GMW-3037-2001.pdf

Test Procedure Road GMW3037 A/C System Maximum Performance Validation for Passenger Vehicles 1 Introduction Note: Nothing in this procedure supersedes applica- ble laws and regulations unless a specific exemption has been obtained. Note: In the event of a conflict between the English and the domestic language, the English language will take precedence. 1.1 Purpose.Validation of the maximum perfor- mance capability of a vehicle air conditioning system by reproducible measurements in a climatic wind tunnel. 1.2 Foreword. Not applicable. 1.3 Applicability. For all passenger vehicles with an AC system. 1.4 Definitions. Breath Level:The breath-level for a particular row is the average of the two outboard breath level tem- perature sensors of that row. The temperature sen- sor(s) for each seat position shall be installed accord- ing to Appendix A. The vent nozzles shall be adjusted in such a way that the main air flow of each nozzle is directed straight backward to a line 200 mm below breath temperature sensors. Air Outlet Vents:Air Outlet Vents is the average of the A/C outlet temperatures at the vent nozzles. The temperature sensors shall be installed in the center of the outlets in such a way that they extend 10 mm into the outlets and do not touch any parts of the air ducting system. Test Temperature:Test Temperature is the cli- matic tunnel ambient as defined per the VTS for the specific test condition. OSA:Outside Air Mode. P/R:Recirculation Mode. Acceleration and Deceleration:Unless other- wise specified, the acceleration and deceleration rates should be within 8 and 10 km/h/s. 2 References Note: Only the latest approved standards are appli- cable unless otherwise specified. 2.1 Normative. None. 2.2 GM. None. 2.3 Additional. None. 3 Resources 3.1 Facilities. 3.1.1 Climatic wind tunnel including a chassis dy- namometer with adjusting possibilities for a vehicle speed of 110 km/h minimum, a wind speed of 110 km/h minimum, an ambient temperature of +50C minimum and a relative humidity of 80 % minimum. 3.1.2 Capability of solar radiation simulation with a power of 1100 W/m2. 3.2 Equipment. 3.2.1 General. 3.2.1.1 Temperature measuring and recording equip- ment as described in Appendix B. 3.2.1.2 Pressure measuring and recording equip- ment as described in Appendix B. 3.2.1.3 Measuring and recording equipment for the engine speed. 3.2.1.4 Measuringandrecordingequipmentfor voltage and current for compartment blower(s), battery(s), and engine cooling fans (if applicable). 3.2.1.5 Device for operation and adjustment of accel- erator pedal. 3.2.1.6 Battery charger to maintain battery during warm up (see 4.2.2.1.1). 3.3 Test Vehicle / Test Piece. Passenger vehicles equipped with an AC system. 3.4 Test Time. See 4.3.1 and 4.3.2. 3.5 Test Required Information. Test conditions as specified by the VTS. © Copyright August 2001 General Motors Corporation All Rights Reserved Originating Department: North American Engineering Standards, Records and Documentation August 2001Page 1 of 9 GMW3037GM WORLDWIDE ENGINEERING STANDARDS 3.6 Personnel / Skills. Two (2) climatic tunnel oper- ator, one driver (if necessary). 4 Procedure 4.1 Preparation. The vehicle shall be prepared for the climatic tunnel and shall be equipped with devices according to 3.2 and 4.3.3. Automatic systems will re- quire additional equipment to override air inlet selec- tion. 4.1.1 Settings. For automatic and manual systems, the vehicle ventilation system controls shall be set to A/C outlet mode, maximum cold and maximum blower.Deviations are described in the following paragraphs. Remark: Automatic systems are operated like man- ual systems. Be sure the air inlet mode (OSA-P/R) can be switched during the test. 4.2 Conditions. 4.2.1 Environmental Conditions. 4.2.1.1 Ambient. Test temperature:(+38 ± 1) C Relative humidity:40 % Sun Load:1000 W/m2 (measured in the center of vehicle roof) Different conditions are described in the correspond- ing VTS. 4.2.2 Test Conditions. Deviations from the require- ments of this procedure shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 4.2.2.1 Vehicle Conditioning. 4.2.2.1.1 Warm Up. Warm up is not necessary if the temperature of the body mass (seat rail) is within 15 C of the test temperature. Wind speed:optional Temperature:Test temperature Engine:off Blower:Blower Position closest to 6 Volts setting Battery:Connected to charger Windows:optional Air direction:A/C outlet mode with all outlets open Sun load:on Time:Until the temperature of the body mass (e.g. seat rail) has achieved the test temperature. 4.2.2.1.2 Pre-Soak. Wind speed:50 km/h Temperature:Test temperature Engine:on (idle) Compressor:off Blower:Blower Position closest to 6 Volts setting Windows:open Air direction:A/C outlet mode with all outlets open Outside air mode(OSA) Sun load:off Time:30 minutes 4.2.2.2 Soak Conditions. Wind speed:As required to maintain test conditions (e.g. 5 km/h) Temperature:Test temperature Engine:off Blower:off Windows:closed Air direction:A/C outlet mode with all outlets open Recirc mode (P/R) Sun load:on Time: Depending on the installed sun simulation equipment, the time shall be defined as the equivalent period, 50 minutes, to reach the same soak results as obtained with natural sun load of 1 h at 1000 W/m2(or as specified by the corresponding VTS) at test temperature. 4.2.2.3 Idle Conditions. The wind speed in front of the radiator shall be 0 km/h. © Copyright August 2001 General Motors Corporation All Rights Reserved Page 2 of 9August 2001 -,-,- GM WORLDWIDE ENGINEERING STANDARDSGMW3037 4.2.2.4 Electrical Power Supply. All electrical sys- tems are supplied by the internal vehicle power sup- ply. The battery shall be fully charged before the test. The blower speed (voltage) is defined by the corre- sponding VTS. 4.2.2.5 Table 1: Gear Step or Drive Positions Speed Transmission50 km/h80 km/h110 km/hIdle Manual Transmission 4 speed 4.4.4.neutral Manual Transmission 5 speed Wide ratio (Note 1) 4.5.5.neutral Manual Transmission 5 speed Close ratio (Note 2) 5.5.5.neutral Manual Transmission 6 speed 6.6.6.neutral Automatic Transmission Highest Drive Gear Highest Drive Gear Highest Drive Gear Highest Drive Gear Note 1: 5th gear = Over Drive Note 2: 5th gear = 1:1 gear ratio The specified vehicle speeds are driven at road load (on level stretches without acceleration). For repeat measurements on vehicles with automatic transmissions, it shall be ensured that same vehicle speeds are driven at the same lowest engine speeds. For Manual transmissions, gears shall be changed as follows: Idle drive away: shifts at 1000 rpm less than red line. Other shifts at (3000 ± 200) rpm. 4.3 Instructions. © Copyright August 2001 General Motors Corporation All Rights Reserved August 2001Page 3 of 9 -,-,- GMW3037GM WORLDWIDE ENGINEERING STANDARDS 4.3.1 Figure 1: Climatic Tunnel Cycle 1 The following notes apply to Figure 1: Note 1: Pre-soak Note 2: Soak Note 3: Idle P/R Note 4: Idle OSA Note 5: 30 minutes Note 6: see 4.2.2.2 Note 7: Test time in minutes 4.3.2 Figure 2: Climatic Tunnel Cycle 2 The following notes apply to Figure 2: Note 1: Warm up Note 2: Pre-soak Note 3: Soak Note 4: Cool down Note 5: Idle P/R Note 6: variable, see 4.2.2.1.1 Note 7: 30 minutes Note 8: see 4.2.2.2 Note 9: Test time in minutes © Copyright August 2001 General Motors Corporation All Rights Reserved Page 4 of 9August 2001 -,-,- GM WORLDWIDE ENGINEERING STANDARDSGMW3037 4.3.3 Measuring Values and Data to be Recorded. All data (see Appendix B) shall be recorded at inter- vals of maximum 30 s. To capture the surges in the head pressures, scan rate shall be increased to 1 s intervals for the 110 km/h (OSA) driveaway after the 160 minute mark in the test. In addition, a single shot data point shall be taken at the end of each speed segment during the course of the test. 4.3.3.1 Further Data. -Vehicle data, mileage and description of the sys- tem to be validated -Test number and date -Name of the person in charge of the test and the driver (if applicable) -List of calibrated test equipment 4.3.4 Test Description Cycle 1. Warm up the vehicle by using the solar light bank until the vehicle mass has reached the test temperature as described in 4.2.2.1.1. Pre-soak the vehicle for 30 minutes as described in 4.2.2.1.2. At the completion of the pre-soak, change air inlet mode from OSA to P/R and then shut the engine off for vehicle soak.Soak time starts after the tunnel operator returns to the control room. Soak the vehicle as described in 4.2.2.2. After the soak is complete, the driver enters the vehi- cle and switches the compressor and the blower fan to on. Blower setting per VTS (default is High 14 Volts). Then the driver starts the engine. This is t = 0 minutes. Remark: If necessary the driver can stay in the ve- hicle (for speed adjustment and gear changing), but it is recommended that the tunnel operator make all adjustments. Accelerate vehicle to 50 km/h and maintain speed for 20 minutes. After recording data, accelerate vehicle to 80 km/h and maintain for 20 minutes. After recording data, decelerate vehicle to 0 km/h to allowtheoperatorto enterthevehicleandshiftairinlet mode to OSA. After the operator comes back to the control room, accelerate the vehicle to 50 km/h and maintain speed for 20 minutes. Note: Time takenbythe operatortochange the airin- let mode should not be greater than 60 s after achiev- ing 0 km/h. After recording data, accelerate vehicle to 80 km/h and maintain for 20 minutes. After recording data, decelerate vehicle to idle, shift air inlet mode to P/R. Maintain idle for 30 minutes. Note: Time taken by the operator to change the air inlet mode after achieving 0 idle should not be greater than 60 s. After recording data, accelerate vehicle to 110 km/h, shift air inlet mode to OSA. Maintain speed for 20 minutes. Note: Time taken by the operator to change the air inlet mode after the end of the 30 minute idle should not be greater than 60 s. After recording data, decelerate vehicle to idle. Main- tain idle for 30 minutes. After recording data, accelerate up to 110 km/h as quickly as vehicle allows.Maintain 110 km/h for 2 minutes. Record data. End of test. 4.3.5 Test Description Cycle 2. Warm up the vehicle by using the solar light bank until the vehicle mass has reached the test temperature as described in 4.2.2.1.1. Pre-soak the vehicle for 30 minutes as described in 4.2.2.1.2. At the completion of the pre-soak, change air inlet mode from OSA to P/R and then shut the engine off for vehicle soak.Soak time starts after the tunnel operator returns to the control room. Soak the vehicle as described in 4.2.2.2. After the soak is complete, the driver enters the vehi- cle and switches the compressor and the blower fan to on. Blower setting per VTS (default is High 14 Volts). Then the driver starts the engine. This is t = 0 minutes. Remark: If necessary the driver can stay in the ve- hicle, but it is recommended that the tunnel operator make all adjustments. Place transmission in gear as described in Table 1, 4.2.2.5. Maintain idle condition for 30 minutes. Record data. Test complete. 5 Data 5.1 Calculations. Not applicable. 5.2 Interpretation of Results. The targets are de- fined by the VTS. © Copyright August 2001 General Motors Corporation All Rights Reserved August 2001Page 5 of 9 -,-,- GMW3037GM WORLDWIDE ENGINEERING STANDARDS 5.3 Test Documentation. With reference to this pro- cedure the results of the measurements shall be pre- sented in a test report. 6 Safety This procedure may involve hazardous materials, op- erations and equipment.This procedure does not propose to addressallthe safetyproblems associated with its use. It is the responsibility of the user of this procedure to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 7 Coding System This procedure shall be referenced in other docu- ments, drawings, VTS, CTS etc. as follows: Test to GMW3037. 8 Release and Revisions 8.1 Release.The specification was first approved July 1998 and published in February 2000. 8.2 Revisions. Rev.DateDescription (Org.) AAUG 2001 Editorial Revision (GMNA) © Copyright August 2001 General Motors Corporation All Rights Reserved Page 6 of 9August 2001 GM WORLDWIDE ENGINEERING STANDARDSGMW3037 Appendix A Figure 3: Breath Level Thermocouple Location The following notes apply to Figure 3: Note 1: Breath Level Thermocouple Location Note 2: Seats Note 3: Front View Note 4: Windshield Molding Note 5: T-Point Note 6: Side View Note 7: Front Seat Note 8: Backlight Molding Note: -The T-point describes the location of the occu- pants head (95 % Oscar) for a seat back angle defined by the manufacturer (See Motor Vehicle Dimensions Procedures). -The T-point coordinates can be taken from the cor- responding package plan. © Copyright August 2001 General Motors Corporation All Rights Reserved August 2001Page 7 of 9 GMW3037GM WORLDWIDE ENGINEERING STANDARDS Appendix B Table 2: Measuring Values and Data to be Recorded No.UnitTest PointRemarks 1.CTemperature Ambient 2.CTemperature Coolant cylinder head 3.CTemperature Refrigerant compressor out 4.CTemperature Refrigerant before TXV/OT 5.CTemperature Refrigerant before rear TXV/OTwhere applicable 6.CTemperature Refrigerant evaporator out 7.CTemperature Refrigerant rear evaporator outwhere applicable 8.CTemperature Refrigerant compressor in 9.CTemperature Compartment blower outside air in 10.CTemperature Compartment blower recirc air in 11.CTemperature Rear compartment blower outside air inwhere applicable 12.CTemperature Rear compartment blower recirc air inwhere applicable 13.CTemperature Instrumental panel air outlet left 14.CTemperature Instrumental panel air outlet center left 15.CTemperature Instrumental panel air outlet center right 16.CTemperature Instrumental panel air outlet right 17.CTemperature Rear A/C air outlet leftwhere applicable 18.CTemperature Rear A/C air outlet centerwhere applicable 19.CTemperature Rear A/C air outlet rightwhere applicable 20.CTemperature Breath level front left 21.CTemperature Breath level front right 22.CTemperature Breath level second seat row leftwhere applicable 23.CTemperature Breath level second seat row rightwhere applicable 24.CTemperature Breath level third seat row leftwhere applicable 25.CTemperature Breath level third seat row rightwhere applicable 26.CTemperature Radiator Grille 27.CTemperature Body mass (e.g. seat rail) 28.kPaPressure Compressor discharge 29.kPaPressure Liquid line (before TXV/OT) 30.kPaPressure Evaporator out 31.kPaPressure Rear evaporator outwhere applicable 32.VVoltage Compartment blower © Copyright August 2001 Gene