GMW3425 for ballot ver2

WORLDWIDE ENGINEERING STANDARDS Test Procedure Road and Laboratory GMW3425 Developing Road Regions Structural Durability Test GMW3425 GM WORLDWIDE ENGINEERING STANDARDS GM WORLDWIDE ENGINEERING STANDARDS GMW3425 1 Scope Note: Nothing in the specification supersedes applicable laws and regulations unless specific exemption has been obtained. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To provide a common GM global structural durability evaluation of a passenger vehicle. This test procedure provides severe chassis structural inputs representing vehicle usage in markets with developing road systems (i.e. South America, Central America, Africa, Asia Pacific, Eastern Europe, the Middle East and parts of Australia). This test procedure is primarily intended as the basis for structural laboratory tests and analytical modeling. The core test provides the basis for laboratory and/or road evaluation (when appropriate) of structural subsystems and components. 1.2 Foreword. This test procedure has been developed to reflect customer usage of markets with developing road systems. These regions have less stable road systems and greater amounts of unpaved and rough roads. Other regional or local requirements may necessitate additional test options. For further information, consult regional Engineering Centre. The basis for the GMW3425 is the structural content of GMB G4 durability test historically used for the Brazilian market. Regional test experts have consented to use the GMB procedure as the basis for a global developing road regions structural durability test. Appropriate structural laboratory tests should also be based on the GMW3425 test procedure. Due to the abbreviated nature of this test procedure, the less damaging and often time-consuming inputs are greatly reduced or eliminated. While the GMW3425 is intended to cover “global” developing road systems, the test does not encompass all known customer usage treatments or road types. Some of the limitations are due to the accelerated nature of the test and some are due to the constraints of the test site environment and test facilities. Additionally, the database for defining the world-wide vehicle operating environment is evolving and periodic content changes to the GMW3425 are expected. If more rigorous exposure to unique customer usage treatments is desired, other specialized testing should be considered as part of the overall vehicle dependability test plan. Some considerations should be given to the following: · Trailer towing · Cold weather operation · Hot weather operation · Low usage operation Comparable structural test results should be achieved by application of test vehicles on the following proving grounds according to the attached route descriptions (see Appendix A – G): Cruz Alta Proving Ground (GM do Brazil) Route description see Appendix A Ding Yuan Proving Ground (PATAC) Route description see Appendix B Dudenhofen Proving Ground (GM Europe) Route description see Appendix C Lang Lang Proving Ground (GM Holden) Route description see Appendix D Milford Proving Ground (GMNA) Route description see Appendix E Millbrook Proving Ground (GM Europe) Route description see Appendix F Tong Xian Proving Ground (GMDAT) Route description see Appendix G It is recognized that many test inputs and test facilities differ for the test sites included, and a continuing effort is being made to commonize some test facilities and driving maneuvers. Results of this test should be regarded as highly probable to also occur in the hands of some customers inasmuch as the module contains vehicle treatments based on measured customer vehicle operation. This procedure specifies vehicle operation designed to match data collected on groups of randomly selected customers’ vehicles. The intent of the test is to subject the vehicle to the treatment of a greater-than-average severity customer for each of the measured structural inputs. 1.3 Applicability. Passenger carrying vehicles 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. GME R-0-19 R.DU.00.059 MB G0-M/1(A/1) 02.610ENG197 GMW3238 2.3 Additional References. 3 Resources 3.1 Facilities. General Motors Proving Grounds: Cruz Alta Proving Ground (GM Brazil) Ding Yuan Proving Ground (PATAC) Dudenhofen Proving Ground (GM Europe) Lang Lang Proving Ground (GM Holden) Milford Proving Ground (GMNA) Millbrook Proving Ground (GM Europe) Tong Xian Proving Ground (GMDAT) 3.2 Equipment. Some method of accurate speed indication, up to the maximum vehicle speed, should be provided to the driver for accurate execution of the driving schedules. Some type of acceleration/deceleration rate indicator should also be provided to the driver. 3.3 Test Vehicle/Test Piece. Vehicle equipped as specified. 3.4 Test Time. See Appendix A to G. Calendar time: days Test hours: hours Coordination hours hours 3.5 Test Required Information. 3.6 Personnel/Skills. The driving modules that comprise this test are intended to be performed by personnel specifically trained in the proper execution of the driving modules. 4 Procedure 4.1 Preparation. Maximum vehicle speeds to be supplied by test responsible personnel for driver reference. If the vehicle is equipped with a manual transmission, the shift point speeds should also be determined and provided. Measurement of adjustments and settings may be made as deemed necessary to document the condition of the vehicle. These measurements must be made without significantly affecting the adjustment or setting being considered. The intent of these measurements is to document the condition of the vehicle without changing the state of the original assembly. Vehicles being operated on this test for any other purposes (e.g., design evaluation, etc.) should be prepared in a manner appropriate to that particular test intent. 4.2 Conditions. 4.2.1 Environmental Conditions. The driving procedures can be performed in all types of weather. However, in situations where severe weather makes certain driving maneuvers unsafe, modules using those maneuvers should be postponed until road conditions improve. 4.2.2 Test Conditions. Deviations from the requirements of the procedure shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. The pothole # 3 test procedure (GMW3238) may be performed in conjunction with GMW3425 test procedure. The program will decide how to incorporate the pothole #3 event into the durability validation plan in order to achieve the reliability target as specified in VTS. 4.3 Instructions. Refer to the driving procedure for the appropriate GM proving ground. (Appendix A to G). 4.3.1 Available Test Options. Optional test content can be run in conjunction with the core test content to meet specific regional needs. 4.3.2 Test Scheduling Guidelines. In order to subject the vehicle to a reasonable simulation of customer usage in a linear manner of operation, distribute the driving routes as evenly as possible throughout the test. The vehicle should not receive any “break-in” miles. The intention of the test is to subject the vehicle to greater than average operation, and it is believed that the omission of “break-in” miles is more severe than is their inclusion. All miscellaneous mileage accrued during the execution of this test should be driven at posted speeds and consist of light accelerations/ decelerations, minimizing any conflicts with existing durability traffic and avoiding any abusive treatments. 4.3.3 Driver Responsibilities. During the execution of the test, the driver is to observe vehicle behavior (as would a customer) and inform the responsible individuals through written comment whenever a malfunction occurs or unusual behavior is experienced. The proper execution of this durability test is highly dependent on close driver adherence to the schedules and the instructions contained therein. This is because accurate correlation with field experience can only be achieved by means of tailored combinations of vehicle speed, road surface, and driving maneuvers. 4.3.4 Maintenance Scheduling Guidelines. Test vehicle maintenance/repair will be based on Owner's Manual recommendations and, as closely as possible, customer maintenance/repair practices. 5 Data 5.1 Calculations. 5.2 Interpretation of Results. 5.3 Test Documentation. With reference to this test procedure the test results shall be presented in a test report. Written and photographic documentation is to be generated and maintained on all factors involved in the test. These include vehicle, personnel, and equipment identifications; time, climate, incidents, or malfunctions; comments or observations from any involved personnel; and other factors that the test user deems appropriate. 6 Safety The driving procedure must be conducted in such a way as to conform to the driving regulations and safety requirements of the appropriate GM test site. Some safety areas of concern are test driver training requirements, ballast restraint methods, etc. This procedure may involve hazardous materials, operations, and equipment. This method does not propose to address all the safety problems associated with its use. It is the responsibility of the user of the method to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 7 Notes 7.1 Glossary. The following will serve as definition of terms used throughout the driving schedules of this specification. 7.1.1 Acceleration. All accelerations should be light unless otherwise specified. A manual transmission is to be shifted in a manner appropriate to moderate driving. With an automatic transmission, the gear selector should be in highest range unless otherwise specified. Light, Moderate, Hard & WOT indicate the initial acceleration levels as specified in the procedure. Hold this position for the duration of the acceleration. Some type of instrumentation is needed by the driver to accurately identify these rates during vehicle accelerations. Note: Due to engine limitation, heavy ballast, hills, etc., some vehicles will stop accelerating or actually begin decelerating before the specified speed is attained. In this case increase the throttle application (WOT if necessary) until attaining the specified speed for the next driving instruction. It is important to make the initial throttle application as specified first. Do not proceed directly to a harder application. 7.1.2 Braking. All brake applications are to be light, unless otherwise stated. Light, Moderate, and Hard indicate deceleration rate as specified in the following table: Acceleration and Deceleration Rates Acceleration Initial Speed Light Moderate Hard (km/h) (m/s2) (m/s2) (m/s2) 0 – 30 1.4 ( 0.3 2.1 ( 0.3 2.8 ( 0.3 40 – 65 0.7 ( 0.2 1.4 ( 0.3 2.1 ( 0.3 70 – 95 0.5 ( 0.1 0.7 ( 0.2 1.4 ( 0.3 100 - 140 0.2 ( 0.1 0.5 ( 0.1 0.7 ( 0.2 Deceleration Braking Light Moderate Hard (m/s2) (m/s2) (m/s2) all speeds 1.0 ( 0.8 2.6 ( 0.8 4.5 ( 0.8 Full Brake Application. Rapidly applied brake application with maximum pedal effort attempting to lock all wheels. Anti-Lock Brake Application. This brake application is rapidly applied with maximum pedal effort attempting to lock all wheels. 7.1.3 Cycle. One (1) complete execution of a driving sequence as identified in a specific driving schedule. 7.1.4 Decelerate without brakes.  Release throttle and allow engine braking to decelerate the vehicle, using brakes only if necessary. 7.1.5 Lap. One (1) complete execution of a closed course driving path (i.e. one lap Circular Track) within a cycle of a driving schedule. 7.1.6 Structural Ballast Condition.  Two (2) occupants per row of seats and 50% of the rated cargo ballast. Occupant ballast (70 kg) should be placed in the outside seating positions of each occupant seating row. 7.2 Acronyms, Abbreviations, and Symbols. 8 Coding System This test procedure shall be called up in other documents, drawings, VTS, CTS etc. as follows: Test to GMW3425 9 Release and Revisions 9.1 Release. The specification was initiated in January 2003 and first approved in October 2003. It was first published in October 2004. Transferred to the new template 3/2006 and updated by the Global Proving Ground Correlation Team. 9.2 Revisions. Rev Approval Date Description (Organization) A June2006 Removed Hokkaido Proving Ground test content and added Ding Yuan, Milford, and Tong Xian Proving Grounds Appendix A Table A1: Cruz Alta Proving Ground Developing Road Region Structural Durability Test Procedure Number Module Name Cycles Distance/Cycle Time/Cycle 2/3rds Payload Ballast R.DU.00.082 Accelerated D1 Track 200 23.0 km 28 min 100% R.DU.00.083 Accelerated D2 Track 1000 18.6 km 29 min 100% R.DU.00.084 Accelerated Torture Track 50 0.4 km 1 min 100% R.DU.00.085 Accelerated High "G" Level 8 4.6 km 6 min 100% R.DU.00.069 Driveway Ramp 100 1.2 km 7 min 100% R.DU.00.065 Pothole #3 4 0.0 km 0 min 100% ABS Optional Content: R.DU.00.075 ABS-Gravel Track 200 1.0 km 10 min 100% R.DU.00.075 ABS-Straightaway Track 5 80.0 km 90 min 100% Appendix B Table B1: Ding Yuan Proving Ground Developing Road Region Structural Durability Test Facility Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast Torture Track Rough Road 2 - 2 Laps 2200 13.2 km 100% Potholes Potholes 1 & 2 200 0.2 km 100% Driveway 16° Driveway 200 0.1 km 100% Braking ABS Gravel 800 0.5 km 100% Braking Full Brake Snubs 200 0.3 km 100% Hill Hill 30% 1st gear 40km/h – 2 Laps 500 0.4 km 100% Skid Pad Lateral 2 200 1.0 km 100% Skid Pad Square Module 10L - 10R at 30km/h 100 0.8 km 100% Skid Pad L-Turns - 2 Laps 20 1.0 km 100% High Speed Circuit High Speed 300 24.0 km 100% High Speed Circuit Straightaway Performance - 4 Laps 250 15.8 km 100% Appendix C Table C1: Dudenhofen Proving Ground Developing Road Region Structural Durability Test Procedure Number Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast G0.1 DPG0 lap without high speed 1010 17.4 km 25 min 100% G0.2 Special lap DPG0 100 4.7 km 5 min 100% G0.3 L- Turns – 2 laps 20 0.3 km 3 min 100% G0.4 "Turracher Höhe", 20%-hill 20 0.1 km 1 min 100% E0.0 2 x Full Lock Steering L/R 655 0.0 km 1 min 100% E0.4 Potholes 1 & 2 for DPE0/G0 100 0.2 km 4 min 100% E0.5 16° Driveway for DPE0/G0 100 0.4 km 5 min 100% E0.6 13° Driveway for DPE0/G0 50 0.4 km 5 min 100% High Speed Optional Content: E0.3 Circular Track for DPE0/G0 1010 24.1 km 14 min 100% Appendix D Table D1: Lang Lang Proving Ground Developing Road Region Structural Durability Test Procedure Number Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast 2 Rough Track 630 1.8 km 4 min 100% 2G0 Rough Track + R03 972 2.2 km 6 min 100% 3 Mud & Water Bath 18 0.3 km 2 min 100% 4.1G0 Hill Route 2540 3.8 km 5 min 100% 4.2G0 Hill Route 1270 5.0 km 7 min 100% PG0 Pothole 3 100 0.1 km 1 min 100% DWG0 Potholes + Driveway 16 200 1.0 km 6 min 100% 7G0 Test Hills 250 2.8 km 7 min 100% 7.1G0 Square Turns – 8L / 8R 250 2.0 km 5 min 100% 7.2G0 L- Turns – 2 laps 20 0.7 km 4 min 100% 8 Access Road 864 6.4 km 7 min 100% 8.1 Access road 756 1.2 km 2 min 100% High Speed Optional Content: 1G0 Circular Track 850 23.5 km 25 min 100% Appendix E Table E1: Milford Proving Ground Developing Road Region Structural Durability Test For Laboratory and Analysis Procedure Number Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast GMN5422 Panic Brake Event 8 1.2 km 1 min 100% GMN5423 Chatter Bump Stop 50 0.7 km 1 min 100% GMN5408 16 Degree Driveway Event 200 0.1 km 3 min 100% GMN5407 13 Degree Driveway Event 100 0.1 km 3 min 100% GMN5401 Belgian Block Lap 4000 3.3 km 5 min 100% GMN5406 Twist Course Lap 1200 0.5 km 3 min 100% GMN5402 Pothole #1 200 0.7 km 2 min 100% GMN5403 Pothole #2 200 0.7 km 2 min 100% GMN5411 Seven Sisters Lap 200 1.2 km 2 min 100% GMN5436 Moderate Fwd & Rev Accels 50 0.3 km 2 min 100% GMN5440 11.6% Engineering Hill Lap 600 2.3 km 5 min 100% GMN5434 WOT from 0 to 30 mph 250 0.4 km 2 min 100% GMN5439 7.2% Hill Lap 900 2.4 km 4 min 100% GMN5437 Straightaway WOTs 800 2.6 km 3 min 100% GMN5429 Full Brake Snubs Event 300 0.1 km 2 min 100% GMN11308 L-Turns -- 1 Left & 1 Right 40 0.3 km 3 min 100% GMN11310 Square Turns at 15 mph 2000 1.2 km 2 min 100% ABS Optional Content: GMN5421 ABS Gravel Road 200 0.6 km 2 min 100% Traction Control Optional Content: GMN5430 Traction Control 10% Gravel Hill 200 1.8 km 4 min 100% Table E1 continued on next page Appendix E Table E1: Milford Proving Ground Developing Road Region Structural Durability Test For Laboratory and Analysis -- Continued Steering Subsystem & Component Optional Content: For steering laboratory tests, the following should be performed in addition to the base test content Procedure Number Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast GMN8907 Steering Belgian Blocks 142 11.4 km 13 min 100% GMN8907 Steering R&H 15 1.3 km 3 min 100% GMN8907 Steering Panic Brake 4 0.6 km 2 min 100% GMN5132 Static Partial Steering 5000 0.0 km 1 min 100% GMN5133 Curb Rimpull - 45# L&R 30 0.0 km 1 min 100% GMN5133 Curb Rimpull - 30# L&R 190 0.0 km 1 min 100% GMN5133 Curb Rimpull - 15# L&R 230 0.0 km 1 min 100% GMN5446 City Course Lap 1600 4.4 km 16 min 100% GMN5447 Static Full Steer - Asphalt 5000 0.0 km 2 min 100% GMN5448 Static Full Steer – High Coefficient Surface 5000 0.0 km 2 min 100% GMN7211 Curb Pushaway Recorded for peak load determination and high load fatigue test input (GMNA Steering SSTS 3.2.2.5) Not for inclusion in GMW3425 fatigue-based laboratory test Appendix F Table F1: Millbrook Proving Ground Developing Road Region Structural Durability Test Procedure Number Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast MBG.0.2 Handling & Potholes 200 1.5 km 4 min 100% MBG.0.3 Driveway 13° 100 1.0 km 5 min 100% MBG.0.4 Driveway 16° 200 1.0 km 5 min 100% MBG.0.5 Truck Slopes 886 2.8 km 6 min 100% MBG.0.6 Special Surfaces 120 3.9 km 6 min 100% MBG.0.7 Belgian Pave A 460 3.2 km 6 min 100% MBG.0.8 Belgian Pave B 100 3.2 km 9 min 100% MBG.0.9 Belgian Pave C 460 3.2 km 6 min 100% MBG.0.10 Belgian Pave D 1000 3.2 km 5 min 100% MBG.0.11 Gravel Road 144 1.6 km 4 min 100% MBG.0.12 Hill Route A 600 4.4 km 8 min 100% MBG.0.13 Max Handling 100 2.8 km 4 min 100% MBG.0.14 High G 40 12.0 km 8 min 100% MBG.0.15 Hill Route Modules 1&2 400 8.8 km 8 min 100% MBG.0.16 Squares 300 1.6 km 4 min 100% MBG.0.17 L-Turns 20 1.6 km 5 min 100% ABS Optional Content: MBG.0.19.1 ABS Loose Surface 200 0.6 km 4 min 100% MBG.0.19.2 ABS Simulated Ice 80 2.0 km 10 min 100% Traction Control Optional Content: MBG.0.20.1 TCS Loose Surface 200 1.5 km 5 min 100% MBG.0.20.2 TCS Simulated Ice 80 2.0 km 10 min 100% High Speed Optional Content: MBG.0.1 Circular Track 924 26.0 km 16 min 100% Appendix G Table G1: Tong Xian Proving Ground Developing Road Region Structural Durability Test Facility Module Name Cycles Distance/Cycle Time/Cycle Structural Ballast Outer Course Rough Road Outer #1 800 6.0 km 100% Outer Course Rough Road Outer #2 800 7.5 km 100% Inner Ramp 13° Driveway 100 1.0 km 100% Inner Ramp 16° Driveway 200 1.0 km 100% Inner Hill Test Hill 200 2.0 km 100% Inner Steering Pad Square Turn Module 300 1.0 km 100% Inner Special Road Inner Rough Road #1 800 2.0 km 100% Inner Special Road Inner Rough Road #2 1000 0.2 km 100% Inner Special Road Pothole 1&2 200 0.2 km 100% Inner Sand Road Gravel Road Sand 200 1.3 km 100% Inner Straight Brake Module 400 2.3 km 100% Inner Skid Pad City Simulation 800 3.0 km 100% Outer Straight Road High G A 40 22.4 km 100% Outer Straight Road L-Turns 20 1.0 km 100% High Speed Track Gear Box Module 800 11.0 km 100% High Speed Track High Speed Module 1000 22.0 km 100% Deviations The Cruz Alta test is being updated to reflect common test content. This test procedure will be revised once the changes are completed. As shown in Appendix A, the current Cruz Alta test deviates in two areas: 1. The ballast condition specified is 2/3rds payload rather than the globally common structural ballast condition as defined in Section 7.1.6. 2. The Cruz Alta test specifies 4 cycles of Pothole #3. Pothole #3 is a separate test (GMW3238) which may be run in conjunction with GMW3425. Refer to Section 4.2.2 for more information. It is desired that all global proving ground sites use the same ballast condition and implement the Pothole #3 in a common manner. Efforts are underway by the Global Proving Ground Correlation Team to improve the test correlation between regions and to eliminate these deviations. © Copyright 2006 General Motors Corporation All Rights Reserved June 2006 Originating Department: North American Engineering Standards Page 1 of 13 © Copyright 2006 General Motors Corporation All Rights Reserved Page 4 of 13 June 2006 © Copyright 2006 General Motors Corporation All Rights Reserved June 2006 Page 3 of 13