VW80101_2006-12英文

Klass.-Nr./Class. No. 8MA00 October 2006 Electrical and Electronic Assemblies in Motor Vehicles General Test Conditions VW 80101 Konzernnorm Descriptors: assembly, electrical assembly, electronic assembly, test condition Page 1 of 49 Fachverantwortung/Technical responsibility Normung/Standards E2TC, 1733 Mr. Guse EE Mr. Hofmann Tel: +49-5361-9-78398 I/EE Mr. Wolfsteiner Tel: +49-841- 8934210 Tel: +49-5361-9-32438 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 AG N o rm v o r A n w en du n g au f A kt u al itä t p rü fe n / C he ck st an da rd fo r cu rr en t i ss u e pr io r to u sa ge . Fo rm FE 41 - 01 . 06 Contents Page 1 Scope .................................................................................................................................. 3 2 General requirements ......................................................................................................... 3 2.1 Specifications and test sequence........................................................................................ 3 2.2 Definitions ........................................................................................................................... 5 2.3 Relevant areas for requirements and types of requirement for vehicles ............................. 6 2.4 Operating modes................................................................................................................. 8 2.5 Functional states ................................................................................................................. 8 2.6 General test conditions ....................................................................................................... 9 3 Electrical requirements...................................................................................................... 10 3.1 Operating voltages ............................................................................................................ 10 3.2 Operating voltage dips ...................................................................................................... 10 3.3 Rear feed .......................................................................................................................... 12 3.4 Voltage level: HIGH/LOW status assignment.................................................................... 12 3.5 Function during undervoltage and overvoltage ................................................................. 13 3.6 Operating current .............................................................................................................. 14 3.7 Closed-circuit current consumption and closed-circuit charge consumption..................... 14 3.8 Reverse-polarity protection ............................................................................................... 15 3.9 Overcurrent resistance...................................................................................................... 16 3.10 Overvoltage protection during long-term operation ........................................................... 16 3.11 Overvoltage resistance during short-term operation ......................................................... 17 3.12 Superimposed alternating voltage..................................................................................... 17 3.13 Slow decrease and increase of the supply voltage ........................................................... 18 3.14 Reset behavior at voltage dip............................................................................................ 18 3.15 Short-circuit protection ...................................................................................................... 20 3.16 Breakdown strength .......................................................................................................... 20 3.17 Insulation resistance ......................................................................................................... 21 3.18 Interruptions ...................................................................................................................... 21 3.19 Voltage drops .................................................................................................................... 21 3.20 Electromagnetic compatibility (EMC) ................................................................................ 22 4 Mechanical requirements .................................................................................................. 23 4.1 Vibration ............................................................................................................................ 23 4.2 Mechanical shock test ....................................................................................................... 31 4.3 Drop test............................................................................................................................ 32 4.4 Crimp and plug connections.............................................................................................. 32 4.5 Push-on connection on electric and electronic components in the vehicle ....................... 32 4.6 Pull-out strength ................................................................................................................ 32 5 Climatic requirements ....................................................................................................... 33 5.1 Testing at constant temperature ....................................................................................... 33 Th e En gl is h tra n sl a tio n is be lie ve d to be a cc u ra te . In ca se o f d is cr e pa n ci e s th e G e rm a n ve rs io n sh a ll go ve rn . N u m e ric a l n o ta tio n a cc o rd in g to IS O pr a ct ic e (se e VW 01 00 0). QU EL LE : N OL IS Page 2 VW 80101: 2006-10 5.2 Temperature cycle tests .................................................................................................... 34 5.3 Multi-stage temperature test.............................................................................................. 35 5.4 Resistance to open air weathering .................................................................................... 35 5.5 Resistance to environmental factors ................................................................................. 35 5.6 Thermal shock test by water ............................................................................................. 38 6 Chemical requirements ..................................................................................................... 40 6.1 Resistance to chemical agents.......................................................................................... 40 7 Endurance test .................................................................................................................. 41 7.1 Endurance testing of electrical and electronic systems/components ................................ 41 7.2 Endurance testing of electromechanical systems/components......................................... 45 7.3 Component-specific endurance testing ............................................................................. 47 8 Table ................................................................................................................................. 47 9 Referenced standards ....................................................................................................... 48 Changes The following changes have been made as compared to Volkswagen standard VW 80101, 2005-06: ─ Section 2, General requirements supplemented ─ Table 5: Note added ─ Section "Material requirements" removed ─ Operating mode 3 added ─ Section 3.4, Voltage level: Table 7, Assignment of voltage levels to input states, and Table 8, Voltage levels when connected to terminal 15 added ─ Undefined functions not permitted for functional states C, D and E ─ Section 3.5, Function during undervoltage and overvoltage: Figure 3, Voltage overview updated ─ Section 3.8, Reverse-polarity protection: Aim added, requirements specified ─ Section 3.9.2, Electronic outputs: Current load specified ─ Section 3.15, Short-circuit protection: Requirements specified and Figure added ─ Section 3.18, Interruptions: Plug interruptions added ─ Section 4.1, Vibration: 1st paragraph updated ─ Section "Climatic requirements": Mechanical activation added in tests for operating mode 3.2 ─ Test dust, Arizona dust A.2 according to ISO 12103-1 ─ Section 5.2.1, Temperature cycle with specified rate of change: operating mode added ─ Section 5.2.2, Rapid change of temperature with specified transfer duration: Printed circuit boards added ─ Section 5.5.2, Engine cleaning was Section 6.2 ─ Temperature profile figures reduced, and specification of operating modes added ─ Endurance test, Section 7.1 and Section 7.1.1: Operating mode and note added Previous issues 1987-06, 1988-08, 1992-01, 1993-04, 1994-05, 1995-06, 1998-01, 1999-06, 2000-09, 2001-04, 2003-05, 2004-07, 2005-06 Page 3 VW 80101: 2006-10 1 Scope Volkswagen standard VW 80101 specifies general test conditions for electrical, electromechanical and electronic components/systems in vehicles. When referring to this standard in component-specific Technical Supply Specifications, drawings and Performance Specifications, Table 27 (Section 8) shall apply and be supplemented with the appropriate specifications in consultation with the responsible Volkswagen Group engineering departments. 2 General requirements The requirements apply to the entire operating voltage and operating temperature range. The functions and test conditions required for the respective test shall be permanently monitored and documented (at least temperature and supply voltage as well as switching performance, voltage drops, load currents, closed-circuit current and bus messages including timing and content, etc., where applicable). If test severity is not indicated, the standard requirements shall apply. VW 80101 specifies values for temperature, vibration resistance and leak tightness for the relevant areas for requirements. Deviations due to the installed position shall be documented in the Performance Specifications. Requirements called out in drawings and Performance Specifications take precedence over component-specific Technical Supply Specifications. Requirements specified in component-specific Technical Supply Specifications take precedence over VW 80101. Requirements called out in drawings, Performance Specifications and component- specific Technical Supply Specifications refer in principle to conditioned components/systems. 2.1 Specifications and test sequence The Table presented below shall be used in the component-specific Technical Supply Specification or Performance Specifications, containing the relevant data. Table 1 – Tests according to VW 80101 The requirements apply to the entire operating voltage and operating temperature range. The functions and test conditions required for testing shall be monitored and documented continuously. The test sequence must be followed. Designation Specifications acc. to VW 80101 Deviations from VW 80101 Operating temperature see Section 2.3 Storage temperature see Section 2.3 Operating voltage see Section 3.1 Test procedures acc. to VW 80101 Test designation Testing required = X Testing not required = – Specifications for tests acc. to VW 80101 Notes to/ deviations from VW 80101 Each component and each specimen shall meet all requirements in the following test sequence. Conditioning (aging in mechanically circulated air, without load) X see Section 5.1.1 Page 4 VW 80101: 2006-10 Low-temperature operation X see Section 5.1.2 High-temperature operation see Section 5.1.3 Temperature cycle with specified rate of change see Section 5.2.1 Breakdown strength see Section 3.16 Insulation resistance see Section 3.17 Endurance shock test for systems/components in doors and lids see Section 4.2.1 Mechanical shock test for systems/components on the body see Section 4.2.2 Vibration resistance X Acc. to relevant area for requirements see Section 4.1 Endurance test X see Section 7 The following tests can be carried out simultaneously after conditioning (aging in mechanically circulated air, without load). Operating voltage dips see Section 3.2 Rear feed see Section 3.3 Function during undervoltage and overvoltage X see Section 3.4 Voltage level: HIGH/LOW status assignment X see Section 3.4 Operating current see Section 3.6 Closed-circuit current consumption see Section 3.7 Reverse-polarity protection X see Section 3.8 Overcurrent resistance see Section 3.9 Overvoltage protection during long-term operation see Section 3.10 Overvoltage protection during short-term operation (external start simulation) see Section 3.11 Superimposed alternating voltage see Section 3.12 Slow lowering and increasing of the supply voltage see Section 3.13 Reset behavior at voltage dip see Section 3.14 Short-circuit protection see Section 3.15 Interruptions X see Section 3.18 Voltage drops see Section 3.19 Interference emission acc. to TL 965 see Section 3.20.2 Conducted interference acc. to TL 820 66 see Section 3.20.1 Radiated interference acc. to TL 821 66 see Section 3.20.3 EMC on sensor lines acc. to TL 823 66 see Section 3.20.1.3 Immunity to electrostatic discharges acc. to TL 824 66 see Section 3.20.4 Drop test see Section 4.3 Crimp and plug connections see Section 4.4 Push-on connection on electric and electronic components in the vehicle see Section 4.5 Pull-out strength see Section 4.6 Thermal shock test by air see Section 5.2.2 Multi-stage temperature test see Section 5.3 Resistance to open air weathering see Section 5.4 X see Section 5.5.1 Sealing against dust and spray water acc. to DIN 40050-9, subsequently (using the same DUT) Moist heat, cyclic X see Section 5.5.3 Salt spray fog see Section 5.5.4 Thermal shock test by water see Section 5.6 Resistance to chemical agents X see Section 6.1 Engine cleaning (test IP X9K) see Section 5.5.2 Page 5 VW 80101: 2006-10 2.2 Definitions 2.2.1 Terms System Functionally linked components, e.g. ABS system, ESP system Component Part of a functionally linked system, e.g. actuator, sensor, control unit DUT The system or component to be tested (device under test) Functions Contains system-specific and diagnostic functions 2.2.2 Abbreviations IN Nominal current TNH The post-heating temperature is the maximum ambient temperature occurring in the relevant area for requirement (see Table 2) after vehicle cut-off. ToL The maximum storage temperature is the highest temperature which is permissible for storage or transportation of the DUT. It comprises temperatures during paint drying and heat built-up in the engine compartment, for example. The DUT is not operated. TRT Room temperature (+23 ± 5) °C; if not otherwise sp ecified this is the test temperature TuB , ToB The minimum/maximum operating temperature is the lowest/highest ambient temperature at which the DUT may be continuously operated. Self-heating is not taken into account. TuL The minimum storage temperature is the lowest temperature which is permissible for storage or transportation of the DUT. The DUT is not operated. UBmax Maximum operating voltage at which the DUT can be continuously operated. UBmin Minimum operating voltage at which the DUT can be operated. UN Nominal voltage UPA Test voltage at running engine UPB Test voltage at battery operation UPC Test voltage for reverse-polarity battery connection at external start Page 6 VW 80101: 2006-10 2.3 Relevant areas for requirements and types of requirement for vehicles See Figures 1 and Table 2. Figure 1 – Relevant areas on vehicle for requirements Page 7 VW 80101: 2006-10 Table 2 – Relevant areas for requirements and types of requirement Operating temperature range (°C) Storage temperature range (°C) Type of requirement Relevant area on vehicle Vibration load acc. to Section Mechanical shock acc. to Section TuB ToB TuL ToL Resistance to environmental factors Resistance to chemical agents 2) acc. to Table 16 Sealing against dust and spray water DIN 40050-9 If the DUT might be subjected to water when used acc. to the specifications or in the event of predictable misuse, protection type IP 6K 8 shall be used (e.g. doors and lids, footwell, plenum panel). If the values in the Table are not sufficiently specified, the requirements have to be defined in the Performance Specifications. 1 a 1 b Front area, interior Front area, exterior 4.1.4 Severity 2 4.2.2 -40 -40 +120 3) +70 -40 -40 +130 +90 Salt spray fog Moist heat e, f, g, i, j, q, s IP 5K 4K and IP X 9K 1) 2 Engine compartment 4.1.4 4.2.2 -40 +120 3) -40 +140 Salt spray fog Moist heat a to q IP 5K 4K and IP X 9K 1) 3 Engine-mounted parts Transmission-mounted parts Intake plenum, not connected to other components 4.1.1 4.1.2 4.1.3 - -40 +140 3) -40 +140 Salt spray fog Moist heat a to q IP 5K 4K and IP X 9K 1) 4 Plenum panel 4.1.4 4.2.2 -40 +70 -40 +90 Salt spray fog Moist heat f, g, j, q, s IP 5K 4K and IP X 9K 1) 5 Dashboard, center console 4.1.4 Severity 2 4.2.2 -40 +70 -40 +90 Moist heat m, r, s, u IP 5K 0 6 Doors (interior) 4.1.4 4.2.1 -40 +80 -40 +100 Moist heat m, r, s, t, u IP 5K 3 7 Doors, side area (exterior) 4.1.4 4.2.2, Doors 4.2.1 -40 +70 -40 +90 Salt spray fog Moist heat f, g, j, q IP 5K 4K and IP X 9K 1) 8 Passenger-compartment floor, cross panel, center tunnel and luggage compartment 4.1.4 4.2.2 -40 +70 -40 +90 Moist heat m, r, s, t IP 5K 0 9 Passenger compartment, roof 4.1.4 4.2.2 -40 +95 -40 +105 Moist heat s, u IP 5K 0 10 Chassis 4.1.4 4.2.2 -40 +70 -40 +90 Salt spray fog Moist heat a to q IP 5K 4K and IP X 9K 1) 11 Roof and rear area, exterior add-on parts Engine hood and trunk lid/tailgate 4.1.4 4.2.2 Engine hood and trunk lid/tailgate 4.2.1 -40 +70 -40 +90 Salt spray fog Moist heat e, f, g, i, j, q, s IP 5K 4K and IP X 9K 1) 1) IP X 9K testing acc. to Section 5.5.2, as well as additional splash water test acc. to Section 5.6. 2) Chemical agent c (battery acid), only if required in Performance Specifications. 3) Temperature profile with post-heating phase acc. to Figure 16 and Table 16. Page 8 VW 80101: 2006-10 2.4 Operating modes The following operating modes are distinguished: 2.4.1 Operating mode 1 The DUT is not electrically operated. ─ Operating mode 1.1 No lines are connected to the DUT. ─ Operating mode 1.2 All lines are connected according to vehicle installation, but no voltage is applied. 2.4.2 Operating mode 2 The DUT is electrically operated with the supply voltage UPB (battery voltage) as in a cut-off vehicle (engine OFF). All system components (e.g. sensors, actuators) and lines are connected to the DUT. ─ Operating mode 2.1 System/component functions are not activated (e.g. sleep mode). ─ Operating mode 2.2 Systems/components with function and activation in normal operating mode. 2.4.3