7. Confidentiality .........................................................................................................................12 TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 2 - 0. Revision record TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 3 - 1. Scope and aim These Performance Specifications apply to body-mounted parts in passenger cars of all model series. They specify the test requirements when test spectra based on acceleration measurements are not available. If test data are available, the requirements must be agreed between the manufacturer and the purchaser. Test profiles for single-axis vibrational excitation for the purpose of ensuring strength with respect to vibrational stress are provided depending on the installation area. Environmental influences (with the exception of ambient temperature) and material aging are not the object of these Performance Specifications. Deviations must be agreed with the responsible engineering departments and require approval. The aim of the Performance Specifications is to establish a uniform procedure for qualification of body-mounted parts at the premises of the supplier or automobile manufacturer. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 4 - 2. General information These Performance Specifications apply only to new parts or existing parts that undergo a technical change. If the requirements are changed, the manufacturer and purchaser must agree whether or not the tests and qualifications must be repeated. The results of the tests performed must be documented. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 5 - 3. Definitions Single-axis vibrator table/shaker In these Performance Specifications, the vibrator table/shaker serves as a test device for body- mounted parts. In conjunction with an appropriate controller, a stochastic, normally-distributed acceleration-time function is generated from a specified PSD spectrum and applied to the component as a base excitation. PSD/spectral acceleration density/power density spectrum Quadratic mean value of an acceleration signal that a narrow-band filter of a certain frequency has passed, divided by the bandwidth of the filter. The spectral acceleration density is the value for the borderline case in which the bandwidth approaches zero and the averaging period approaches infinity. Base excitation The vibrational excitation that a body-mounted part experiences at the contact point with the vehicle body. Crest factor Ratio of the peak value to the root-mean-square value (RMS). Sigma clipping (peak value limiting) Limiting of the maximum value of the control signal. DOF (degree of freedom) Control parameter of vibration controllers during the noise test. Frequency interval Df Frequency width into which the utilized frequency band is subdivided for the analysis. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 6 - RMS value (root mean square) The RMS value designates the square root of the mean value of the individual squares. In terms of vibration, the RMS value specifies the mean power of a PSD spectrum and corresponds to the square root of the area under the curve of the PSD spectrum. Warning and shutdown limits of the controller The inner and outer tolerance bands are used to specify to the vibration controller the permissible deviation of the actual PSD of the acceleration-time function specified by the controller and the desired PSD of the test spectrum in the adjusted condition. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 7 - 4. Test requirement 4.1 General information Unless otherwise specified, the tests must be performed under the following conditions: · Room temperature (RT) 23 ± 5 °C · Relative humidity (RH) 45% to 75% Prior to the tests, it must be ensured that the specimens are at a stable temperature. 4.2 Test 4.2.1 Setup The specimen must be mounted in a suitable fixture on the shaker. The installation position and the stiffnesses of the connections must be simulated according to real conditions, including for lines, cable harnesses, etc. If a given component is mounted by means of an additional bracket and not directly on the vehicle body, the bracket must be included in the test setup. Deviations must be agreed by the manufacturer and the purchaser. The test setup must conform to IEC 60068-2-47. 4.2.2 Sequence During the test, the stresses are applied to the specimen from the 3 spatial directions in succession. Unless otherwise agreed, the vertical direction (Z) must be tested first, followed by the transverse direction (Y) and then the longitudinal direction (X). 4.2.3 Test spectra The mechanical stresses acting on the specimen are specified by a stochastic acceleration-time function with a duration of 12 hours per spatial direction. For this, one test spectrum between 5 and 200 Hz is defined for each spatial direction as the desired PSD for the vibration controller (PSD_vertical_Z, PSD_horizontal_transverse_Y, PSD_horizontal_longitudinal_X). For add-on parts that are located below the top edge of the sill and between the A- and C- pillars, including the tunnel, the attenuated spectrum PSD_horizontal_transverse_Y Passenger compartment bottomis used for the Y-direction. In case of doubt, the manufacturer and purchaser must agree on which profile must be used. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 8 - PSD_horizontal_longitudinal_X Hz g 2 /Hz (m/s 2 ) 2 /Hz 5 0,0125 1,20 10 0,03 2,89 20 0,03 2,89 200 0,00025 0,02 RMS 0,96 g 9,42m/s 2Table 1: PSD_horizontal_longitudinal_X PSD_horizontal_transverse_Y Hz g 2 /Hz (m/s 2 ) 2 /Hz 5 0,04 3,85 20 0,04 3,85 200 0,0008 0,08 RMS 1,23 g 12,07m/s 2Table 2: PSD_horizontal_transverse_Y PSD_horizontal_transverse_ Y Passenger_compartment_bottomHz g 2 /Hz (m/s 2 ) 2 /Hz 5 0,01 0,96 10 0,015 1,44 20 0,015 1,44 50 0,01 0,96 200 0,0004 0,04 RMS 0,95 g 9,32m/s 2Table 3: PSD_horizontal_transverse_Y Passenger_compartment_bottom TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 9 - PSD_vertical_Z Hz g 2 /Hz (m/s 2 ) 2 /Hz 5 0,05 4,81 10 0,06 5,77 20 0,06 5,77 200 0,0008 0,08 RMS 1,44 g 14,13m/s 2Table 4: PSD_vertical_Z Prüfspektren: Karosserieanbauteile 0,0001 0,001 0,01 0,1 1 10 100 1000 Frequenz [Hz] Lesitungsdichte [g2/Hz] PSD_horizontal_l?ngs_X PSD_horizontal_quer_Y PSD_horizontal_quer_ YFahrgastzelle_unten PSD_vertikal_Z 0,0096 0,0962 0,962 9,62 [(m/s2)2/Hz]Figure 1: PSD test spectra Test spectra: Body-mounted parts Power density [g2/Hz] PSD_horizontal_longitudinal_X PSD_horizontal_transverse_Y Passenger_compartment_bottom PSD_horizontal_transverse_Y PSD_vertical_Z TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 10 - 4.2.4 Parameters During generation of the acceleration-time function on the shaker, the following control parameters must be complied with in order to ensure that the stress of the specimen can be reproduced. · DOF 140 ± 20 · Df 1,25 ± 0,25 Hz · Crest factor (sigma clipping) = 3 · Inner tolerance band (warning limit) = ±3 dB · Outer tolerance band (shutdown limit) = ±6 dB The test is performed in compliance with IEC 60068-2-64. 4.2.5 Number of specimens The test is performed with three parts. All specimens are tested in all three spatial directions and must fulfill the requirements defined in Section 4.3. If only two specimens are available, the test duration increases from 12 h to 15 h per spatial direction. For one specimen, the test duration increases from 12 h to 21 h per spatial direction. Number of specimens 3 2 1 Test duration/spatial axis 12 h 15 h 21 h Table 5: Number of specimens 4.3 Requirement 100% of test duration (in each of the 3 spatial axes) without damage. TEAM PERFORMANCE SPECIFICATIONS Version October 2008 AK5.18 Add-On Parts Team Body-Mounted Parts AK-LH 1 AK-LH: Team Performance Specifications Team of companies: Audi AG, Bayerische Motoren Werke AG, Daimler AG, Porsche AG, Volkswagen AG - 11 - 5. Superimposition of temperature profile When components are tested for which the number of cycles at which the component is damaged is dependent on the temperature (for temperature range, see Table 6), a temperature load cycle (see Table 7) must be superimposed during the vibrational stress. The manufacturer and purchaser must agree whether environmental influences, such as moisture, corrosive media, dust. etc., are required during the test. Classification Installation area T min [° C] T max [° C] A Passenger compartment A1 - No special requirements -40 75 A2 -40 100 - Direct sun radiation and thermal radiation effect A4 - Passenger compartment door -40 75 B Engine compartment B1 - Mounted on body -40 110 B5 - Mounted on radiator -40 110 C Exterior C1 - On body -40 75 C2 - Underbody/wheel housing -40 75 C5 Engine hood -40 120 C6 Liftgate -40 75 D Cavity (open towards outside or inside) -40 75 E Luggage compartment, load compartment -40 75 Table 6: Temperature ranges. A tolerance range of ±3 K applies to all temperatures Time [min] 3 specimens 2 specimens 1 specimen Temperature [° C] 0 0 0 20 60 75 105 T min 240 300 420 T min 300 375 525 20 400 500 700 T max 620 775 1 085 T max 720 900 1 260 20 Table 7: Temperature profile
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