GMW14906Feb2012.pdf

WORLDWIDE ENGINEERING STANDARDS

General Specification

GMW14906

Lamp Development and Validation Validation Test Procedures Table of Contents Section # 1

Section Name

Section #

Introduction

4

Section Name Requirements and Procedures (cont)

4.6.1

Dimension

4.6.2

Aim

2

Reference

2.1

External Standards

4.6.3

Seal Leak Test Pressure (LTP)

2.2

GM Standards/Specification

4.6.4

Light Output

2.3

Additional References

4.6.5

Appearance

3

Test Preparation and Evaluation

4.6.6

Function

3.1

Resources

3.2

Preparation

3.3

Conditions

3.4

4.7

Electrical Components and Electronic Interfaces

4.7.1

Electrical Connectors and Power Interface

Instructions

4.7.1.1

Electrical Connectors

3.5

Data

4.7.1.2

3.6

Safety

Electrical Wiring and Lamp Harness Cables

3.7

Documentation

4.7.2

Headlamp Bulb and Connector Temperature Cycle

4.7.3

Solenoids Bulb and Socket Removal Force

4

Requirements and Procedures

4.1

Development

4.7.4

4.2

Highly Accelerated Life Test (HALT)

4.8

Accelerated Corrosion

4.3

Pre-test Requirements

4.9

Weatherability Internal and External Heat

4.3.1

Dimension

4.10

4.3.2

Aim

4.10.1

Internal Heat

4.3.3

Seal

4.10.2

External Heat

4.3.4

Light Output

4.10.3

4.3.5

Appearance

External Heat Test for Headlamp Bulb Connector Terminals

4.3.6

Function

4.11

Light Up

4.4

SAE J575e August 1970 Vibration

4.12

Weld Joint and Snap Attach Stress

4.5

Temperature and Vibration

4.13

LED Light Source Requirements

4.5.1

Temperature Cycling

4.13.1

LED Lamp Actuation Cycle

4.5.2

Vibration.

4.13.2

LED Continuous Activation

4.6

Post-Test Requirements © Copyright 2012 General Motors Company All Rights Reserved

February 2012

Originating Department: North American Engineering Standards

Page 1 of 59

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GM WORLDWIDE ENGINEERING STANDARDS Table of Contents continued Section # 4 4.14

Section Name Requirements and Procedures (cont.) Condensation for Lamps with Oleophobic Membranes

4.15

High Humidity Environments

4.16

High Pressure Water

4.17

Leak Check for Production Processing Determination

4.18

HID Component Ignition Reliability

4.19

Adaptive Forward Lighting and Dynamic Headlamp Leveling System

4.20

Solar Load Test

4.21

Submersion Test

4.22

Free Fall

4.23

Storage

4.24

Thermal Shock

4.25

Headlamp Aim Adjustment Retainer and Fixed Pivot Pull Force

4.26

Solar Irradiance for Lamps with Condensing Lenses

5

Provisions for Shipping

6

Notes – Glossary/Acronyms

7

Additional Paragraphs

7.1

Restricted and Reportable Substances for Parts

8

Coding System

9

Release and Revisions

Appendix A

Data Sheets

Appendix

Test Setup Photos and Illustrations

GMW14906















WORLDWIDE ENGINEERING STANDARDS

General Specification

GMW14906

Lamp Development and Validation Validation Test Procedures 2.3 Additional References.

1 Introduction Note: Nothing in this standard applicable laws and regulations.

supercedes

GM1829 Analysis Development Validation Plan and Report

Note: In the event of conflict between the English and domestic language, the English language shall take precedence.

USCAR 15 - Bulb Insertion/Removal Force

1.1 Scope. This document defines the mechanical, electrical, and environmental performance requirements, test conditions, and procedures for lamps and reflective devices used for functional and durability tests.

3.1 Resources. If not otherwise stated, resources are indicated in the test methods.

1.2 Mission/Theme. This procedure applies to all original equipment and replacement exterior lighting devices for passenger cars, Multipurpose Passenger Vehicles (MPV), and trucks. 1.3 Classification. Not applicable.

2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM C150 ASTM E927-10 FMVSS 108 IEC 60068-2-27 Ea ISO 4892-1/2 ISO 16750-3 ISO 16750-4

ISO/IEC 17025 SAE J564 SAE J575e (AUG 1970) SAE J577 SAE J1889 SAE J2527

2.2 GM Standards/Specifications. GMW3059 GMW3172 GMW3191 GMW8287 GMW14264 GMW14444 GMW14528 GMW14570 GMW14571 GMW14572

GMW14650 GMW14651 GMW14668 GMW14669 GMW14729 GMW14872 GMW15272 GMW15308 GMW15626 GMW15760

3 Test Preparation and Evaluation

3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. Exception to this is if the information is otherwise preserved in the test facility records. 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with respect to their physical definition. 3.1.3 Facilities. Any specific facility requirements are listed in each individual test procedure. The test facilities shall be accredited to ISO/IEC 17025 or by the International Laboratory Accreditation Cooperation. 3.1.4 Equipment. The test equipment needed for each test is listed in each individual test procedure. 3.1.5 Test Vehicle/Test Piece. The test samples shall be production intent design and materials for design validation (DV) or production intent design and materials manufactured with production processes (homeline) for product validation (PV). Any changes to the components or material, e.g., design, fit, form, function, properties, manufacturing process, and/or location of manufacture, require revalidation. GM shall approve validation methods for product/process changes before the supplier is committed to the change. 3.1.6 Test Time. The total estimated time for DV and PV testing is shown below. Calendar time:

154 days (22 weeks)

Test hours:

3700 hours















GM WORLDWIDE ENGINEERING STANDARDS

GMW14906

3.1.7 Test Required Information. See individual procedures.

for Europe (ECE) and SAE International regulated regions select one test method.

3.1.8 Personnel/Skills. The test facility shall have sufficient personnel having the necessary education, training, technical knowledge, and experience for performing the required tests.

If the vehicle provides a Pulse Width Modulation (PWM) voltage to the lamp, activate the specified function at the specified PWM - rms voltage +0.25 V. In all other tests that require a test voltage input, use 13.9 V ± 0.2 V.

3.2 Preparation. 3.2.1 Fixtures. Fixtures. Unless otherwise specified, mount the test sample on a fixture of welded construction designed to place the test sample in its vehicle orientation. Photometric measurement fixtures may be of alternate construction and do not need to meet the requirements of 4.5.2.4. 3.2.2 Wire Harnesses. Harnesses. All testing that requires a vehicle interface harness shall have a terminal and wire inserted into each connector cavity per the production intent design. 3.2.3 Test Samples. Samples. All test samples shall be design intent and meet all functional and dimensional pre-test requirements, as defined by this document. Lamp assembly designs with secondary components such as cameras, handles, sensors, washer nozzles, etc., shall have those secondary components installed in test samples during test. Reuse of secondary components for multiple tests is allowed where function of the secondary part is not critical to lamp testing. The GM Validation Engineer and GM Designing Engineer (DE) shall approve any exceptions prior to the start of testing. 3.3 Conditions. All test conditions shall be adjusted to specified values and remain within given (±) tolerances. Target test values shall not be adjusted within tolerances unless the target value cannot be maintained. If such an adjustment is made, it shall be approved by the applicable GM engineer prior to the start of any testing. Unless otherwise specified perform the tests in the as received condition without any special preconditioning. 3.3.1 Environmental Conditions. See individual procedures in Section 4. 3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. Such deviations shall be approved by the GM Validation Engineer and specified on the GM1829 Analysis Development and Validation Plan and Report and test reports. Voltage

for

photometric

testing

pre-test

and

3.4 Instructions. See the specific procedures in Section 4. 3.5 Data. Record Appendix A.

on

the

data

sheets

in

3.6 Safety. This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 3.7 Documentation. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and approved by the responsible GM department prior to the start of delivery of production level components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation of any change or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed to between the responsible GM department and the supplier. Document the test results in a test report. Test reports shall include all of the following: test equipment serial numbers, calibration information, test Data Sheets A1 through A17, description of test material (including design revision, lot or batch, options, etc.) test specification date, pertinent setup information, and photographs. 3.7.1 Test Results. Record on the data sheets in Appendix A.

4 Requirements and Procedure 4.1 Development. This section of the test specification outlines the development tests for















GM WORLDWIDE ENGINEERING STANDARDS with GM to determine if corrective action is necessary. 4.2 Highly Accelerated Life Test (HALT). Reference GMW3172 and GMW8287. See Data Sheet A1. 4.2.1 Purpose. To quickly determine the weaknesses of the product when subjected to environmental and vibration stresses. The supplier shall perform this test prior to all other subsystem level testing as soon as representative samples are available. Only complex lamp assemblies shall be tested. Examples of lamps to be tested are: 

Headlamps



Front fog lamps



Lamps with electronic or electro-mechanical components



Lamps with components



Lamps using any non-traditional fastening techniques



Lamps with multi-color lenses



Lamps using non-traditional vehicle mounting

complex

or

many

internal

Examples of lamps not to be tested include: 

Simple lamps consisting of a lens and housing mounted in a traditional manner



Simple signal lamps mounted in in a fascia or to sheet metal



Simple tail lamps

The GM Validation Engineer and GM Designing Engineer shall approve any lamp type that is not tested. With the approval of the GM Validation Engineer and GM Designing Engineer the supplier may test non-dimensionally correct or non-representative samples if the time to obtain dimensionally correct or representative samples is prohibitive. The supplier engineer shall be present during testing, and a GM representative should be present during the testing. The supplier and GM engineer shall analyze each test incident to determine its likelihood of occurring in the field. Quick and simple tests may be used when applicable to verify the potential incident (i.e., a heat test). Not all incidents require corrective action based on the above analysis. The GM Validation Engineer and GM Designing Engineer, along with Engineering Group Manager,

GMW14906

additional HALT test. Incidents occurring above the temperature limits of materials, for example, do not require corrective action if the material is suitable for the particular application. 4.2.2 Equipment. Environmental chamber with the following specifications. 4.2.2.1 Thermal capability of -100 °C to +200 ° +200 °C C with a ramp rate of at least 40 ° 40 °C C per minute. 4.2.2.2 Omni-axial (six degrees of freedom) repetitive shock system with 50G rms capability between 2 Hz and 2000 Hz frequency bandwidth. 4.2.3 Sample Size. Three (3) samples per part number (excluding color) or two pair. For example, Center High Mounted Stop Lamps (CHMSL) would require three parts. High Intensity Discharge (HID) and halogen headlamps would require a total of four parts. Test all test samples regardless of the results of previous tests. 4.2.4 Setup. 4.2.4.1 Specifics of the test setup parameters are the responsibility of the GM Validation Engineer and GM Designing Engineer. Parameters which need to be defined are: 4.2.4.1.1 Fundamental part operating Temperature limits are the following.

limits.

4.2.4.1.1.1 Headlamps, front fog lamps, and interior CHMSLs: -100 °C to +120 ° +120 °C. C. 4.2.4.1.1.2 Remaining lamps: -100 °C to +85 ° +85 °C. C. 4.2.4.1.2 Activate all functions during the test including non-lighted system components such as dynamic headlamp leveling (DHL) motors and adaptive forward lighting (AFL) system motors. 4.2.4.1.3 Mount 4.2.4.1.3 Mount the sample(s) to a rigid, lightweight test fixture of welded construction that represents the vehicle mounting orientation and installation and uses production fasteners or equivalent. Note requirements for the functional response of the test part mounted to the test fixture, included below. If possible, lamp locating features and body interfaces must be represented in the fixture design. Position the fixture retention points to the test base such that the fixture can be removed without removing the lamp. 4.2.4.1.4 4.2.4.1.4 The collection of product response data from temperature and vibration is required to provide credible response that temperature and vibration stress was applied to the product. Reference GMW8287 for thermocouple and accelerometer specifications.















GM WORLDWIDE ENGINEERING STANDARDS 4.2.4.1.5 4.2.4.1.5 Functional test goals are to achieve 100% of thermal and vibration inputs. Functional response, of the test part mounted to the test fixture, from vibration, shall be 70% or greater than the vibration input. The GM Validation Engineer and GM Designing Engineer shall approve the design. 4.2.5 Procedure. Cycle the samples through the HALT test procedure in the order listed. Samples shall be leak tested as described in 4.3.3 at the start and after each test segment. If possible, continue testing until three distinct failure modes are observed. Activate all light sources and motors, where applicable, continuously during the high temperature portions of the test sequence and any transitions to a high temperature. For example, activate stop lamps, turn signal lamps, and DHL motors continuously. High temperature is defined as temperatures above ambient. 4.2.5.1 Thermal Step Stress. Cycle sample(s) in temperature steps to the fundamental temperature limits. First test the upper limits, then the lower limits. Recommended temperature steps are 20 ° 20 °C C with a minimum dwell of 10 minutes until 20 °C °C from the expected upper temperature limit is reached. Then step 10 ° 10 °C C with a minimum dwell of 10 minutes.

GMW14906

4.2.5.3 Vibration Step Stress. Cycle sample(s) in vibration steps at ambient to 50G rms. Recommended vibration steps are 5G rms with a minimum dwell of 10 minutes. 4.2.5.4 Combined Environment. While subjecting the sample(s) to the Rapid Thermal Transition in 4.2.5.2, vibrate the sample(s) in steps per the Vibration Step Stress procedure in 4.2.5.3. If no incidents occur, continue testing at the maximum vibration level with Rapid Thermal Transitions until an incident does occur. 4.2.6 Report. An interim test report shall be provided per 3.5 including which cycle the incident occurred, and GM/supplier participants of the test. 4.3 Pre-test Requirements for all Remaining Tests. 4.3.1 Dimension. Measure all assembly checkpoints on one lamp or pair of handed lamps and record on the test log sheet. All measured assemblies shall be dimensionally within twice the drawing tolerance for development and design validation (DV) testing. Measure and record one lamp or pair of handed lamps used in product validation (PV) testing. The GM Validation Engineer and GM Designing Engineer must review the dimensional data prior to start of test.

4.3.2 Aim. 4.2.5.2 Rapid Thermal Transition. Cycle 4.3.2.1 Aim Position. All aimable lamps shall be sample(s) between the operational temperature aimed. Lamps with DHL or AFL shall be centered limits. At least five cycles are recommended to design nominal position. utilizing transitions greater than 40 ° 40 °C C per minute. Allow for thermal stabilization between transitions with a recommended minimum dwell of 10 minutes. Table 1: Seal Test Method Lamp Description

Test Method

Small lamp with no lighted function; no tooled openings in housing (i.e., reflex reflector)

Vacuum Chamber per 4.3.3.1

Small lamp with lighted function; no socket; lamp side connector is sealed (i.e., light emitting diode (LED) CHMSL with internal potted lamp side connector)

Vacuum Chamber per 4.3.3.1

Small lamp with lighted function; with sealed socket (i.e., license lamp with bulb and socket)

Submersion per 4.3.3.2

Small lamp with lighted function; with no socket; lamp side connector is not sealed (i.e., LED CHMSL with vented lamp side connector – connector – body body connector contains seal)

Pressurization per 4.3.3.3

Body sealed lamp


(Note: A Note: A rigid fixture that represents the lamp mating sealing surface and attachment is required.)

Other lamp with lighted function(s)



















4.3.3 Seal. Leak test each lamp per the test method described in Table 1. Data shall be recorded for all lamps subject to Seal Test Methods (Table 1), including data for those lamps that may not meet pre-test requirements. Indicate in test incident notes, on the data sheets, if lamp quantities greater than the minimum sample size were required to collect test ready lamps. 4.3.3.1 Vacuum Chamber Method. Lamp shall be tested at room temperature. Allow lamp to stabilize at 23 °C ± 3 °C temperature for a minimum 1 h. Submerse the lamp in 23 °C ± 3 °C water, inside of the vacuum chamber (mount lamp to a simple fixture using production mounting points, if required). Let stand for 5 minutes. Observe the lamp for leakage. A leak is defined as any bubbles originating from a single point on the lamp. If no leakage is noted; evacuate the chamber with submersed lamp inside to reduce the pressure to 21.0 kPa for 15 s. Lamps shall show no bubbles during test. Caution: Caution: Safety precautions shall be taken to protect test engineer. Monitor pressure to prevent water from boiling at low pressures. 4.3.3.2 Submersion Method. Energize lamp for 30 minutes at ambient. Continue to supply voltage and submerse to a depth ≥10 mm under water at 2 °C ± 2 °C for 5 minutes. With the lamp under water, turn off supply voltage to the lamp and let stand for 5 minutes. Remove the lamp from the water and inspect for water ingress. Repeat this instruction three times per lamp assembly. There shall be no cracking, ingress of water or evidence of internal condensation. 4.3.3.3 Pressurization Method. Pressurize each lamp completely under 2.5 cm of water at 7.0 kPa for 5 minutes using the pressurization guidelines in 4.17. All aimable lamps shall be cycled through their total travel while pressurized. If the leak test pressure (LTP) was determined using procedure 4.17, this pressure shall be used.

GMW14906

regulatory requirements and measured over a matrix that spans the horizontal and vertical beam pattern extents defined in the applicable regulatory requirements at an increment of 0.2 degrees. Other lamp functions shall be measured at an increment of 1.0 degree. License lamps and reflex reflectors are not required to follow this measurement method; but measurement data to evaluate pre-test requirements shall be provided, as noted below. This data shall be provided electronically to GM upon request. Headlamps shall be aimed properly and the gradient recorded if applicable. Light emitting diodes (LED) sha ll be tested per SAE J1889 or ECE regulations for the specific lamp stabilization time. Lamp functions that are required to operate with vehicle "Start/Stop" conditions shall also be measured for light output at 12.8 V at horizontal-vertical (H-V). This data shall be provided electronically to GM upon request. Reflex and license lamps shall be measured to the regulatory requirements instead of a matrix; non-functional reflex does not need to be measured, and electronic data need not be provided. If the photometric regulatory requirements require an accurate rated light source, measure and record the device photometric output using an accurate rated source activated at the proper current. Then use a standard light source for testing. If the photometric regulatory requirements do not require an accurate rated light source or the sample uses non-replaceable light sources, measure and record the photometric output of the device using a standard source energized at 12.8 V unless otherwise specified by the device. If a standard replaceable source is used for the photometric measurements, another standard source shall then be used for testing other than photometry. Use the same standard light source for the initial and final photometry.

















GM WORLDWIDE ENGINEERING STANDARDS Note: To verify aim adjustment, cycle the lamp full down, then full up, then back to nominal position evaluating breakaway and prevailing torque using a performance console to record and chart values. Attach charts to the existing data sheets. During this evaluation, also verify the number of turns to adjust aim one degree and record. 4.3.7 Squeak and Rattle. Perform a subjective evaluation for squeak and rattle by holding a complete lamp assembly in hand and twisting in multiple directions. With the same lamp assembly in hand, gently shake the assembly in all directions. Evaluations during each condition shall be evaluated per GMW14264 in a room with no ambient noise. 4.4 SAE J575e August 1970 Vibration. Note: Operators Note: Operators are to use the SAE J575e August 1970 version which aligns with a prior standard referenced in Federal Motor Vehicle Safety Standards (FMVSS) documents. Although this test is not for compliance, only only this version is to be used. Operators are not not to use the latest/current version of SAE J575e for GMW14906. 4.4.1 Equipment. Vibration described in SAE J577.

test

equipment

4.4.2 Sample Size. Two (2) pair or three samples. 4.4.3 Procedure. Test samples to the vibration procedure described in SAE J577 for 60 minutes. Inspect the parts for the acceptance criteria listed in FMVSS 108 without removing from the fixture, If the sample(s) passes, continue testing for an additional 30 minutes. Remove from the fixture and repeat the part inspection. See Data Sheet A2. 4.5 Temperature and Vibration. Conduct the tests in this section in the order presented with the same samples through the entire sequence of pre-test measurements, temperature, vibration, and post-test requirements. In addition, inspect all sample(s) after each test section using the procedure specified. See Data Sheet A3. Note: Note: Optional HID or Adaptive Forward Lighting

GMW14906

Validation Engineer and GM Designing Engineer shall approve any combination assumptions. 4.5.1 Temperature Cycling. 4.5.1.1 Purpose. To verify the lamp assembly can withstand temperature extremes and precondition the lamp assembly for vibration testing. 4.5.1.2 Equipment. Environmental chamber capable of -40 °C to +120 ° +120 °C C with either random air circulation or circulating air with a predominant air flow direction. The chamber shall be capable of 3 °C ± 1 ° 1 °C C per minute. 4.5.1.3 Sample 14 samples.

Size.

Seven

(7)

pair

or

4.5.1.4 Temperature Procedure. Perform the temperature cycle in Figure 1 two times with lamp assemblies positioned in vehicle orientation. 4.5.2 Vibration. 4.5.2.1 Purpose. Purpose. To determine if the lamp will withstand severe vibration input. 4.5.2.2 Equipment. Equipment. Random vibration equipment described in ISO 16750-3, SAE J575, or equivalent. 4.5.2.3 Sample Size. The same seven pair or 14 samples used in 4.5.1 Temperature Cycling. 4.5.2.4 Test Fixture Rigidity. Rigidity. Mount all test samples to the vibration equipment using a test fixture that duplicates the production vehicle mounting interfaces, fasteners, and vehicle orientation. Measure the first resonant frequency of one sample of each assembly in each axis and record. The procedure shall include the measurement of the vibration input and the fixture response from 10 Hz to 1000 Hz. This fixture, when coupled with the test sample or equivalent mass and center of gravity, shall not have a resonant frequency between 10 Hz and 250 Hz in any axis and no vibration responses greater than two times the input signal in this frequency range. In addition, the test fixture acceleration amplitude frequency responses at the individual mounting


















GMW14906

Temperature Cycling for Interior CHMSL's, and all Other Lamps 120 100 80

) C ( e 60 r u t a 40 r e p m 20 e T

0 -20 -40 0

2

4

6

8

10

12

14

16

18

20

22

24

Time (hours) Inter nteriior CHMS CHMSL L Cycl Cycliing

1 hour 4 hours 2 hours 16 hours 1 hour

Other her Lamp Lamp Cycl Cycliing

Cooling to -40 °C At -40 °C Heating to +80 °C (110 °C for Interior CHMSLs) At +80 °C (110 °C for Interior CHMSLs) Cooling to +23 °C ± 5 °C Figure 1: Temperature Cycling

4.5.2.5 Lamp Assembly Resonance. Resonance. Measure the lamp assembly’s first resonant frequency prior to testing. In addition, measure the first resonant frequency of lamp components retained through an aim mechanism using optical aids such as a laser. Record the specific procedure used and measured data on Data Sheet A3.

the angular mechanism during random vibration as directed in Figure 3 while simultaneously activating the lamp functions as directed in Figure 2.

4.5.2.6 Accelerometer Locations. Test all component lamps in random vibration. Mount redundant vibration control accelerometers on the fixture. Mount one at the base and one as far as practical from the base to reduce the test fixture influence on the lamp. The test shall be limited by the higher of the two values. Record the locations

Note: Note: AFL/DHL systems shall not be reinitialized prior to post-test measurements. If an electronic control module is used to control the AFL/DHL system during test, any calibration used to automatically zero the lamp position shall be deactivated.

If the headlamp contains Dynamic Headlamp Leveling (DHL), activate during random vibration as directed in Table 7 when the high and low beam lamp functions are activated in Figure 2.

4.5.2.9 Vibration Duration.

















GM WORLDWIDE ENGINEERING STANDARDS 4.5.2.9.2 Pickups. For lamps on pickups, vibrate lamps for the duration specified in Table 3 using the temperature profile outlined in Figure 4 and the Power Spectral Density in Figure 5. 4.5.2.9.3 Vibration Axis Sequence. The axis of vibration sequence need not be the same for each sample tested, but must be noted in test log data. The lamp orientation during testing is always to be as in the vehicle.

GMW14906

Table 3: Vibration Duration for Pickups Vertical

8 hours

Fore/aft

8 hours

Lateral

8 hours

Lamp Activation Profile for Light-Up and Vibration (min) 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 5 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Lamp functions High Be a m - 4 Bulb Burn

Low Beam; (incl. AFS/DHL)

Duration on off on off

High Beam - 2 Bulb Burn on & Bi-Funtion Projector off

Low Beam;

on

(incl. AFS/DHL)

off

Dedicated DRL (tested separately)

off

Front Fog

on

on off

on Turn Signal / Hazard/ Side Repeater off

on Static bending/ Cornering

Stop / CHMSL

Rear Fog

Backup

Taillamps/License Lamps

off

30 on / 60 off

180 on

40 off / 20 on / 70 off

40 on / 20 off / 70 off

180 on

90 on / 90 off

120 on flashing / 60 off

180 on / 3s cycle @50% on time

on off

30 on, then 15 off / 15 on

on

60 on / 30 off / 60 on

off on off on

10 on / 50 off

180 on


















Figure 3: Adaptive Forward Lighting System Cycle

GMW14906




















GMW14906



















GM WORLDWIDE ENGINEERING STANDARDS 4.5.2.10 Temperature Curve for Vertical Test Direction. The vibration test in the vertical direction only uses a superimposed temperature as shown in Figure 4 and described below, as well as the lamp activation profile according to Fi gure 2. Perform testing in the fore/aft and lateral directions at 23 °C ± 5 °C. 4.5.2.11 After random vibration is complete on all three axes, re-measure the first resonant frequency of the specimen tested in 4.5.2.5 and record on Data Sheet A3. 4.5.2.12 Record All Results per 3.5. 4.5.3 Temperature and Vibration Acceptance Criteria. 4.5.3.1 The first natural frequency post-test shall not have degraded >15% compared with the pre-test value; however, it shall be >35 Hz in every case. 4.5.3.2 Lamps shall pass all of the post-test requirements in 4.6 after completing the entire 4.5 test sequence. 4.5.3.3 Replaceable light source filament failures are acceptable. If filament failures occur, replace the light source immediately and continue the test so that the light sources are activated as intended for the entire test duration. Record each incident on the test log sheets and retain the bulbs to review with the GM Validation Engineer and GM Designing Engineer. 4.6 Post-Test Requirements.

GMW14906

Reflex shall be measured to the regulatory requirements instead of a matrix, non-functional reflex does not need to be measured, and electronic data need not be provided. If the photometric regulatory requirements require an accurate rated light source; measure and record the photometric output of the device using an accurate rated source activated at the proper current. A standard source shall then be used for the test. If the photometric regulatory requirements do not require an accurate rated light source or the sample uses non-replaceable light sources, measure and record the photometric output of the device using a standard source energized at 12.8 V unless otherwise specified by the device. If a standard replaceable source is used for the photometric measurements, another standard source shall then be used for testing other than photometry. The standard source originally used for the initial photometry shall be used for final photometry. LED functions that are required to operate with vehicle "Start/Stop" conditions shall also be measured for light output at 6V, 8V and 10V at H-V. Functions required to operate with vehicle "Start/Stop" functionality shall meet the requirements of applicable technical specifications and Figure 6, as required. If any test point measurements change >25% and the change cannot be attributed to slight




















Function Required Output Conditions

Typical Execution

GMW14906

Light Output from LED Functions [Φ v-100 = 100% light output @ 12.8 V at H-V] >90% of Φ v-100 at 6 V

>75% of Φ v-100 at 10 V

>50% of Φ v-100 at 10 V

>50% of Φ v-100 at 8 V

>25% of Φ v-100 at 8 V

>25% of Φ v-100 at 6 V

>0% of Φ v-100 at 6 V

Control Module

2 LED in Series

3 LED in Series

Minimum Required

NOT ALLOWED

NOT ALLOWED

Stop

Allowed

Minimum Required

NOT ALLOWED

Rear Fog

Allowed

Minimum Required

NOT ALLOWED

Cornering light (AFL)

Allowed

Minimum Required

NOT ALLOWED

Front Position/Park

Allowed

Minimum Required

NOT ALLOWED

DRL

Allowed

Minimum Required

NOT ALLOWED

High Beam

Allowed

Minimum Required

NOT ALLOWED

Tail/Rear Position

Allowed

Minimum Required

NOT ALLOWED

Backup lamp

Allowed

Allowed

Minimum Required

Front Fog

Allowed

Allowed

Minimum Required

Side Repeater

Allowed

Allowed

Minimum Required

Low Beam




















GMW14906

4.6.6.6 The lamp is removable without loss of function to fasteners.

4.7.2 Headlamp Temperature Cycle.

4.6.6.7 Bulb filament fractures are not necessarily test failures. Record filament fractures on the test log sheets.

4.7.2.1 4.7.2.1 Rigidly mount ten production intent headlamp bulbs (representative of the intended bulb type, bulb variant (long life, standard life, etc.), bulb orientation, bulb terminal material (nickel plated stainless, etc.), and bulb supplier) inside a thermal chamber capable of -40 C to 140 C. Chamber shall be capable of maintaining the specified temperature with the ten bulbs energized.

4.6.6.8 Bulbs and bulb sockets shall not show any evidence of arcing, deformation, or melting. Gaskets shall not deform or result in loss of sealing capability. Some discoloration of bulbs, sockets and socket gaskets is acceptable, but must be approved by the GM Validation Engineer and GM Designing Engineer. All sockets and bulbs shall be removed from the lamp post-test in order to perform the inspection. Test reports shall detail specific sockets, bulbs and gaskets affected with photographs. 4.6.7 Squeak and Rattle. Perform a subjective evaluation for squeak and rattle by holding a complete lamp assembly in hand and twisting in multiple directions. With the same lamp assembly in hand, gently shake the assembly in all directions. Evaluations during each condition shall be evaluated per GMW14264 in a room with no ambient noise. The subsystem shall have a subjective rating of at least nine (9) when evaluated to GMW14264 Subjective Rating Scale for Squeaks and Rattles. 4.6.8 Record All Results per 3.5. 4.7 Electrical Interfaces. 4.7.1

Components

Electrical

Connectors

and

Electronic

and

Power

Bulb

and

Connector

°

°

4.7.2.2 4.7.2.2 Mount thermocouples to each terminal of each connector as close as possible to the bulb terminal interface. Thermocouples shall be permanently attached. Ensure that the thermocouple mounting will not disturb the performance of the connection system and that all the connection system components (connector body, terminal position assurance (TPA), etc.) are installed properly. 4.7.2.3 4.7.2.3 Cycle thermal chamber while energizing bulbs at 14.5 V following the schedule below. During entire test, measure and record the temperature of each connector ground terminal every 5 minutes. 4.7.2.3.1 Set thermal chamber to 140 °C with a minimum transition of 2 °C/minute while energizing bulbs at 14.5 V. Transition and hold 140 °C for 240 minutes total. 4.7.2.3.2 4.7.2.3.2 Set thermal chamber to -40 °C with a minimum transition of 2 °C/minute with all bulbs off. Transition and hold -40 °C for 120 minutes total.



















GM WORLDWIDE ENGINEERING STANDARDS 4.7.2.4.5 Measured 4.7.2.4.5 Measured terminal temperatures shall be recorded and shall be less than or equal to the specified maximum rated temperature for the terminal substrate and plating materials. 4.7.3 Solenoids. 4.7.3.1 4.7.3.1 Solenoids shall meet durability requirements per methods defined in SAE J564. Test shall be performed using the projector assembly or partial lamp assembly to which the solenoid is mounted. 4.7.3.2 4.7.3.2 Verify that the mechanical connection of the solenoid to lamp shield and solenoid to its mounting surface is made. Power the solenoid and cycle to 200 000 cycles or four (4) lives (1 life = 50 000 cycles).

GMW14906

CHMSLs with no external exposure are excluded from this procedure. 4.8.1 Purpose. To primarily determine the corrosion and humidity resistance of lamp assemblies and to secondarily determine stress levels are acceptable in welded assemblies and in lamps with snap fit attachments. 4.8.2 Sample Size. The sample size for all corrosion testing is three pair or six samples through each test. 4.8.3 Procedure. 4.8.3.1 Perform pre-test requirements 4.3.3, 4.3.5, and 4.3.6.

4.7.3.3 4.7.3.3 Evaluate for proper operation (full open to full close) every 50 000 cycles and record results on the data sheet.

4.8.3.2 For lamps with snap fit attachments, test attached to the mating component or a representation of it. For other attachments to the body, represent the fastener, torque, and interface as close as possible.

4.7.3.4 4.7.3.4 Continue to cycle solenoid to failure or 300 000 cycles and record results on the data sheet.

4.8.3.3 Cyclic Corrosion Testing GMW14872. See Data Sheet A4. Test all parts as assemblies in cyclic corrosion per GMW14872 for validation.

4.7.3.5 Acceptance Criteria. Solenoid shall remain functional at the end of 200 000 cycles.

4.8.3.3.1 For coatings and substrates test as assemblies in cyclic corrosion per GMW14872.

4.7.4 Bulb and Socket Removal Force.

4.8.3.3.2 For headlamps, side repeaters, front fog lamps and under hood (UH) areas.

4.7.4.1 The cold removal force shall be determined on ten (10) actual bulb/socket samples intended for the application using the procedure outlined in USCAR 15, titled Bulb Insertion/Removal Force. Lamp assemblies may be reused. 4.7.4.2 The hot removal force shall then be

4.8.3.3.2.1 UH, All, Method 1/2, Exposure B + D. 4.8.3.3.3 For all other lamps. 4.8.3.3.3.1 Exterior (EXT) Applications, All, Method 1/2/3, Exposure C + D.





















GM WORLDWIDE ENGINEERING STANDARDS 4.8.5.2 All Other Lamps: Lamps: After exposure C, all visible metal surfaces shall fulfill cosmetic requirements as defined in Table A1, Cosmetic Corrosion Resistance Requirements, of GMW15272. Surfaces visible when hoods, decklids, liftgates, etc., are in the open position are classified as visible surfaces. Samples shall pass post-test requirements of 4.6.5. No cracks near attachments or interfaces of welded components are permissible. 4.8.5.3 Functional. Functional. After Exposure D there shall be no loss of function per GMW15272 (Reference section titled: Functional Corrosion Resistance). The samples shall pass post-test requirements of 4.6.3 and 4.6.6. 4.8.5.4 Record All Results per 3.5. 4.9 Weatherability. This test is required on all lamps with externally visible multi-color and overlay interfaces, adhesive bonded lens to housing joints, and externally visible unpainted and uncoated plastics. See Data Sheet A5.

GMW14906

4.10.1.3 Sample Size. Three (3) pair of headlamps. Two (2) pair or three samples of all other lamps. 4.10.1.4 Test Procedure. 4.10.1.4.1 Perform requirements in 4.3.

and

pass

all

pre-test

4.10.1.4.2 For headlamps and front fog lamps, uniformly apply by brush or spray to the lamp lens surface normally exposed to road dirt a mixture of fine powdered cement and water in accordance with ASTM C150 or equivalent composition and particle size. For all rear lighting do not apply this mixture to the lens. Reduce the photometric output at the horizontal-vertical (H-V) test point of the upper beam, the 0.5°D-1.5°R test point of the lower beam, the H-2°D point of the fog lamp, to 25% ± 2% of the clean lens photometric output (equal to t o a 75% ± 2% reduction). re duction). Determine the reduction under the same conditions as the original measurement. AFL headlamps shall be tested with the movable beam contributor in the nominal





















GM WORLDWIDE ENGINEERING STANDARDS 4.10.1.4.6.5 For rear combination lamps, activate the stop, backup and other functions that can be energized with the stop and backup according to the first hour in the Lamp Activation Profile (LAP) in Figure 2. 4.10.1.4.7 Maintain set temperature plus tolerance for 60 minutes while lamps are being cycled. If the lamp contains a dedicated DRL, dwell for 90 minutes while the lamps are being cycled.

4.10.2.4.2 Set the front side chamber temperature to 50 °C and the back side chamber temperature to 100 °C and allow the chamber temperatures temperature s to stabilize. 

If the lamp contains an independent DRL, fog lamp or, both; test to sections 4.10.2.4.3 daytime mode activation and then 4.10.2.4.4 nighttime mode activation.



If the lamp is is a dedicated DRL, DRL, fog lamp or, combination DRL/fog lamp using the same light source; test to section 4.10.2.4.3 daytime mode activation.



For all other lamp types, test to section 4.10.2.4.4 nighttime mode activation.

4.10.1.4.8 Remove the samples to ambient and clean the lens. 4.10.1.4.9 Perform post-test requirements in Data Sheet A6. 4.10.1.4.10 Re-test steps 4.10.1.4.1 through 4.10.1.4.9 on a new set of lamps with the temperature in 4.10.1.4.4 set at 50 °C instead of 39 °C. If three samples are being tested, test the second and third samples at 50 °C. 4.10.2 External Heat Test. 4.10.2.1 Purpose. To determine the effect of

GMW14906

Note: Note: The same set of lamps is to be used for daytime and nighttime testing, if both test modes are required. 4.10.2.4.3 Daytime Mode Activation. Activate Activation. Activate the function(s) allowed by the vehicles mechanization in daytime mode (i.e., for dedicated DRL activate





















GM WORLDWIDE ENGINEERING STANDARDS 4.10.2.4.4.1.1 At 100 °C, with the lamp in the chamber, apply a 10 N load normal to the socket or external heat sink (if exposed) of the active light source for 20 s. See Figure B2 for a sample photo displaying load direction and load tip. 4.10.2.4.4.1.2 After loading, remove the t he lamp from the chamber, cool to ambient temperature, and evaluate according to 4.10.4. 4.10.2.4.4.2 For all lamp types noted in 4.10.2.4.3 that do not not contain a socket or heat sink that directly connects to the housing, remove the lamp from the chamber and evaluate according to 4.10.4. 4.10.3 External Heat Test for Headlamp Bulb Connector Terminals. 4.10.3.1 Purpose. To verify that heat generated by the lamp subsystem does not exceed thermal properties of the headlamp bulb connector(s). This procedure applies to all headlamps. 4.10.3.2 Equipment. Reference equipment noted

GMW14906

substrate and plating materials as provided by the terminal supplier. 4.10.4.5 Record All Results per 3.5. 4.11 Light Up. See Data Sheet A7. 4.11.1 Purpose. To determine the effects of long term lamp activation on lamp components. 4.11.2 Equipment. 4.11.2.1 An area where three pair or six samples can be positioned in vehicle position spaced >300 mm apart horizontally and vertically edge to edge (to minimize heating affects) with minimal airflow less than 3 km/h at an ambient temperature of 23 °C ± 5 ° 5 °C. C. 4.11.2.2 Direct Current (DC) power supply capable of supplying 9 V to 16 V DC. 4.11.2.3 Controller capable of energizing all lamp functions contained in the sample following the cycles specified in the LAP in Figure 2. 4.11.3 Sample Size. Three (3) pair or six samples.





















GM WORLDWIDE ENGINEERING STANDARDS 4.11.4.7 Unswitched Lamps. If a lamp function does not have a switching mechanism that allows the function to be on continuously such as puddle lamps, assist step lamps, etc., then activate the function on and off at the vehicle time out duration at a cycle of 1 h activated and 1 h off. If the vehicle time out duration is not provided, activate the function for 1 minute on and 1 minute off. 4.11.4.8 Dedicated DRL and Stand Alone DRL. Separately test lamp assemblies containing a dedicated DRL (including H15 bulb or other two filament executions) with three pair of unique samples for 23 h on and 1 h off with the DRL activated for 28 days. LED dedicated DRL stand alone lamps are not required to complete this test and shall fulfill the LED Light Source Requirements. 4.11.4.9 Inspections. A visual inspection is required after the first 4 h and then once after every 24 h cycle until complete. Inspect the lamp with functions activated and off. Monitoring can be

GMW14906

4.12.4.1 Lamps require production representative molding stress levels of the bonded materials and production representative bonding between the joints to be tested. Snap features shall be tested in their installed design nominal position and orientation, requiring a mounting plate or fixture. Annealing shall also be representative of the production process with the time and temperature noted in the test report. 4.12.4.2 Solution Preparation. Prepare solutions as follows: 

Solution Number 1, 34% ethyl acetate in methanol



Solution Number 2, 50% ethanol in water



Solution Number 3, 50% methanol in water



Solution Number 4, 50% isopropanol in water



Solution Number 5, reagent grade ethanol

4.12.4.3 Apply 4.12.4.3 Apply the applicable solution from Table 4 to the lamp welded joint and/or snap features with





















GM WORLDWIDE ENGINEERING STANDARDS Table 4: Weld Joint Stress Test Solutions by Lamp Material Housing Substrate PC

Lens/Frame Substrate

Stress Solution

PC (Lens or Frame) Solution #1

Cracking substrate PC

PC

ABS+PC (Frame)

Solutions 2, 3, and 4

ABS+PC

PC

ABS (Frame)


ABS

PC

ASA (Frame)


ASA

PC

ASA+PC (Frame)

PC

PMMA (Lens)

ABS+PC

Solution #3 Solutions 2, 3, and 4

PC (Lens or Frame) Solutions 2, 3, and 4

ASA+PC PMMA ABS+PC

ABS+PC

ABS+PC (Frame)


ABS+PC

ABS+PC

ABS (Frame)


ABS

ABS+PC

ASA (Frame)


ASA

ABS+PC

ASA+PC (Frame)


ABS+PC

ABS+PC

PMMA (Lens)


PMMA

ABS

PC (Lens or Frame) Solutions 2, 3, and 4

ABS

ABS

ABS+PC (Frame)


ABS

ABS

ABS (Frame)


ABS

GMW14906

4.13.2.3 Procedure. 4.13.2.3.1 Perform pre-test photometric testing 4.3.4. 4.13.2.3.2 Set 23 °C ± 5 ° 5 °C. C. 4.13.2.3.3 Activate assembly.

ambient light

temperature source

and

to

circuit

4.13.2.3.4 Activate for 2000 h continuously without interruption. 4.13.2.3.5 Perform post-test photometric testing per 4.6.4. 4.13.2.4 Acceptance criteria. All circuitry shall function; all LEDs shall function with no more than 25% change in photometric output. 4.13.2.5 Record All Results per 3.5. 4.14 Condensation for Lamps with Oleophobic Membranes. See Data Sheet A10. 4.14.1 Purpose. To determine if condensation will form inside a lamp after exposure to high humidity























GM WORLDWIDE ENGINEERING STANDARDS 4.14.4.2 Cool to ambient temperature, re-install bulbs and bulb access covers and mount the lamp in the thermal chamber in vehicle position; pre-conditioned at 20 °C ± 4 °C and 70% ± 10% RH on the back side of lamp. The front side environment shall be at 20 °C ± 4 °C and 75% ± 25% RH. Install a baffle around the lamp to separate the front and rear of lamp. Pre-condition the lamp for at least 24 h. 4.14.4.3 For headlamps, fog lamps, and other

GMW14906

4.15 High Humidity Environments. See Data Sheet A11. 4.15.1 Purpose. To determine if the lamp is resistant to extended humidity exposure. 4.15.2 Sample Size. Two (2) pair or three (3) samples. 4.15.3 Equipment. Thermal chamber capable of temperatures from 20 °C to 50 °C with circulating air and humidity levels of 50% to 97% RH.























GM WORLDWIDE ENGINEERING STANDARDS 4.17.2.2 Mass Flow equipment capable of measuring a decay rate accurate to ± 1 Standard Cubic Centimeter per Minute (SCCM) at the above pressures. 4.17.3 Sample Size. Fourteen (14) samples are required for LTP determination and 30 samples for the PDR. Note: Forty Note: Forty four (44) unique samples are required. Do not reuse samples. 4.17.4 Procedure.

GMW14906

pressure that will not exceed its pressure failure limit. 4.17.4.8 The LTP is 80% of the LCL calculated above. The LTP shall be at least 7.0 kPa. Any An y pressure above 28.0 kPa shall be tested at 28.0 kPa. 4.17.5 Pressure Determination.

Decay

Rate

(PDR)

4.17.5.1 Measure all decay rates in Standard Cubic Centimeters per Minute (SCCM) using a























GM WORLDWIDE ENGINEERING STANDARDS 4.18.2 Sample Size. Seven (7) pair pa ir or 14 HID igniter assemblies. 4.18.3 Procedure. 4.18.3.1 HID High Temperature Test. Test. Pre-soak igniter assemblies at 100 °C ± 3 °C for 2 h. Activate as in Table 5, eight times sequentially for a total of 16 h at 100 °C ± 3 °C, monitoring for correct ignition throughout. 4.18.3.2 HID Low Temperature Test. Test. Pre-soak the same igniter assemblies at -40 °C ± 3 °C for

GMW14906

operation shall be from the full inboard to full outboard positions for a total number of movements equal to 10% of total movements required during the Component Reliability Test defined in 4.19.3. 4.19.2 AFL/DHL Component Mechanical Shock. Conduct this test according to test methods of IEC 60068-2-27 Ea or as included in GMW3172. Use samples tested to High Temperature Degradation, only. With the mechanism securely























GM WORLDWIDE ENGINEERING STANDARDS 4.19.3.1.4 4.19.3.1.4 Measure accuracy in degrees to the nominal (photometric) position and response time every 1.0 million cycles. Systems designed to interface with vehicle Local Interconnect Network (LIN) shall also be tested and monitored for functionality using the corresponding AFS/DHL electronic control module. LIN communication shall be replicated in the test setup and used to control movements and diagnose potential incidents. 4.19.3.1.5

Calculate

reliability

at

8.0 million

GMW14906

4.20.1.1 Linear distance of the exposed class A lens surface is more than 450 mm and lamp is mounted above the rear or front bumper/fascia. Examples would include cross-car CHMSL, appliqué or, vertically oriented tail lamps; such as shown in Figure B3 of Appendix B. 4.20.1.2 Any 4.20.1.2 Any part of the lens surface extends to an adjacent interfacing panel providing exposure of a horizontal surface to the sun. Examples are shown in Figure B3 of Appendix B.
























GMW14906

Table 7: Movement Requirements for AFS/DHL Combined AFL (Swiv e l Only)

) s l t n e v e i e m w l e l g e g v S n o n ) A @ A M s 0 l l l 0 t e ) e a n 0 v s i v t e 1 i x w w o

DHL M ov e me nts (x1000) When Combined with AFL

) . ) x . a x ) a . M x M a e M l e e ⅓ ( l l g ( g ⅔ ( g s n s n s n e e A e A e A r

n o i t i s o P l a

Note 1

AFL Advanc dvanced ed Lig Light htin ing g Modes Modes

) ) ) . . ) . g 0 0 x x x i n 0 a a a t 1 h M M x M i g ( e ⅓ l e ⅔ l e ( l L g ( g ( g s s n n s n e d t n A s a e e A e A e r o

s t n e m e v o M g n i t h g i L

) 0 0 g 0 n 1 i x t h ( g t i s L n y e

s t n e m e v o M y a

) 0 0 r e 0 h t 1 x a ( e t s W n e e

DHL Syst System em Only Only

. x a M [ ) s e e r g e d ( ] m e u l g m n

l a t o T f o % ( ) s e t l g n e n

) 0 0 0 1 x ( s t n e m e v o


























GMW14906


























GMW14906


























GMW14906


























GMW14906


























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GMW14906Feb2012.pdf

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