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1、 WORLDWIDE ENGINEERING STANDARDS General Specification HVAC and Powertrain Cooling GMW15845 HVAC and Powertrain Cooling Test Vehicle Instrumentation Procedure Copyright 2008 General Motors Corporation All Rights Reserved October 2008 Originating Department: North American Engineering Standards Page
2、1 of 23 1 Introduction Note: Nothing in this standard supersedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This standard describes the preferred installation techniques for the com
3、mon instrumentation list. Using these techniques will aid in data correlation from vehicle to vehicle. 1.2 Mission/Theme. Not applicable. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specif
4、ications. None 2.2 GM Standards/Specifications. GMW3059 2.3 Additional References. GM Part Number 12346240 Vehicle Technical Specification (VTS), paragraph 3.2.1.5.4.1.4.2 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 Calibration. The test facilities and equipment shall be in good working o
5、rder and shall have a valid calibration label. 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this specification shall be determined correctly with respect to its physical definition. 3.1.3 Facilities. Not applicable.
6、3.1.4 Equipment. Not applicable. 3.1.5 Test Vehicle/Test Piece. Not applicable. 3.1.6 Test Time. Not applicable. 3.1.7 Test Required Information. Not applicable. 3.1.8 Personnel/Skills. Not applicable. 3.2 Preparation. Not applicable. 3.3 Conditions. 3.3.1 Environmental Conditions. Not applicable. 3
7、.3.2 Test Conditions. Not applicable. 3.4 Instructions. Not applicable. 3.5 Data. Not applicable. 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
8、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 standa
9、rd 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
10、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 st
11、art 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. 3.7.1 Test Results. Not applicable. 3.7.2 Deviations from this Standard. Deviations from the requirements of this standard shall have been agreed
12、upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4 Requirements and Procedure 4.1 Temperature Requirements GMW15845 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2008 General Motors Corporation All Rights Reserved Page 2 of 23 October 2008 4.1.1 Engin
13、e Oil Sump/Dipstick. Verify the instrumentation procedure to ensure the fluid temperature measured represents the bulk engine oil sump fluid average temperature. The measurement location of engine oil may require special care due localized hot or cold regions in the oil sump. Consult with the approp
14、riate engine application development engineer prior to testing. 4.1.1.1 Sump. Instrument engine oil drain plug with a 1.6 to 3.2 mm (1/16 or 1/8 in) or equivalent diameter thermocouple probe. Extend thermocouple probe tip 15 mm beyond drain plug. (Refer to Figure A1.) 4.1.1.2 Dipstick. Instrument en
15、gine dipstick with thermocouple wire (recommend 30 AWG K-30-2- 506), down the length with the junction at the tip of the dipstick. The dipstick may be substituted with a probe type thermocouple that is set up to the same length as the dipstick. A rubber cork should be used to seal the dipstick tube.
16、 4.1.2 Transmission Oil Sump/Dipstick. 4.1.2.1 Sump. Locate thermocouple at inlet midpoint of the transmission filter screen as follows; 4.1.2.1.1. Install and tighten plug to case. 4.1.2.1.2. Insert thermocouple until it bottoms out on the oil filter. 4.1.2.1.3. Retract the thermocouple 3 mm from t
17、he filter. 4.1.2.1.4. Tighten compression nut while holding plug. 4.1.2.2 Dipstick. Instrument transmission dipstick with thermocouple wire,(recommend 30 AWG K- 30-2-506) down the length with the junction at the tip of the dipstick. The dipstick may be substituted with a 1.6 to 3.2 mm or equivalent
18、probe type thermocouple that is set up to the same length as the dipstick. A rubber cork should be used to seal the dipstick tube. 4.1.3 Rear Axle. Instrument (1st) the drain plug or (2nd) the fill plug with 1.6 to 3.2 mm or equivalent diameter thermocouple probe. Note: Alternate method is to instru
19、ment the cover plate, locating the thermocouple in approximately the 5 o-clock position to avoid the ring gear. (Refer to Figure A1.) 4.1.4 Radiator Coolant Inlet and Outlet. 4.1.4.1 Technique 1. (Refer to Figure A2.) Use a thermocouple well in the radiator hoses as close as practical to the inlet a
20、nd outlet. 4.1.4.2 Technique 2. (Refer to Figure A3.) Use a piece of welded junction thermocouple (K24-2-505) wire. Fold the junction end in a Z shape and place on radiator hose nipple, apply a small amount of room temperature vulcanizing (RTV) sealant on the wire before sliding radiator hose over t
21、he thermocouple. Consider replacing the spring clamp with a worm gear clamp. The Z shape will prevent the wire from slipping back while the hose is being installed, and will maintain the junction in the midpoint of the fluid flow. Allow sufficient time for the RTV to cure before applying pressure or
22、 vacuum to the system. Warning: DO NOT use thermocouple wire with an extruded outer jacket. The system pressure will force coolant into the jacket and a leak will occur. 4.1.5 Engine Air Intake Manifold. The position and method of instrumentation of this thermocouple is to be determined by the reque
23、stor. 4.1.6 Power Steering Sump Oil. Instrument with 1.6 to 3.2 mm or equivalent diameter thermocouple probe. Locate the thermocouple junction at the tip of the dipstick of a remote fluid reservoir. 4.1.7 Transmission Oil Auxiliary Cooler Air Inlet and Outlet. Locate at midpoint and 10 mm off the co
24、oler surface. 4.1.8 Transmission Oil Cooler Fluid Inlet and Outlet Pipe. Locate thermocouple probe in the cooler pipe within 50 to 100 mm of the radiator connection. 4.1.8.1 Technique 1. Weld (silver solder) a 1.6 mm to 3.2 mm or equivalent thermocouple probe in the cooler pipe. The probe tip must b
25、e in the midpoint of the flow stream. Typically these pipes are steel and can be silver soldered. If an aluminum pipe is used, go to technique 2. 4.1.8.2 Technique 2. Clamp welded thermocouple junction to pipe with a small worm gear clamp. Be sure to clamp only the welded tip, trying not to create a
26、 new junction with the exposed wire. Wrap the clamped thermocouple junction and clamp with No Drip tape or equivalent insulation tape. This minimizes the influence of other heat sources or air-cooling of the thermocouple. This technique should only be used for non-invasive testing, example: competit
27、ive, saleable or show vehicles. 4.1.8.3 Technique 3. Fix the TC with an applicable reliable tape on the pipe surface. Wrap the clamped thermocouple junction and clamp with No Drip tape or equivalent insulation tape. This minimizes the influence of other heat sources or air-cooling of the thermocoupl
28、e. This technique should only be used for non-invasive testing, example: competitive, saleable or show vehicles. 4.1.9 Transmission Oil Auxiliary Cooler Fluid Inlet and Outlet Pipe. Refer to 4.1.8. GM WORLDWIDE ENGINEERING STANDARDS GMW15845 Copyright 2008 General Motors Corporation All Rights Reser
29、ved October 2008 Page 3 of 23 4.1.10 Charge Air Cooler Inlet and Outlet Pipe. Locate thermocouple in the cooler pipe within 50 to 100 mm of the air cooler inlet and outlet. 4.1.10.1 Technique 1. Drill and tap the cooler pipe to accept a pipe thread (often National Pipe Thread or NPT) of the fitting
30、being installed. Use a bored through fitting for temperature measurements. 4.1.10.2 Technique 2. (See to Figure A3.) Use a piece of welded junction thermocouple (K24-2-505) wire. Fold the junction end in a Z shape and place on air cooler hose nipple, apply a small amount of RTV sealant (GM Part Numb
31、er 12346240 or equivalent) on the wire before sliding the air cooler hose over the thermocouple. The Z shape will prevent the wire from slipping back while the hose is being installed, and will maintain the junction in the midpoint of the fluid flow. Allow sufficient time for the RTV to cure before
32、operating the system. Warning: DO NOT use thermocouple wire with an extruded outer jacket. The system pressure will allow a leak to occur. 4.1.10.3 Technique 3. Drill the cooler pipe In and Outlet and fix (solder or bond) screw nut to enable a thread fitting to be installed. Use a bored through fitt
33、ing for temperature measurements. 4.1.11 Turbocharger Air Inlet and Outlet. Locate thermocouple in the turbocharger pipe within 50 to 100 mm of the air cooler inlet and outlet. Drill and tap the Turbocharger pipe to accept the fitting (often NPT) being installed. Use a bored through fitting for temp
34、erature measurements. 4.1.12 Engine Oil Cooler Inlet and Outlet Pipe. Locate thermocouple probe in the cooler pipe within 50 to 100 mm of the radiator connections. See 4.1.8. The primary engine oil cooler may be in the radiator end tank or may be pan caked to the oil filter. 4.1.13 Engine Oil Cooler
35、 Air Inlet and Outlet. Locate at midpoint and 10 mm off the cooler surface. 4.1.14 Engine Oil Cooler Coolant Inlet and Outlet Pipe. Locate thermocouple probe in the cooler pipe within 50 to 100 mm of the cooler. See 4.1.8 4.1.15 Transmission Oil Case Inlet and Outlet. Locate thermocouple probe in th
36、e cooler line within 50 to 100 mm of the transmission case. See 4.1.8. 4.1.16 Transmission Stator. Vendor installed. 4.1.17 Grille. Locate thermocouple 50 to 125 mm behind and near midpoint of vehicle grille or fascia opening, but not behind any emblems or supports. The thermocouple needs to be in t
37、he airflow stream. 4.1.17.1 Technique 1. After welding the junction. Attach the T/C to the grille with tie wraps. 4.1.17.2 Technique 2. Use 32 x 102 mm (1 x 4 in) long polyvinyl chloride (PVC) tubing and locate the thermocouple at the midpoint of the tube and center of the air stream inside the tube
38、. Attach to the vehicle at grille level. 4.1.18 Roof. Use 32 x 102 mm (1 x 4 in) long PVC and locate the thermocouple at the midpoint of the tube and center of the air stream inside the tube. Attach to the vehicle roof (with Velcro or magnet) at the midpoint or above the drivers door. 4.1.19 Dry and
39、 Wet Bulb Exterior. The Instrumentation method and location is to be determined by the requestor. 4.1.20 Cowl Air Inlet. Locate thermocouple below the cowl cover, in the main air stream between the major inlet screen and the blower air inlet, protected from the solar radiation influence. 4.1.21 Reci
40、rculation Air Inlet. Locate thermocouple near midpoint of the recirculation opening on the cabin side of the inlet opening. 4.1.22 Front Blower Air Inlet. Locate thermocouple near midpoint of the air stream and approximately 12.5 mm before the blower air inlet orifice. 4.1.23 Front Blower Air Outlet
41、. Locate thermocouple at midpoint of discharge throat of the blower scroll. Drill a hole in the module case and install the thermocouple 25 to 30 mm into the air stream. 4.1.24 Rear Blower Air Inlet. Locate thermocouple near midpoint of the air stream and approximately 12.5 mm before the blower air
42、inlet orifice. 4.1.25 Compressor Outlet (Refrigerant). Locate thermocouple midpoint of the flow stream in the pressure line using one of the following techniques: 4.1.25.1 Technique 1 .Weld a port on the pressure line. Drill a hole in the pressure line large enough for a 1.6 mm (1/16 in) diameter th
43、ermocouple probe (leak check weld before proceeding). Use a bored through fitting for temperature only measurements or special pressure and temperature fitting to capture both data readings (refer to Figure A4). Note: Do not use Teflon on refrigerant fittings - Loctite 272 is suggested. 4.1.25.2 Tec
44、hnique 2. Drill and tap the compressor block fitting to accept NPT of fitting being installed. Use a bored through fitting for temperature only or special pressure and temperature fitting to capture both data readings (refer to Figure A4). Note: Do not use Teflon on refrigerant fittings - Loctite 27
45、2 is suggested. Note: GMW15845 GM WORLDWIDE ENGINEERING STANDARDS Copyright 2008 General Motors Corporation All Rights Reserved Page 4 of 23 October 2008 Be sure to identify the block fitting as being sweated to the aluminum tubing. If you drill and tap a fitting that is not sweated (can be referred
46、 to as a Lock - Block) you can create a leak path between the tubing and the block. 4.1.25.3 Technique 3. Clamp welded thermocouple junction to pipe with a small worm gear clamp. Be sure to clamp only the welded tip, trying not to create a new junction with the exposed wire. Wrap the clamped T/C and
47、 clamp with No Drip insulation tape. This minimizes the influence of other heat sources or air-cooling of the thermocouple. This technique should only be used for non-invasive testing, example: competitive, saleable or show vehicles. 4.1.26 Condenser Inlet and Outlet (Refrigerant). Locate thermocoup
48、le in the pressure line within 50 to 75 mm of the condenser header and midpoint of the flow stream. See 4.1.25. 4.1.27 Front Before Expansion Device (BXD) Inlet (Refrigerant). Locate thermocouple in the pressure line within 50 to 75 mm of the expansion device and midpoint of the flow stream. See 4.1
49、.25. 4.1.28 Front Evaporator Inlet and Outlet (Refrigerant). Ideal is inside the module. Practical is as close to the evaporator as possible, or as directed by the requestor for alternate locations. See 4.1.25. 4.1.29 Accumulator/Dehydrator Inlet (Refrigerant). Locate thermocouple in the pressure line within 50 to 75 mm of the accumulator/dehydrator and midpoint of the flow stream. See 4.1.25. 4.1.30 Receiver Drier Outlet (Refrigerant). Locate thermocouple in the pressure line within 50 to 75 mm of the receiver drier and midpoint of the flow stream. See 4.1.25. 4.1.31 Compress
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