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GMW3103(april 2012) WORLDWIDE ENGINEERING STANDARDS General Specification GMW3103 General Specification for Electrical/Electronic Components and Subsystems, Electromagnetic Compatibility Global EMC Component/Subsystem Validation Acceptan...

GMW3103(april 2012)
WORLDWIDE ENGINEERING STANDARDS General Specification GMW3103 General Specification for Electrical/Electronic Components and Subsystems, Electromagnetic Compatibility Global EMC Component/Subsystem Validation Acceptance Process © Copyright 2012 General Motors Company All Rights Reserved April 2012 Originating Department: North American Engineering Standards Page 1 of 42 1 Introduction Note: Nothing in this standard supercedes 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 document applies to the Electromagnetic Compatibility (EMC) design, development and validation of electrical/electronic components and subsystems for passenger vehicles, light duty trucks and medium duty trucks. This document is one out of a series of three global EMC documents that specify EMC test and validation requirements. The complete series consists of the following documents: GMW3091, GMW3097, and GMW3103. 1.2 Mission/Theme. This document specifies the Global Electromagnetic Compatibility Component/Subsystem Validation Acceptance Process to ensure components and subsystems are properly designed, developed and validated prior to vehicle validation. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ISO 7637-2 SAE J2602 2.2 GM Standards/Specifications. GMW3059 GMW3091 GMW3122 GMW3089 GMW3097 2.3 Additional References. CG3044 Best Practice - The supplier shall work with the GM responsible engineer to comprehend this requirement General Motors Component EMC and Environmental Test (CEMENT) Database Production Part Approval Process (PPAP) 3 Requirements 3.1 Requirements. The Global EMC Component/Subsystem Validation Acceptance Process defined within this document shall be followed for all EMC component/subsystem design, development and validation. Appendix B: EMC Lessons Learned should be reviewed and considered prior to the first electrical design and layout of the product. Unless otherwise agreed upon by the GM Design/Release-Responsible Engineer, the initial draft of Appendix A: Component EMC Test Plan shall be completed by the supplier and uploaded in the Component EMC and Environmental Test (CEMENT) database within 60 days (less than 12 weeks from supplier sourcing) prior to the start of EMC testing, with the final version required within 10 days prior to the start of testing. (Refer to Figure A1 in Appendix A). Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS - - ` ` , ` , , ` ` ` , , ` , , ` , , ` , , ` ` ` , , ` - ` - ` , , ` , , ` , ` , , ` - - - GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 2 of 42 An editable version of Appendix A can be obtained on request from the GM EMC Engineer via the Global Document Management (GDM) database, or from GM's Engineering Standards distributor, IHS Inc. (www.ihs.com), where the blank template is referenced as CG3044. 3.2 Process. 3.2.1 Design, Build, and Validate Design Iteration. The objectives of the Design, Build and Validate Design Iteration phase shown in Figure 1, include component/subsystem design, development and validation. Design validation shall occur during this phase to confirm all Electromagnetic Compatibility technical requirements contained in the Component/Subsystem Technical Specification are met. An EMC Detailed Design Review, shown in Figure 1, shall be conducted for all new components and subsystems and applications, and for revisions to existing components and subsystems that could affect Electromagnetic Compatibility compliance. This process does not apply to carryover components or subsystems. The term carryover means that the product qualified for a prior program and is exactly the same product being used for the future program. Modifications, alterations, internal part swaps, hardware and software changes are not considered carryover and must be validated according to the requirements. Detailed Design Review(s) shall be scheduled and led by the supplier, and attended by the EMC Design Review Team. The GM Design/Release-Responsible Engineer must be consulted on scheduling and informed of all design review results and supplier action plans. The GM Validation-Responsible Engineer's acceptance of review results and supplier action plans does not relieve the supplier of the obligation to meet contracted performance requirements. The objectives of the Detailed Design Review should be to:  Review component/subsystem schematic design and circuit board layout.  Examine any prior relevant analysis, calculations and test results.  Evaluate potential changes to the component/subsystem design.  Propose solutions to problems and appropriate revalidation.  Verify that the proposed design and circuit board layout satisfies component/subsystem EMC technical and validation requirements. The GM Design/Release-Responsible Engineer may also schedule a design review on his/her own initiative, or upon the advice of a GM EMC engineer. The GM Design/Release-Responsible Engineer may make any appropriate arrangement for leadership of such a review or delegate the actual review activity to other team members. Supplier Deliverables: Documentation required to be delivered, as one package, to vehicle manufacturer EMC design review team at least 10 working days ahead of the scheduled meeting:  Printed Circuit Board (PCB) Layout.  Components List.  Hardware Schematic Drawing.  Component Placement Drawing.  Functional Description.  Interface Description.  EMC Math Simulation Results (if available).  EMC Test Reports (if available).  EMC Component Test Plan (Appendix A of GMW3103, may be referred to as CG3044), in electronic editable format. Note: Actual hardware samples or physical mock-up for visual examination is desirable but not required. Electronic documents must be in an editable format compatible with Microsoft Office. Design Analysis and Performance. Design analysis and performance is a part of the design review. In a design review the supplier shall demonstrate and give technical rationale for the following:  EMC filter design and performance, characterization data for proposed input/output (I/O) filtering, clock circuits, bypassing and decoupling. Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS --``,`,,```,,`,,`,,`,,```,,`-`-`,,`,,`,`,,`--- GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 3 of 42  Number of PCB layers in combination with use of selected clock frequency and housing material.  Identification and protection of critical/susceptible parts to both emission and immunity (including Transient and Electrostatic Discharge (ESD) protection).  Identification of fundamental operating frequencies: clock rates, switching frequencies, and other potential coherent EMC sources. Initial EMC test results shall be studied and reviewed, and if not available, identify when review of test results can be done. Some of the data may include:  Output waveforms for all pulsed, pulse width modulated (PWM), or power outputs indicating the dV/dt, and dI/dt.  Provide output voltage and current time domain measurements for power outputs and inputs.  Review results of performed radiated emissions and immunity testing.  Provide data from other modules which may have used similar components. Resources needed for a successful EMC design review (other specialists, engineers, purchasing or managers depending on situation and complexity.)  GM: o EMC Specialist and/or EMC Release Engineer o Design/Release-Responsible Engineer and/or o Component/System Responsible Engineer (optional) o Validation-Responsible Engineer (optional)  Supplier: o Hardware/Design Responsible Engineer o EMC Engineer/Specialist o Project/System Responsible Engineer (optional) o Validation Engineer (optional) 3.2.2 Vehicle Validation and Component/Subsystem Production Release. The objectives of the Vehicle Validation and Component/Subsystem Production Release phase shown in Figure 1 include product validation and component/subsystem production release. Component/Subsystem validation re-confirmation of all Electromagnetic Compatibility technical requirements contained in the Component/Subsystem Technical Specification shall occur during vehicle level validation. The component/subsystem shall pass both the component/subsystem level electromagnetic compatibility test(s) and the vehicle level electromagnetic compatibility test(s). In the event that the component/subsystem passes the component/subsystem level electromagnetic compatibility test(s) but does not pass the vehicle level electromagnetic compatibility test(s), the vehicle level test results shall be the determining factor for validation test pass/fail status. Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS - - ` ` , ` , , ` ` ` , , ` , , ` , , ` , , ` ` ` , , ` - ` - ` , , ` , , ` , ` , , ` - - - GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 4 of 42 Define EMC Test Plan Perform 'Detailed' Design Review Design and Build 'Design Iteration n' Test 'Design Iteration n' Review Test Results Is the Data Compliant to GMW3097? No Release 'Design Iteration n' Part Supplier Supplier Supplier Process Step Primary Responsibility Design, Build and Validate 'Design Iteration' Note: n = number of iterations = 1,2,3,4,..... Validate Vehicle Vehicle Platform Review Validation Results Vehicle Platform Pass Vehicle Test? Product Validation? *see Glossary Vehicle Platform Vehicle Validation and Production Release Yes; end of EMC, continue to .... Production Part Approval Process & Production Release End Review / Approve EMC Test Plan Supplier Is Design Review Required/ Necessary?Yes No EMC Design Review Team EMC Design Review Team EMC Design Review Team EMC Design Review Team EMC Design Review Team EMC Design Review Team GM Responsible Engineer GM Responsible Engineer Supplier selected $ $ $ Worldwide Purchasing Yes Yes No No No Figure 1: Design, Build, and Validate Design Iteration/Vehicle Validation and Component/Subsystem Production Release 4 Validation 4.1 General. Not applicable. 4.2 Validation Cross Reference Index. Not applicable. 4.3 Supporting Paragraphs. Not applicable. Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS - - ` ` , ` , , ` ` ` , , ` , , ` , , ` , , ` ` ` , , ` - ` - ` , , ` , , ` , ` , , ` - - - GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 5 of 42 5 Provisions for Shipping Not applicable. 6 Notes 6.1 Glossary. Carryover: The product qualified for a prior program and is exactly the same product being used for the future program. Modifications, alterations, internal part swaps, hardware and software changes are not considered carryover and must be validated according to the requirements. Design Validation (DV): The process of confirming through analysis, demonstrations, inspections, and/or tests that the product design meets its technical requirements (SSTS, CTS/component drawing) without including the effects of manufacturing induced variations. Variation will exist in the parts on test, but not representative of the variation from the production process. Design Validation must be complete according to the Program Schedule of Engineering Deliverables section of the Statement of Requirements (SOR). EMC Design Review Team: The EMC Design Review Team should include as a minimum, the vehicle manufacturer Responsible Engineer with release authority over the product, one or more vehicle manufacturer EMC Engineers, the supplier's EMC expert and members of the supplier's project team directly involved with the design, development and validation of the product. IHS Inc.: IHS Incorporated, General Motors' Engineering Standards distributor. Product Validation (PV): The process of confirming through analysis, demonstrations, inspections and/or tests that the product design meets its technical requirements (VTS, SSTS, CTS/component drawing) when including the effects of manufacturing variation. To complete this validation in time to affect pilot, this variation should be simulated in pre-production hardware or analyses, or by exception, with product hardware produced from production tools/equipment. Shall: Denotes a binding provision; a must. Should: Denotes preferences when specifying alternatives or desired conformance with objectives, standards, etc. GM Design/Release-Responsible Engineer: Individual with release authority over the product. Via: A plated thru-hole on a printed circuit board to route a signal between layers. 6.2 Acronyms, Abbreviations, and Symbols.  Wavelength + Positive - Negative A/D Analog to Digital AC Alternating Current ACCY Accessory (Power Mode) ALSE Absorber Lined Shielded Enclosure AM Amplitude Modulation AN Artificial Network B+ Battery (Voltage) BCI Bulk Current Injection BER Bit Error Rate BM Brush Commutated Electric Motor C Capacitance C Capacitor C Propagation Velocity of Electromagnetic Wave CAN Controller Area Network CE Conducted Emissions CEMENT Component EMC and Environmental Test (Database) Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS - - ` ` , ` , , ` ` ` , , ` , , ` , , ` , , ` ` ` , , ` - ` - ` , , ` , , ` , ` , , ` - - - GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 6 of 42 CI Conducted Immunity CTE Conducted Transient Emissions CTS Component Technical Specification DC Direct Current dI/dt Change in Current (I) with respect to Time DUT Device Under Test DV Design Validation dV/dt Change in Voltage (V) with respect to Time EEPROM Electrically Erasable Programmable Read-Only Memory EICD Electrical Interface Control Document EMC Electromagnetic Compatibility ESD Electrostatic Discharge ESR Effective Series Resistance fc Cutoff Frequency FET Field Effect Transistor GDM Global Document Management GM General Motors GMNA General Motors North America GND Ground GPS Global Positioning System GSSLT Global Subsystem Leadership Team HBM Human Body Model HS High Speed HS-CAN High Speed Controller Area Network HV High Voltage HVAC Heating Ventilation Air Conditioning I Current I/O Input/Output IC Integrated Circuit ID Identification IEC International Electrotechnical Commission IGN Ignition (Power Mode) ISO International Organization for Standardization ITDC International Technical Development Center L Inductance LED Light-Emitting Diode LF Low Frequency LIN Local Interconnect Network LS Low Speed LS-CAN Low Speed Controller Area Network [m] Largest Dimension of Any Discontinuity MOV Metal Oxide Varistor n Number (of Iterations) N/A Not Applicable NTC Negative Temperature Coefficient Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS --``,`,,```,,`,,`,,`,,```,,`-`-`,,`,,`,`,,`--- GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 7 of 42 PCB Printed Circuit Board PDF Portable Document Format PEPS Passive Entry Passive Start PID Parameter Identifier PLL Phase Locked Loop PPAP Production Part Approval Process PPEI Platform Powertrain Electrical Interface PTC Positive Temperature Coefficient PV Production Validation PWM Pulse Width Modulated R Resistance R Resistor RAM Random Access Memory RE Radiated Emissions RESS Reserve Energy Storage System RF Radio Frequency RI Radiated Immunity RKE Remote Keyless Entry RUN Run (Power Mode) SAE SAE International SDM Sensing and Diagnostic Module SMD Surface Mounted Device SOR Statement of Requirements SSTS Subsystem Technical Specification Sw B+ Switched Battery (Voltage) TPIM Traction Power Inverter Module TPMS Tire Pressure Monitoring System µP Microprocessor V Voltage VCC (Integrated Circuit Power Supply) VDDA (Integrated Circuit Power Supply) A Vref Reference Voltage VTS Vehicle Technical Specification WVDC Working Voltage DC XTAL Crystal 7 Additional Paragraphs 7.1 All parts or systems supplied to this standard must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. 8 Coding System This standard shall be referenced in other documents, drawings, etc., as follows: GMW3103 Copyright General Motors Company Provided by IHS under license with General Motors Company Sold to:IHS Standards Store Purchase, 768210 Not for Resale,08/03/2012 23:06:31 MDTNo reproduction or networking permitted without license from IHS - - ` ` , ` , , ` ` ` , , ` , , ` , , ` , , ` ` ` , , ` - ` - ` , , ` , , ` , ` , , ` - - - GM WORLDWIDE ENGINEERING STANDARDS GMW3103 © Copyright 2012 General Motors Company All Rights Reserved April 2012 Page 8 of 42 9 Release and Revisions This standard was originated in May 1998. It was first approved by the GM Global EMC Committee in January 2000. It was first published in June 2000. Issue Publication Date Description (Organization) 1 JUN 2000 Initial publication. 2 OCT 2000 Reworked (ITDC) 3 AUG 2001 Reworked. List of tests matched to GMW3091, GMW3094, GMW3097, and GMW3100. More detailed appendices for design review and test plan. Editorial changes. (ITDC) 4 DEC 2003 Reworked. Consolidated appropriate material from GMW3106 (eliminated) into this document, removed Suppliers Questionnaire, moved Appendix "A" into body requirements section, renumbered remaining appendices, modified motor filtering in Lessons Learned appendix, more detailed appendices for design review and test plan. Editorial changes. (GMNA and ITDC) 5 FEB 2004 Editorial revision, typographical errors corrected. 6 JUL 2006 Minor technical changes (addition of GM Approval Number requirement, addition of EMC Design Requirements Checklist in Table A2.2, PWM slew rate recommendations, motor CE transient suppression). Coordinated release with GMW309
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