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VW80000:2009-10 Volkswagen Electrical Test Specification Introduction
Release time:
2023-02-13 15:07
Source:
VW80000:2009-10 Volkswagen Electrical Test Specification Introduction
The current version of this standard is based on the original version of LV (Supply Specification) 124, which was prepared by representatives of the automobile manufacturers: Audi, BMW, Daimler, Porsche and Volkswagen. This article describes only the electrical test part of this specification.
Scope of application
This standard specifies the test items, test conditions and test requirements for electrical, electronic, mechanical and electronic components and systems used in automobiles under 3.5 tons.
PART 1: ELECTRICAL REQUIREMENTS
1 Reference standard
Table 1: Reference Standards
2 General Part
2.1 operating voltage range
Table 2: Operating Voltage Ranges
Test voltages, especially those used for over-voltage and under-voltage tests, may differ significantly from the voltage ranges listed above and should be listed separately.
The effective voltage range of the component must meet the functional status A at any time.
2.2 functional status
This chapter describes the functional state of the sample during and after the test. The functional state of the test piece for each test must be stated. Additional requirements must be specified and prepared in the component design task book.
The memory function must always remain in the-function state in any case. The integrity (not timeliness) of the non-volatile memory must be guaranteed at all times.
The time flow of the functional status must be stated in the part design task book. Allowed fault memory items must be coordinated and specified with the principal.
2.2.1 Functional state A
The test piece must meet all the functions specified in advance during and after loading the test parameters.
Note: When there is a deviation from the design power (the function is limited by high temperature or low temperature), the test piece must also reach the functional state A below or above the working voltage, if the working voltage is stated as allowed in the component design task book (Derating).
2.2.2 Functional state B
During the loading of test parameters, the test piece must meet all the functions specified in advance, but one or more functions may be outside the specified tolerance range. After the end of the loading test parameters, the test piece must again meet all the functions specified in advance.
2.2.3 Functional state C
The test piece does not meet one or more pre-specified functions during the loading test parameters, but after the loading test parameters are completed, the test piece must automatically meet all pre-specified functions. Unspecified functions are not allowed.
2.2.4 Functional state D
The test piece does not meet one or more pre-specified functions during the loading test parameters, but after the loading test parameters are completed, the test piece re-meets all pre-specified functions due to a reset or a simple intervention (e. g. replacing a failed fuse). Unspecified functions are not allowed.
2.2.5 Functional state E
The test piece does not fulfill one or more predefined functions during the loading test parameters and must be repaired or replaced after the loading test parameters are completed.
The test piece must meet the non-flammability requirements as UL94-v0.
2.3 way of working
Electrical, electronic and mechatronic components and systems operate in a variety of modes of operation throughout their life, and these modes of operation must be reflected accordingly in the test project. The details of the mode of work, the details of the workload (e. g. controls, original sensors, original actuators or equivalent circuits) and the indispensable marginal conditions must be agreed and written between the client and the trustee.
2.3.1 Working Mode I-Test piece not electrically connected
2.3.1.1 Working Mode I.a
The sample is not supplied with current, without plug and wire group.
2.3.1.2 Working Mode I. B
The test piece is not supplied with current, but is connected with the plug and the wire set.
2.3.2
Working Mode II-Electrical Connection of Test Piece
2.3.2.1 Working Mode II.a
The test piece must work without working load.
2.3.2.2 Working Mode II. B
The test piece must be worked with the minimum working load.
The test piece must at the same time produce the lowest temperature rise by itself (e. g. by reducing a continuous output power or by rare external load control).
2.3.2.3 Working Mode II.c
The test piece must be operated with the highest working load (Power-User, but not abuse).
The test piece must be operated while producing its own maximum temperature rise (e. g. by maximizing a continuous output power or by frequent external load control).
2.3.2.4 Examples of working methods
Table 3: Examples of ways of working
3 Electrical test items and requirements
3.1 E-01 long time overvoltage
3.1.1 Purpose
The purpose of the test is to test the stability of the component against long-term overvoltage. A generator regulator effect is simulated during driving operation.
3.1.2 Test
Table 4:E-01 long-term overvoltage test parameters
3.1.3 Requirements
Evaluate the test results according to the application of the components. The difference is:
a) Function indispensable for driving: Function state B
Emergency start must be determined if necessary. The relevant "Derating-Strategie" must be stated in the component design assignment ".
B) For all components: functional state C
3.2 E-02 transient overvoltage
3.2.1 Purpose
Transient overvoltages in the floor wire harness as a result of switching off electrical appliances and in the event of short-term gas shocks (Tip-In). This overvoltage is simulated with this test.
This test can be combined with the electrical life test.
3.2.2 Test
Table 5:E-02 Transient Overvoltage Test Parameters
Figure 1:E-02 Transient Overvoltage Test Pulse
3.2.3 Requirements
Functional state A
All relevant outputs must be maintained within the time limits specified during the test-this requirement must be verified throughout the duration of the test.
3.3 E-03 transient undervoltage
3.3.1 Purpose
Transient undervoltage in floor wiring harness due to utility connection. Use this test to simulate this undervoltage
3.3.2 Test
Table 6:E-03 Transient Undervoltage Test Parameters
Figure 2:E-03 Transient Undervoltage Test Pulse
3.3.3 Required functional state A
3.4 E-04 Jumpstart (jump start)
3.4.1 Purpose
Simulate the external start of the car. Generate the maximum test voltage from the operating vehicle and its elevated floor harness voltage.
3.4.2 Test
Table 7:E-04 Jumpstart (jump start) test parameters
Figure 3:E-04 Jumpstart (jump start) test pulse
3.4.3 Requirements
Evaluate the test results according to the application of the components.
The difference is:
a) For start-up related components (e. g. starter): functional state B
The sensor must provide a valid value for the entire time (or guaranteed by the equivalent table of components).
B) For all other components: functional state C
3.5 E-05 Load Dump
3.5.1 Purpose
Due to electrical load shedding, a high-energy surge pulse results due to the performance of the generator in the case of a connection to a battery with reduced float capacity. This test was used to simulate this pulse.
3.5.2 Test
Table 8:E-05 Load Dump Test Parameters
Figure 4:E-05 Load Dump Test Pulse
3.5.3 Requirements
Functional state C must be reached. In addition, the fault memory of the component must be read out.
3.6 E-06 superimposed AC voltage
3.6.1 Purpose
AC voltage may be superimposed on the floor harness. There may be a superimposed AC voltage during the entire engine operation. This experiment is to simulate this situation.
If it is a high-load electrical appliance, the linear drop of Peak-to-Peak (between positive and negative peaks) voltage from a certain frequency must be specified in the component design task book.
3.6.2 Test
Table 9: AC Voltage Test Parameters for E-06 Superposition
3.6.2.1 Test structure
This test must imitate the actual condition of the car, preferably using the original car line set.
Figure 5:E-06 superimposed AC voltage test pulse
3.6.3 Required functional state A
All relevant outputs must be maintained within the time limits specified during the test-this requirement must be verified throughout the duration of the test.
3.7 E-07 supply voltage slow down and slow up
3.7.1 Purpose
The analog supply voltage slowly drops and slowly increases, just like the process of slow discharge and slow charging of a car battery.
3.7.2 Test
Table 10:E-07 Supply Voltage Slow Drop and Slow Rift Test Parameters
Figure 6:E-07 supply voltage slow drop and slow rise test pulses
3.7.3 Requirements
The test results are evaluated against the range of voltages applied to the component during the test.
The difference is:
a) Within the specified component operating voltage range: functional state A. must not cause a failed memory write.
B) Outside the specified component operating voltage range: functional state C
3.8 E-08 supply voltage drops slowly and increases rapidly
3.8.1 Purpose
This test simulates a situation in which the battery voltage drops slowly to 0V and then the battery voltage is applied rapidly, for example by applying an external starting power supply.
3.8.2 Test
Table 11:E-08 Supply Voltage Slow Drop and Fast Rift Test Parameters
Figure 7:E-08 supply voltage slow drop and fast rise test pulse
3.8.3 Requirements
The test results are evaluated against the range of voltages applied to the component during the test.
The difference in the voltage range is:
a) Within the specified component operating voltage range: functional state A.
B) Outside the specified component operating voltage range: functional state C
3.9 E-09 reset feature
3.9.1 Purpose
This test is to simulate and test the reset characteristics of the component in its environment. The marginal conditions of detection (e. g. interconnection, terminal, system) must be specified.
A sequence of repeated switching on/off at any time during operation shall not lead to uncertainty of component characteristics. The reset characteristic is reflected by a voltage variance and a time variance. In order to simulate the various shut-off times, two different test procedures were required. A component must go through both test processes from start to finish.
3.9.2 Test
Table 12:E-09 Reset Characteristic Test Parameters
Figure 8:E-09 Reset Characteristic Test Pulse
3.9.3 Requirements
Functional state A at U Bmin
It is absolutely not allowed to lead to an uncertain working state. Evidence of compliance with the listed thresholds must be provided and it must be recorded from which voltage level the component first left functional state A.
3.10 E-10 short interruption
3.10.1 The purpose of this test is to simulate the characteristics of various durations under short interruptions.
3.10.2 Test
Table 13:E-10 Short Interruption Test Parameters
The duration of the voltage disturbance is increased by the step time listed in Table 20. This results in a block diagram as shown in FIG. 9.
Figure 9:E-10 Short Interruption Test Pulse
Figure 10:E-10 Short Interruption Principle Wiring Diagram
3.10.3 Requirements
It must be recorded from which time value t1 the test piece left functional state A for the first time.
If the test piece reaches functional state A in the range of 100 μs or less, and reaches functional state C in other cases, the test is considered to be passed. The allowable deviation value of functional state C must be specified in the component design task book.
3.11 E-11 start pulse
3.11.1 Purpose
At start-up (starting the engine) the battery voltage drops to a low value for a short period of time and then increases slightly. Most components are activated directly for a short time before starting, then de-excited during start-up, and then activated again when the engine is running after start-up. This test was used to verify proper operation under these conditions.
This start-up process can be carried out in a variety of different vehicle start-up situations, cold start-up and hot start-up. In order to cover these two cases, two different test procedures are required. A component must go through both test processes from start to finish.
3.11.2 Test
Table 14:E-11 Start Pulse Test Parameters
3.11.2.1 Test 1-Cold Start
Table 15:E-11 Start Pulse Test Parameters
Figure 11: Cold Start Test Pulse
3.11.2.2 Test 2-Hot Start
Table 16:E-11 Hot Start Pulse Test Parameters
Figure 12: Hot Start Test Pulse
3.11.3 Requirements
3.11.3.1 Components related to startup: must not cause faulty memory to be written. Must be able to start the car anyway.
Test 1-Cold Start
"Standard" test pulse: Functional state A
"Enhanced" test pulse: Functional state B
Test 2-Hot Start
"Long" test procedure: Functional state A
"Short" test procedure: Functional state A
3.11.3.2 Components unrelated to startup:
Test 1-Cold Start
"Standard" test pulse: Functional state C
"Enhanced" test pulse: Functional state C
Test 2-Hot Start
"Long" test procedure: Functional state A
"Short" test procedure: Functional state A
3.12 E-12 Voltage Fluctuation Waveform with Intelligent Generator Regulator
3.12.1 Purpose
This test is to simulate the characteristics of the floor harness in the case of the intelligent generator adjustment device. It is sufficient to detect this characteristic within a maximum range of 300ms DC (direct current) before the voltage change.
3.12.2 Test
Table 17: Voltage Fluctuation Waveform Test Parameters for E-12 with Intelligent Generator Regulator
Figure 13: Voltage ripple waveform test pulse E-12 with smart generator regulator
3.12.2.1 Test process Connect the test piece to the voltage source.
The voltage drop ΔU adjusted in the vehicle between the test piece and the battery terminal must be taken into account by adjusting the voltage source.
In other cases, the parameter 2) must be used according to Table 24 between the voltage source and the test piece. The line set installed in the car must be applied.
3.12.3 Requirements
Functional state A
By taking corresponding measures for the components or (component) systems, the functional changes due to voltage variances in the floor harness components cannot make the passengers nor other personnel involved in road traffic feel such a possible change (optical, acoustic, tactile, thermal, movement).
As defined by these changes, the requirements of the part design task book must be followed.
3.13 E-13 pin break
3.13.1 Purpose Simulate line interruptions for each pin. The test was carried out in two different operating conditions. Because such time-specific interruptions can cause a wide variety of malfunctions (from bad contacts to persistent interruptions), a wide variety of pulse shapes must be used.
3.13.2 Test
Table 18:E-13 Pin Interruption Test Parameters
Figure 14:E-13 Pin Interrupt Test Pulse
3.13.3 Requirements
Test Case 1: Functional Status C
Test case 2: Functional state C
Test Case 3: Functional State A
3.14 E-14 plug interruption
3.14.1 Purpose
Analog plug line interruption.
3.14.2 Test
Table 19:E-14 Plug Interruption Test Parameters
3.14.3 It is required that functional state C must be reached after the plug is inserted again.
3.15 E-15 polarity conversion
3.15.1 Purpose
This test is to test the resistance of the test piece to the battery polarity change connection with an external starting aid. At the same time, it must be stated that the polarity change can be produced many times without causing damage to the components.
3.15.2 Test
All relevant connections must be tested with the original wiring. The test piece is started according to the misconnection in the car.
From 0V to any of the maximum voltage values described in Table 28 and Table 29, the robustness test of the polarity change is applicable.
Table 20:E-15 Polarity Change Test Parameters
There is a distinction between "general purpose" and "semiconductor circuit breaker" input wiring. Parameter groups must be selected based on the input wiring.
3.15.2.1 General part of polarity conversion
Table 21:E-15 Polarity Change Test Parameters-General Part
3.15.2.2 Polarity change protection semiconductor circuit breaker
Table 22:E-15 Polarity Change Test Parameters-Semiconductor Circuit Breaker
4.15.3 Requirements
Safety-related functions, such as electric window shakers, electric sliding roof, starters, etc., must not be tripping during the polarity change.
The components must not exceed the limits (electrical and temperature) listed and permitted in the data sheet during the polarity change. The nominal current of the car fuse shall not be exceeded during the test. There shall be no pre-damage or latent damage to components due to polarity reversal. The polarity change safety also applies to any voltage from 0V to the maximum test voltage. Polarity change safety satisfies functional state C.
The current consumption during the test must be recorded.
3.16 E-16 grounding offset
3.16.1 Purpose
If the component has a plurality of voltage inputs, a potential difference may be formed between the individual supply points. It must be ensured that the component ground potential difference within/-1V does not affect the function of the component.
3.16.2 Test
If the test piece has several voltage and ground connections, each connection point must be tested separately. Connect the components according to Figure 15.
Table 23
Figure 15: Schematic diagram of E-16 ground offset wiring
3.16.3 Requirements
If there is a potential difference of/-1V, functional state A must be reached.
3.17 E-17 signal line and load circuit short circuit
3.17.1 Purpose
Simulate short circuits for all electrical inputs and outputs and in the load circuit.
All input and output terminals must be designed to be protected against UB and GND (ground) short circuits (on active and inactive outputs, and in the absence of voltage supply and absence of ground).
The components must be designed to be durable and short-circuit proof.
3.17.2 Test
Table 24:E-17 Signal Circuit and Load Circuit Short Circuit Test Parameters
Figure 16: Schematic diagram of short-circuit wiring of E-17 signal lines and load circuits
3.17.3 Requirements
The following functional states must be achieved in order to pass the test
-At input and output terminals (E and A): functional state C
-In terms of supply voltage (PWR): functional state D
-In terms of device grounding (GRD): functional state E
3.18 E-18 insulation resistance
3.18.1 Purpose
Measurement of insulation resistance between components by current partition
3.18.2 Test
Table 25:E-18 Insulation Resistance Test Parameters
3.18.3 Requirements
Insulation resistance must be at least 10 MΩ. Evidence must be provided that there is no damage to the test piece.
3.19 E-19 quiescent current
3.19.1 Purpose
Measurement of component static current energy consumption
3.19.2 Test
If the component has a follow-up function (e. g. fan assembly), the static current energy consumption can be measured only after this function is completed.
Table 26:E-19 Static Current Test Parameters
3.19.3 Requirements
In principle, the quiescent current energy consumption target for all test pieces is 0mA.
For those test pieces that must be operated after KL15 AUS (terminal 15 cut off), a quiescent current equivalent value <0.1mA (taking the average value of 12h), equivalent to 1.2 mAh (over 40 ℃<0.2 mA), is applied in the quiescent phase. This value must always be observed when the car is in a special stationary state and during any 12h period. Otherwise, it must be approved by the competent static current management department.
The follow-up function must also be approved by the competent static current management department.
3.20 E-20 breakdown strength
3.20.1 Purpose
This test is to simulate the breakdown strength between the components of the current isolation of the test piece, such as plug pins, relays, windings or wiring.
3.20.2 Test
Table 27:E-20 Breakdown Strength Test Parameters
3.20.3 Requirements
Evidence that the test piece is not damaged must be provided.
3.21 E-21 feedback
3.21.1 Purpose
Simulate the behavior of the test piece on KL15 (terminal 15). All components connected to KL15 (terminal 15) must traverse this test.
Other terminals with "wake-up function" must also undergo this test.
3.21.2 Test
Table 28:E-21 Feedback Test Parameters
3.21.2.1 Test process
Connect the test piece according to the wiring conditions in the car (including sensors, actuators, etc.) and work under normal working conditions. The voltage fluctuation waveform is measured with the KL15 (terminal 15) cut off. It must be cut off by, for example, a relay or a switch (RSchalter_offen-∞). Other possible voltage sources, such as KL30 (terminal 30), are not allowed to be blocked or cut off during the test (according to the characteristics of the car). Other resistors on KL15 (terminal 15) are not allowed for this test.
Use an external resistor (e. g. oscilloscope) with KL31 (terminal 31)≥ 10MΩ to detect the voltage fluctuation waveform of KL15 (terminal 15).
Figure 17: Schematic diagram of E-21 feedback test wiring
3.21.3 Requirements
Only voltage levels below a maximum of 1.0V are allowed to be fed back to KL15 (terminal 15). This voltage range must be reached within t = 20ms from the time point of switching off.
The voltage not connected to KL15 (terminal 15) must drop below U terminal 15=1V within t = 20ms from the time of disconnection.
For the voltage fluctuation waveform, a function of stably dropping is required. An unstable curve due to a positive pulse is not allowed.
3.22 E-22 overcurrent
3.22.1 Purpose
The overcurrent strength of the mechanical switch, the electronic output and the contacts is detected. Attention must also be paid to currents higher than normal load conditions (e. g. the blocking current of a motor).
3.22.2 Test
Table 29:E-22 Overcurrent Test Parameters
3.22.3 Requirements
Functional state A is used for fuseless mechanical components. If a fuse element is present in the load circuit, this element is allowed to trip.
Functional state C is used for electronic outputs equipped with overload recognition devices (current, voltage, temperature).
In addition, the visual inspection of all components is not allowed to have adverse changes (appearance and electrical performance) that obviously limit the function or life.
4. Test equipment
At present, our century huize (Suzhou) testing technology co., ltd. has the testing capability of VW80000:2009-10 specification. the testing equipment adopts global brand Swiss EMtest products: UCS200N, VDS200N, PFM200N, AMP200N Netwave and other types of equipment.
