GMW14906Feb2012.pdf

WORLDWIDE ENGINEERING STANDARDS

General Specification GMW14906

Lamp Development and Validation Test Procedures

Copyright 2012 General Motors Company All Rights Reserved

February 2012 Originating Department: North American Engineering Standards Page 1 of 59

Table of Contents

Section # Section Name

1 Introduction

2 Reference

2.1 External Standards

2.2 GM Standards/Specification

2.3 Additional References

3 Test Preparation and Evaluation

3.1 Resources

3.2 Preparation

3.3 Conditions

3.4 Instructions

3.5 Data

3.6 Safety

3.7 Documentation

4 Requirements and Procedures

4.1 Development

4.2 Highly Accelerated Life Test (HALT)

4.3 Pre-test Requirements

4.3.1 Dimension

4.3.2 Aim

4.3.3 Seal

4.3.4 Light Output

4.3.5 Appearance

4.3.6 Function

4.4 SAE J575e August 1970 Vibration

4.5 Temperature and Vibration

4.5.1 Temperature Cycling

4.5.2 Vibration.

4.6 Post-Test Requirements


4 Requirements and Procedures (cont)

4.6.1 Dimension

4.6.2 Aim

4.6.3 Seal Leak Test Pressure (LTP)

4.6.4 Light Output

4.6.5 Appearance

4.6.6 Function

4.7 Electrical Components and Electronic Interfaces

4.7.1 Electrical Connectors and Power Interface

4.7.1.1 Electrical Connectors

4.7.1.2 Electrical Wiring and Lamp Harness Cables

4.7.2 Headlamp Bulb and Connector Temperature Cycle

4.7.3 Solenoids

4.7.4 Bulb and Socket Removal Force

4.8 Accelerated Corrosion

4.9 Weatherability

4.10 Internal and External Heat

4.10.1 Internal Heat

4.10.2 External Heat

4.10.3 External Heat Test for Headlamp Bulb Connector Terminals

4.11 Light Up

4.12 Weld Joint and Snap Attach Stress

4.13 LED Light Source Requirements

4.13.1 LED Lamp Actuation Cycle

4.13.2 LED Continuous Activation

GM WORLDWIDE ENGINEERING STANDARDS GMW14906


February 2012 Page 2 of 59

Table of Contents continued


4 Requirements and Procedures (cont.)

4.14 Condensation for Lamps with

Oleophobic Membranes

4.15 High Humidity Environments

4.16 High Pressure Water

4.17 Leak Check for Production Processing Determination

4.18 HID Component Ignition Reliability

4.19 Adaptive Forward Lighting and

Dynamic Headlamp Leveling System

4.20 Solar Load Test

4.21 Submersion Test

4.22 Free Fall

4.23 Storage

4.24 Thermal Shock

4.25 Headlamp Aim Adjustment Retainer and Fixed Pivot Pull Force

4.26 Solar Irradiance for Lamps with Condensing Lenses

5 Provisions for Shipping

6 Notes Glossary/Acronyms

7 Additional Paragraphs

7.1 Restricted and Reportable

Substances for Parts

8 Coding System

9 Release and Revisions

Appendix A

Data Sheets

Appendix B

Test Setup Photos and Illustrations

WORLDWIDE ENGINEERING STANDARDS

General Specification GMW14906

Lamp Development and Validation Test Procedures


February 2012 Originating Department: North American Engineering Standards Page 3 of 59

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 defines the mechanical, electrical, and environmental performance requirements, test conditions, and procedures for lamps and reflective devices used for functional and durability tests.

1.2 Mission/Theme. This procedure applies to all original equipment and replacement exterior lighting devices for passenger cars, Multipurpose Passenger Vehicles (MPV), and trucks.

1.3 Classification. Not applicable.

2 References

Note: Only the latest approved standards are applicable unless otherwise specified.

2.1 External Standards/Specifications.

ASTM C150 ISO/IEC 17025

ASTM E927-10 SAE J564

FMVSS 108 SAE J575e (AUG 1970)

IEC 60068-2-27 Ea SAE J577

ISO 4892-1/2 SAE J1889

ISO 16750-3 SAE J2527

ISO 16750-4

2.2 GM Standards/Specifications.

GMW3059 GMW14650

GMW3172 GMW14651

GMW3191 GMW14668

GMW8287 GMW14669

GMW14264 GMW14729

GMW14444 GMW14872

GMW14528 GMW15272

GMW14570 GMW15308

GMW14571 GMW15626

GMW14572 GMW15760

2.3 Additional References.

GM1829 Analysis Development Validation Plan and Report

USCAR 15 - Bulb Insertion/Removal Force

3 Test Preparation and Evaluation

3.1 Resources. If not otherwise stated, resources are indicated in the test methods.

3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. Exception to this is if the information is otherwise preserved in the test facility records.

3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with respect to their physical definition.

3.1.3 Facilities. Any specific facility requirements are listed in each individual test procedure. The test facilities shall be accredited to ISO/IEC 17025 or by the International Laboratory Accreditation Cooperation.

3.1.4 Equipment. The test equipment needed for each test is listed in each individual test procedure.

3.1.5 Test Vehicle/Test Piece. The test samples shall be production intent design and materials for design validation (DV) or production intent design and materials manufactured with production processes (homeline) for product validation (PV). Any changes to the components or material, e.g., design, fit, form, function, properties, manufacturing process, and/or location of manufacture, require revalidation. GM shall approve validation methods for product/process changes before the supplier is committed to the change.

3.1.6 Test Time. The total estimated time for DV and PV testing is shown below.

Calendar time: 154 days (22 weeks)

Test hours: 3700 hours

Coordination hours: 100 hours




3.1.7 Test Required Information. See individual procedures.

3.1.8 Personnel/Skills. The test facility shall have sufficient personnel having the necessary education, training, technical knowledge, and experience for performing the required tests.

3.2 Preparation.

3.2.1 Fixtures. Unless otherwise specified, mount the test sample on a fixture of welded construction designed to place the test sample in its vehicle orientation. Photometric measurement fixtures may be of alternate construction and do not need to meet the requirements of 4.5.2.4.

3.2.2 Wire Harnesses. All testing that requires a vehicle interface harness shall have a terminal and wire inserted into each connector cavity per the production intent design.

3.2.3 Test Samples. All test samples shall be design intent and meet all functional and dimensional pre-test requirements, as defined by this document. Lamp assembly designs with secondary components such as cameras, handles, sensors, washer nozzles, etc., shall have those secondary components installed in test samples during test. Reuse of secondary components for multiple tests is allowed where function of the secondary part is not critical to lamp testing. The GM Validation Engineer and GM Designing Engineer (DE) shall approve any exceptions prior to the start of testing.

3.3 Conditions. All test conditions shall be adjusted to specified values and remain within given () tolerances. Target test values shall not be adjusted within tolerances unless the target value cannot be maintained. If such an adjustment is made, it shall be approved by the applicable GM engineer prior to the start of any testing.

Unless otherwise specified perform the tests in the as received condition without any special preconditioning.

3.3.1 Environmental Conditions. See individual procedures in Section 4.

3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. Such deviations shall be approved by the GM Validation Engineer and specified on the GM1829 Analysis Development and Validation Plan and Report and test reports.

Voltage for photometric testing pre-test and post-test use the voltage specified by the regulation in the countries where the lamp will be sold. For lamps sold in both Economic Commission

for Europe (ECE) and SAE International regulated regions select one test method.

If the vehicle provides a Pulse Width Modulation (PWM) voltage to the lamp, activate the specified function at the specified PWM - rms voltage +0.25 V. In all other tests that require a test voltage input, use 13.9 V 0.2 V.

3.4 Instructions. See the specific procedures in Section 4.

3.5 Data. Record on the data sheets in Appendix A.

3.6 Safety. This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

3.7 Documentation. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and approved by the responsible GM department prior to the start of delivery of production level components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation of any change or modification to the product/process, and to apply for a new release.

If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed to between the responsible GM department and the supplier.

Document the test results in a test report. Test reports shall include all of the following: test equipment serial numbers, calibration information, test Data Sheets A1 through A17, description of test material (including design revision, lot or batch, options, etc.) test specification date, pertinent setup information, and photographs.

3.7.1 Test Results. Record on the data sheets in Appendix A.

4 Requirements and Procedure

4.1 Development. This section of the test specification outlines the development tests for lamps and reflective devices for which there are no defined acceptance criteria. Review the results




with GM to determine if corrective action is necessary.

4.2 Highly Accelerated Life Test (HALT). Reference GMW3172 and GMW8287. See Data Sheet A1.

4.2.1 Purpose. To quickly determine the weaknesses of the product when subjected to environmental and vibration stresses. The supplier shall perform this test prior to all other subsystem level testing as soon as representative samples are available.

Only complex lamp assemblies shall be tested. Examples of lamps to be tested are:

Headlamps

Front fog lamps

Lamps with electronic or electro-mechanical components

Lamps with complex or many internal components

Lamps using any non-traditional fastening techniques

Lamps with multi-color lenses

Lamps using non-traditional vehicle mounting

Examples of lamps not to be tested include:

Simple lamps consisting of a lens and housing mounted in a traditional manner

Simple signal lamps mounted in a fascia or to sheet metal

Simple tail lamps

The GM Validation Engineer and GM Designing Engineer shall approve any lamp type that is not tested.

With the approval of the GM Validation Engineer and GM Designing Engineer the supplier may test non-dimensionally correct or non-representative samples if the time to obtain dimensionally correct or representative samples is prohibitive.

The supplier engineer shall be present during testing, and a GM representative should be present during the testing.

The supplier and GM engineer shall analyze each test incident to determine its likelihood of occurring in the field. Quick and simple tests may be used when applicable to verify the potential incident (i.e., a heat test). Not all incidents require corrective action based on the above analysis.

The GM Validation Engineer and GM Designing Engineer, along with Engineering Group Manager, and the Validation Technical Integration Engineer (TIE) shall determine which incidents require corrective action and verification through an

additional HALT test. Incidents occurring above the temperature limits of materials, for example, do not require corrective action if the material is suitable for the particular application.

4.2.2 Equipment. Environmental chamber with the following specifications.

4.2.2.1 Thermal capability of -100 C to +200 C with a ramp rate of at least 40 C per minute.

4.2.2.2 Omni-axial (six degrees of freedom) repetitive shock system with 50Grms capability between 2 Hz and 2000 Hz frequency bandwidth.

4.2.3 Sample Size. Three (3) samples per part number (excluding color) or two pair. For example, Center High Mounted Stop Lamps (CHMSL) would require three parts. High Intensity Discharge (HID) and halogen headlamps would require a total of four parts. Test all test samples regardless of the results of previous tests.

4.2.4 Setup.

4.2.4.1 Specifics of the test setup parameters are the responsibility of the GM Validation Engineer and GM Designing Engineer. Parameters which need to be defined are:

4.2.4.1.1 Fundamental part operating limits. Temperature limits are the following.

4.2.4.1.1.1 Headlamps, front fog lamps, and interior CHMSLs: -100 C to +120 C.

4.2.4.1.1.2 Remaining lamps: -100 C to +85 C.

4.2.4.1.2 Activate all functions during the test including non-lighted system components such as dynamic headlamp leveling (DHL) motors and adaptive forward lighting (AFL) system motors.

4.2.4.1.3 Mount the sample(s) to a rigid, lightweight test fixture of welded construction that represents the vehicle mounting orientation and installation and uses production fasteners or equivalent. Note requirements for the functional response of the test part mounted to the test fixture, included below. If possible, lamp locating features and body interfaces must be represented in the fixture design. Position the fixture retention points to the test base such that the fixture can be removed without removing the lamp.

4.2.4.1.4 The collection of product response data from temperature and vibration is required to provide credible response that temperature and vibration stress was applied to the product. Reference GMW8287 for thermocouple and accelerometer specifications.




4.2.4.1.5 Functional test goals are to achieve 100% of thermal and vibration inputs. Functional response, of the test part mounted to the test fixture, from vibration, shall be 70% or greater than the vibration input.

The GM Validation Engineer and GM Designing Engineer shall approve the design.

4.2.5 Procedure. Cycle the samples through the HALT test procedure in the order listed. Samples shall be leak tested as described in 4.3.3 at the start and after each test segment. If possible, continue testing until three distinct failure modes are observed. Activate all light sources and motors, where applicable, continuously during the high temperature portions of the test sequence and any transitions to a high temperature. For example, activate stop lamps, turn signal lamps, and DHL motors continuously. High temperature is defined as temperatures above ambient.

4.2.5.1 Thermal Step Stress. Cycle sample(s) in temperature steps to the fundamental temperature limits. First test the upper limits, then the lower limits. Recommended temperature steps are 20 C with a minimum dwell of 10 minutes until 20 C from the expected upper temperature limit is reached. Then step 10 C with a minimum dwell of 10 minutes.

4.2.5.2 Rapid Thermal Transition. Cycle sample(s) between the operational temperature limits. At least five cycles are recommended utilizing transitions greater than 40 C per minute. Allow for thermal stabilization between transitions with a recommended minimum dwell of 10 minutes.

4.2.5.3 Vibration Step Stress. Cycle sample(s) in vibration steps at ambient to 50Grms. Recommended vibration steps are 5Grms with a minimum dwell of 10 minutes.

4.2.5.4 Combined Environment. While subjecting the sample(s) to the Rapid Thermal Transition in 4.2.5.2, vibrate the sample(s) in steps per the Vibration Step Stress procedure in 4.2.5.3. If no incidents occur, continue testing at the maximum vibration level with Rapid Thermal Transitions until an incident does occur.

4.2.6 Report. An interim test report shall be provided per 3.5 including which cycle the incident occurred, and GM/supplier participants of the test.

4.3 Pre-test Requirements for all Remaining Tests.

4.3.1 Dimension. Measure all assembly checkpoints on one lamp or pair of handed lamps and record on the test log sheet. All measured assemblies shall be dimensionally within twice the drawing tolerance for development and design validation (DV) testing. Measure and record one lamp or pair of handed lamps used in product validation (PV) testing. The GM Validation Engineer and GM Designing Engineer must review the dimensional data prior to start of test.

4.3.2 Aim.

4.3.2.1 Aim Position. All aimable lamps shall be aimed. Lamps with DHL or AFL shall be centered to design nominal position.

Table 1: Seal Test Method

Lamp Description Test Method

Small lamp with no lighted function; no tooled openings in housing (i.e., reflex reflector) Vacuum Chamber per 4.3.3.1

Small lamp with lighted function; no socket; lamp side connector is sealed (i.e., light emitting diode (LED) CHMSL with internal potted lamp side connector)

Vacuum Chamber per 4.3.3.1

Small lamp with lighted function; with sealed socket (i.e., license lamp with bulb and socket)

Submersion per 4.3.3.2

Small lamp with lighted function; with no socket; lamp side connector is not sealed (i.e., LED CHMSL with vented lamp side connector body connector contains seal)

Pressurization per 4.3.3.3

Body sealed lamp

(Note: A rigid fixture that represents the lamp mating sealing surface and attachment is required.)

Pressurization per 4.3.3.3

Other lamp with lighted function(s) Pressurization per 4.3.3.3




4.3.3 Seal. Leak test each lamp per the test method described in Table 1. Data shall be recorded for all lamps subject to Seal Test Methods (Table 1), including data for those lamps that may not meet pre-test requirements. Indicate in test incident notes, on the data sheets, if lamp quantities greater than the minimum sample size were required to collect test ready lamps.

4.3.3.1 Vacuum Chamber Method. Lamp shall be tested at room temperature. Allow lamp to stabilize at 23 C 3 C temperature for a minimum 1 h. Submerse the lamp in 23 C 3 C water, inside of the vacuum chamber (mount lamp to a simple fixture using production mounting points, if required). Let stand for 5 minutes. Observe the lamp for leakage. A leak is defined as any bubbles originating from a single point on the lamp. If no leakage is noted; evacuate the chamber with submersed lamp inside to reduce the pressure to 21.0 kPa for 15 s. Lamps shall show no bubbles during test.

Caution: Safety precautions shall be taken to protect test engineer. Monitor pressure to prevent water from boiling at low pressures.

4.3.3.2 Submersion Method. Energize lamp for 30 minutes at ambient. Continue to supply voltage and submerse to a depth 10 mm under water at 2 C 2 C for 5 minutes. With the lamp under water, turn off supply voltage to the lamp and let stand for 5 minutes. Remove the lamp from the water and inspect for water ingress. Repeat this instruction three times per lamp assembly. There shall be no cracking, ingress of water or evidence of internal condensation.

4.3.3.3 Pressurization Method. Pressurize each lamp completely under 2.5 cm of water at 7.0 kPa for 5 minutes using the pressurization guidelines in 4.17. All aimable lamps shall be cycled through their total travel while pressurized. If the leak test pressure (LTP) was determined using procedure 4.17, this pressure shall be used. Lamps shall show no bubbles as defined in 4.17.4.5.

4.3.4 Light Output. The purpose of this measurement is to compare the light output before and after the tests described in this document. Measurements are not an indication of compliance to regulations and are for pre-test and post-test comparison only.

Measure and record the luminous flux photometric output of one lamp or pair of handed lamps. Low beam, high beam and fog lamp functions shall be measured by positioning the test lamp on a goniometer per guidelines in the applicable

regulatory requirements and measured over a matrix that spans the horizontal and vertical beam pattern extents defined in the applicable regulatory requirements at an increment of 0.2 degrees. Other lamp functions shall be measured at an increment of 1.0 degree. License lamps and reflex reflectors are not required to follow this measurement method; but measurement data to evaluate pre-test requirements shall be provided, as noted below. This data shall be provided electronically to GM upon request.

Headlamps shall be aimed properly and the gradient recorded if applicable. Light emitting diodes (LED) shall be tested per SAE J1889 or ECE regulations for the specific lamp stabilization time. Lamp functions that are required to operate with vehicle "Start/Stop" conditions shall also be measured for light output at 12.8 V at horizontal-vertical (H-V). This data shall be provided electronically to GM upon request.

Reflex and license lamps shall be measured to the regulatory requirements instead of a matrix; non-functional reflex does not need to be measured, and electronic data need not be provided.

If the photometric regulatory requirements require an accurate rated light source, measure and record the device photometric output using an accurate rated source activated at the proper current. Then use a standard light source for testing.

If the photometric regulatory requirements do not require an accurate rated light source or the sample uses non-replaceable light sources, measure and record the photometric output of the device using a standard source energized at 12.8 V unless otherwise specified by the device. If a standard replaceable source is used for the photometric measurements, another standard source shall then be used for testing other than photometry. Use the same standard light source for the initial and final photometry.

4.3.5 Appearance. All lamps shall be visibly free of warps, cracks, crazing, blistering, chalking, condensation, delamination, out-gassing, or any other visible change without magnification.

4.3.6 Function. Assure all functions are operational, i.e., aimable lamps can be adjusted through full travel, aimable lamps will not incur damage or loss of function if adjusted past their effective adjustment range, all vehicle headlamp aiming devices (VHAD) function and read correctly, replaceable bulbs can be removed from their sockets, etc., and all joints are tight with all fasteners engaged.




Note: To verify aim adjustment, cycle the lamp full down, then full up, then back to nominal position evaluating breakaway and prevailing torque using a performance console to record and chart values. Attach charts to the existing data sheets. During this evaluation, also verify the number of turns to adjust aim one degree and record.

4.3.7 Squeak and Rattle. Perform a subjective evaluation for squeak and rattle by holding a complete lamp assembly in hand and twisting in multiple directions. With the same lamp assembly in hand, gently shake the assembly in all directions. Evaluations during each condition shall be evaluated per GMW14264 in a room with no ambient noise.

4.4 SAE J575e August 1970 Vibration.

Note: Operators are to use the SAE J575e August 1970 version which aligns with a prior standard referenced in Federal Motor Vehicle Safety Standards (FMVSS) documents. Although this test is not for compliance, only this version is to be used. Operators are not to use the latest/current version of SAE J575e for GMW14906.

4.4.1 Equipment. Vibration test equipment described in SAE J577.

4.4.2 Sample Size. Two (2) pair or three samples.

4.4.3 Procedure. Test samples to the vibration procedure described in SAE J577 for 60 minutes. Inspect the parts for the acceptance criteria listed in FMVSS 108 without removing from the fixture, If the sample(s) passes, continue testing for an additional 30 minutes. Remove from the fixture and repeat the part inspection. See Data Sheet A2.

4.5 Temperature and Vibration. Conduct the tests in this section in the order presented with the same samples through the entire sequence of pre-test measurements, temperature, vibration, and post-test requirements. In addition, inspect all sample(s) after each test section using the procedure specified. See Data Sheet A3.

Note: Optional HID or Adaptive Forward Lighting (AFL) System (AFL headlamps are examples requiring separate vibration validation. Slight variations of lamp options (up-level vs. base, lens color changes, flashed over sockets for corner lamps, multiple cavities for the same part, multiple assembly lines, etc.) shall be intermixed in the assemblies according to GMW15760. The GM

Validation Engineer and GM Designing Engineer shall approve any combination assumptions.

4.5.1 Temperature Cycling.

4.5.1.1 Purpose. To verify the lamp assembly can withstand temperature extremes and precondition the lamp assembly for vibration testing.

4.5.1.2 Equipment. Environmental chamber capable of -40 C to +120 C with either random air circulation or circulating air with a predominant air flow direction. The chamber shall be capable of 3 C 1 C per minute.

4.5.1.3 Sample Size. Seven (7) pair or 14 samples.

4.5.1.4 Temperature Procedure. Perform the temperature cycle in Figure 1 two times with lamp assemblies positioned in vehicle orientation.

4.5.2 Vibration.

4.5.2.1 Purpose. To determine if the lamp will withstand severe vibration input.

4.5.2.2 Equipment. Random vibration equipment described in ISO 16750-3, SAE J575, or equivalent.

4.5.2.3 Sample Size. The same seven pair or 14 samples used in 4.5.1 Temperature Cycling.

4.5.2.4 Test Fixture Rigidity. Mount all test samples to the vibration equipment using a test fixture that duplicates the production vehicle mounting interfaces, fasteners, and vehicle orientation. Measure the first resonant frequency of one sample of each assembly in each axis and record. The procedure shall include the measurement of the vibration input and the fixture response from 10 Hz to 1000 Hz. This fixture, when coupled with the test sample or equivalent mass and center of gravity, shall not have a resonant frequency between 10 Hz and 250 Hz in any axis and no vibration responses greater than two times the input signal in this frequency range. In addition, the test fixture acceleration amplitude frequency responses at the individual mounting points, when the entire fixture is subjected to constant excitation, shall only differ from each other within the frequency range to be tested by 3 dB maximum (between 250 Hz and 1000 Hz by 10 dB maximum). The fore-aft and lateral resonances shall be at least 10 dB below the signal in the test direction. The test fixture performance shall be approved by the GM Validation Engineer and GM Designing Engineer.




1 hour Cooling to -40 C

4 hours At -40 C

2 hours Heating to +80 C (110 C for Interior CHMSLs)

16 hours At +80 C (110 C for Interior CHMSLs)

1 hour Cooling to +23 C 5 C

Figure 1: Temperature Cycling

4.5.2.5 Lamp Assembly Resonance. Measure the lamp assemblys first resonant frequency prior to testing. In addition, measure the first resonant frequency of lamp components retained through an aim mechanism using optical aids such as a laser. Record the specific procedure used and measured data on Data Sheet A3.

4.5.2.6 Accelerometer Locations. Test all component lamps in random vibration. Mount redundant vibration control accelerometers on the fixture. Mount one at the base and one as far as practical from the base to reduce the test fixture influence on the lamp. The test shall be limited by the higher of the two values. Record the locations in the test report.

4.5.2.7 Lamp Activation During Vibration. During vibration testing, activate all light sources according to the Lamp Activation Profile in Figure 2. Using this profile, activate the lamp functions for 3 h as described in Figure 4, of each 8 h vibration test on each axis. If a dedicated Daytime Running Light (DRL) is contained in another lamp assembly, activate the DRL for the first 5 h, then low beam/high beam as indicated for 3 h.

4.5.2.8 AFL and DHL Activation During Vibration. If a headlamp assembly contains an Adaptive Forward Lighting System (AFL), activate

the angular mechanism during random vibration as directed in Figure 3 while simultaneously activating the lamp functions as directed in Figure 2.

If the headlamp contains Dynamic Headlamp Leveling (DHL), activate during random vibration as directed in Table 7 when the high and low beam lamp functions are activated in Figure 2.

Note: AFL/DHL systems shall not be reinitialized prior to post-test measurements. If an electronic control module is used to control the AFL/DHL system during test, any calibration used to automatically zero the lamp position shall be deactivated.

4.5.2.9 Vibration Duration.

4.5.2.9.1 All Lamps Except Pickups. Vibrate samples for the duration specified in Table 2 using the temperature profile outlined in Figure 4 and the Power Spectral Density in Figure 5.

Table 2: Vibration Duration by Axis

Vertical 8 hours

Fore/aft 8 hours

Lateral 8 hours

Temperature Cycling for Interior CHMSL's, and all Other Lamps

-40

-20

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14 16 18 20 22 24

Time (hours)

Te

mp

era

ture

(C

)

Interior CHMSL Cycling Other Lamp Cycling




4.5.2.9.2 Pickups. For lamps on pickups, vibrate lamps for the duration specified in Table 3 using the temperature profile outlined in Figure 4 and the Power Spectral Density in Figure 5.

4.5.2.9.3 Vibration Axis Sequence. The axis of vibration sequence need not be the same for each sample tested, but must be noted in test log data. The lamp orientation during testing is always to be as in the vehicle.

Table 3: Vibration Duration for Pickups

Vertical 8 hours

Fore/aft 8 hours

Lateral 8 hours

Figure 2: Lamp Activation Profile During Vibration and Light-up Tests

5 10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

105

110

115

120

125

130

135

140

145

150

155

160

165

170

175

180

Lamp functions Duration

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

Note: Lamp assemblies with multiple lamp functions shall have all functions on/off according to the activation profiles

above. Use the specific vehicle mechanization to determine activation behavior (for example, Scandanavian countries

may require mechanization of park function on with DRL on).

120 on flashing

/ 60 off

10 on / 50 off

30 on / 60 off

Side Marker / Park /

Position/Clearance/ID

Taillamps/License Lamps

Turn Signal / Hazard/

Side Repeater

Switched lamps: Cargo,

Spot, etc.

180 on

60 on / 30 off /

60 on

Static bending/ Cornering

180 on / 3s

cycle @50% on

time

30 on, then 15

off / 15 on

Rear Fog

Unswitched lamps:

puddle, assist step1 on / 1 off

High Beam - 2 Bulb Burn

& Bi-Funtion Projector

Front Fog

40 off / 20 on /

70 off

90 on / 90 off

40 on / 20 off /

70 off

180 on

180 on

Lamp Activation Profile for Light-Up and Vibration (min)

Dedicated DRL

(tested separately)

Stop / CHMSL

Backup

Low Beam;

(incl. AFS/DHL)

High Beam - 4 Bulb Burn 30 on / 60 off

Low Beam;

(incl. AFS/DHL)180 on




Figure 3: Adaptive Forward Lighting System Cycle

1 hour Cooling from 23 C 5 C to -40 C

1 hour at -40 C

2 hour Heating to 50 C

2 hours At 50 C (with lamp activated as described in Figure 2; begin at time = 0)

1 hour Cooling to 23 C 5 C (with lamp activated as described in Figure 2; begin at time = 120)

1 hour at 23 C

Figure 4: Temperature Curve for Vertical Random Vibration Test Only




Vertical Axis - All Lamps Except Pickups

( )

Horizontal Axis - All Lamps Except Pickups

( - - - )

Vertical and Horizontal Axes - Pickups Only

( -- -- -- )

Frequency range: 10 Hz to 1000 Hz

Power spectral density:

0.201 G2/Hz at 10 Hz 0.1006 G

2/Hz at 10 Hz 0.08184 G

2/Hz at 10 Hz

0.00666 G2/Hz at 300 Hz 0.00339 G

2/Hz at 300 Hz 0.08184 G

2/Hz at 40 Hz

0.0006158 G2/Hz at

1000 Hz 0.000308 G

2/Hz at

1000 Hz 0.01364 G

2/Hz at 250 Hz

0.0001364 G

2/Hz at

500 Hz

0.0001364 G

2/Hz at

1000 Hz

Total G: 2.84Grms 2.0Grms 3.04Grms

Figure 5: Frequency Range and Power Spectral Density Graph




4.5.2.10 Temperature Curve for Vertical Test Direction. The vibration test in the vertical direction only uses a superimposed temperature as shown in Figure 4 and described below, as well as the lamp activation profile according to Figure 2. Perform testing in the fore/aft and lateral directions at 23 C 5 C.

4.5.2.11 After random vibration is complete on all three axes, re-measure the first resonant frequency of the specimen tested in 4.5.2.5 and record on Data Sheet A3.

4.5.2.12 Record All Results per 3.5.

4.5.3 Temperature and Vibration Acceptance Criteria.

4.5.3.1 The first natural frequency post-test shall not have degraded >15% compared with the pre-test value; however, it shall be >35 Hz in every case.

4.5.3.2 Lamps shall pass all of the post-test requirements in 4.6 after completing the entire 4.5 test sequence.

4.5.3.3 Replaceable light source filament failures are acceptable. If filament failures occur, replace the light source immediately and continue the test so that the light sources are activated as intended for the entire test duration. Record each incident on the test log sheets and retain the bulbs to review with the GM Validation Engineer and GM Designing Engineer.

4.6 Post-Test Requirements.

4.6.1 Dimension. The measured sample shall be dimensionally correct within twice the drawing tolerance.

4.6.2 Aim. Measure the change in all aimable lamps. The aim shall not have changed more than 0.2 degree for vertical or 1.0 degree for horizontal. This criteria applies to all aimable lamps including lamps that are part of an AFL system. Record the amount of aim change.

4.6.3 Seal Leak Test Pressure (LTP). Leak test and evaluate each lamp per the test method described in Table 1.

4.6.4 Light Output. Measure and record the photometric output of the original test sample(s) over the same matrix extents at an increment of 0.2 degree for forward lighting and 1.0 degree for rear and side lighting using the original light source. Test LED per SAE J1889 or the ECE regulation for the specific lamp. Headlamps shall be aimed properly and the gradient recorded if applicable. This data need not be provided electronically to GM.

Reflex shall be measured to the regulatory requirements instead of a matrix, non-functional reflex does not need to be measured, and electronic data need not be provided.

If the photometric regulatory requirements require an accurate rated light source; measure and record the photometric output of the device using an accurate rated source activated at the proper current. A standard source shall then be used for the test.

If the photometric regulatory requirements do not require an accurate rated light source or the sample uses non-replaceable light sources, measure and record the photometric output of the device using a standard source energized at 12.8 V unless otherwise specified by the device. If a standard replaceable source is used for the photometric measurements, another standard source shall then be used for testing other than photometry. The standard source originally used for the initial photometry shall be used for final photometry.

LED functions that are required to operate with vehicle "Start/Stop" conditions shall also be measured for light output at 6V, 8V and 10V at H-V. Functions required to operate with vehicle "Start/Stop" functionality shall meet the requirements of applicable technical specifications and Figure 6, as required.

If any test point measurements change >25% and the change cannot be attributed to slight mis-position, or total lumen output changed >20%, determine and record the root cause of the change and ensure that the root cause does not violate any other acceptance criteria. Ensure that the repeatability and reproducibility of the photometric test setup is not a major contributor.

4.6.5 Appearance. All external lamp surfaces and all internal surfaces visible through the lens or during normal service procedures shall be visibly free of fractures or mechanical damage, warps, cracks, crazing, blistering, condensation, delamination, discoloration, or deterioration of any component, without magnification.

Some chalking (also called powdering or dusting) and outgassing is acceptable, but must be approved by the GM Validation Engineer and GM Designing Engineer. Test reports shall detail the region(s) of the lamp affected with photographs and when during the test the onset of chalking occurred.




Function Light Output from LED Functions

[v-100 = 100% light output @ 12.8 V at H-V]

Required Output Conditions >90% of v-100 at 6 V

>75% of v-100 at 10 V

>50% of v-100 at 8 V

>25% of v-100 at 6 V

>50% of v-100 at 10 V

>25% of v-100 at 8 V

>0% of v-100 at 6 V

Typical Execution Control Module 2 LED in Series 3 LED in Series

Low Beam Minimum Required NOT ALLOWED NOT ALLOWED

Stop Allowed Minimum Required NOT ALLOWED

Rear Fog Allowed Minimum Required NOT ALLOWED

Cornering light (AFL)

Allowed Minimum Required NOT ALLOWED

Front Position/Park Allowed Minimum Required NOT ALLOWED

DRL Allowed Minimum Required NOT ALLOWED

High Beam Allowed Minimum Required NOT ALLOWED

Tail/Rear Position Allowed Minimum Required NOT ALLOWED

Backup lamp Allowed Allowed Minimum Required

Front Fog Allowed Allowed Minimum Required

Side Repeater Allowed Allowed Minimum Required

Front/Rear Side Marker (US)

Allowed Allowed Minimum Required

License Plate Allowed Allowed Minimum Required

Turn Signal Allowed Allowed Minimum Required

CHMSL Allowed Allowed Minimum Required

Figure 6: Exterior Lamp Functions Start/Stop Minimum Requirements

4.6.6 Function.

4.6.6.1 All illumination functions are operational. If multi-source function, each discrete light source must remain illuminated.

4.6.6.2 Aimable lamps are adjustable through full travel, including Adaptive Forward Lighting (AFL) System and Dynamic Headlamp Leveling (DHL). Adjusters shall meet the following requirements:

a. Headlamp Adjuster

1. Dynamic Breakaway Torque: 3.5 Nm

2. Dynamic Prevailing Torque: 2.0 Nm

3. Adjuster Gear Ratio shall provide: 2 to 4 turns per degree of lamp movement

b. Fog Lamp Adjuster

1. Dynamic Breakaway Torque: 3.5 Nm

2. Dynamic Prevailing Torque: 2.0 Nm

3. Adjuster Gear Ratio shall provide: 2 to 4 turns per degree of lamp movement

4.6.6.3 All VHADs function and read correctly.

4.6.6.4 Replaceable bulbs are removable from their sockets.

4.6.6.5 All joints are tight with all fasteners engaged.




4.6.6.6 The lamp is removable without loss of function to fasteners.

4.6.6.7 Bulb filament fractures are not necessarily test failures. Record filament fractures on the test log sheets.

4.6.6.8 Bulbs and bulb sockets shall not show any evidence of arcing, deformation, or melting. Gaskets shall not deform or result in loss of sealing capability. Some discoloration of bulbs, sockets and socket gaskets is acceptable, but must be approved by the GM Validation Engineer and GM Designing Engineer. All sockets and bulbs shall be removed from the lamp post-test in order to perform the inspection. Test reports shall detail specific sockets, bulbs and gaskets affected with photographs.

4.6.7 Squeak and Rattle. Perform a subjective evaluation for squeak and rattle by holding a complete lamp assembly in hand and twisting in multiple directions. With the same lamp assembly in hand, gently shake the assembly in all directions. Evaluations during each condition shall be evaluated per GMW14264 in a room with no ambient noise. The subsystem shall have a subjective rating of at least nine (9) when evaluated to GMW14264 Subjective Rating Scale for Squeaks and Rattles.

4.6.8 Record All Results per 3.5.

4.7 Electrical Components and Electronic Interfaces.

4.7.1 Electrical Connectors and Power Interface.

4.7.1.1 Electrical Connectors. Electrical connections shall meet GMW3191 for the following environments:

Temperature: Class 2 for headlamps and Class 1 for all other lamps.

Vibration: Class 1.

Sealing: Class 2 for headlamps, fog lamps, and side repeater lamps; Class 1 for all other lamps.

Connector Mating Force: Use appropriate classification based on physical size.

4.7.1.2 Electrical Wiring and Lamp Harness Cables. Lamp wiring and lamp harness cables shall meet GMW15626 for the following environment:

Temperature: Class C for external headlamp cables and other external lamp cables exposed to the engine compartment. Class A for all other external lamp cables. Internal cable classifications shall be determined per results of lamp thermal analysis.

4.7.2 Headlamp Bulb and Connector Temperature Cycle.

4.7.2.1 Rigidly mount ten production intent headlamp bulbs (representative of the intended bulb type, bulb variant (long life, standard life, etc.), bulb orientation, bulb terminal material (nickel plated stainless, etc.), and bulb supplier) inside a

thermal chamber capable of -40 C to 140 C. Chamber shall be capable of maintaining the specified temperature with the ten bulbs energized.

4.7.2.2 Mount thermocouples to each terminal of each connector as close as possible to the bulb terminal interface. Thermocouples shall be permanently attached. Ensure that the thermocouple mounting will not disturb the performance of the connection system and that all the connection system components (connector body, terminal position assurance (TPA), etc.) are installed properly.

4.7.2.3 Cycle thermal chamber while energizing bulbs at 14.5 V following the schedule below. During entire test, measure and record the temperature of each connector ground terminal every 5 minutes.

4.7.2.3.1 Set thermal chamber to 140 C with a minimum transition of 2 C/minute while energizing bulbs at 14.5 V. Transition and hold 140 C for 240 minutes total.

4.7.2.3.2 Set thermal chamber to -40 C with a minimum transition of 2 C/minute with all bulbs off. Transition and hold -40 C for 120 minutes total.

4.7.2.3.3 Repeat cycle above for 2500 h. Replace any bulb which burns out during test and continue test. Record each bulb replacement and verify that the bulb filament has failed. Connectors shall not be disconnected other than to replace bulbs due to burnout.

4.7.2.4 Acceptance Criteria.

4.7.2.4.1 If more than 10 samples are tested, all samples shall comply with the acceptance criteria.

4.7.2.4.2 All samples tested shall continue to power the bulb throughout the test.

4.7.2.4.3 All measured terminal temperatures shall not increase from the maximum temperature measured within the first 48 h by more than 20 C throughout the test. All temperature shall be graphed and provided to GM. In addition, the temperature of the terminals shall not increase above the heat deflection temperature of the connector body materials.

4.7.2.4.4 All samples shall show no heat distortion of any component after the test. Any discoloration of any components shall be reviewed with GM for approval.




4.7.2.4.5 Measured terminal temperatures shall be recorded and shall be less than or equal to the specified maximum rated temperature for the terminal substrate and plating materials.

4.7.3 Solenoids.

4.7.3.1 Solenoids shall meet durability requirements per methods defined in SAE J564. Test shall be performed using the projector assembly or partial lamp assembly to which the solenoid is mounted.

4.7.3.2 Verify that the mechanical connection of the solenoid to lamp shield and solenoid to its mounting surface is made. Power the solenoid and cycle to 200 000 cycles or four (4) lives (1 life = 50 000 cycles).

4.7.3.3 Evaluate for proper operation (full open to full close) every 50 000 cycles and record results on the data sheet.

4.7.3.4 Continue to cycle solenoid to failure or 300 000 cycles and record results on the data sheet.

4.7.3.5 Acceptance Criteria. Solenoid shall remain functional at the end of 200 000 cycles.

4.7.4 Bulb and Socket Removal Force.

4.7.4.1 The cold removal force shall be determined on ten (10) actual bulb/socket samples intended for the application using the procedure outlined in USCAR 15, titled Bulb Insertion/Removal Force. Lamp assemblies may be reused.

4.7.4.2 The hot removal force shall then be determined using the same USCAR 15 method. Energize all the filaments in same bulb/socket samples as in 4.7.4.1, at 14.1 V for 30 minutes in the lamp assembly at ambient temperature. If the lamp assembly is not yet available, utilize a surrogate lamp with a similar cavity volume as the intended lamp assembly. GM shall approve the lamp chosen prior to testing. With the bulb still energized, remove the socket and measure the removal force of the bulb within 30 seconds of removal. Only one (1) pull force measurement is required (instead of the five (5) required in the USCAR 15 procedure).

4.7.4.3 The cold removal force of the same bulb/socket combination shall then be re-measured using the same USCAR 15 procedure.

4.7.4.4 Acceptance Criteria. Bulb removal force shall not degrade more than 10% or degrade below the minimum removal force requirements contained in SAE/USCAR 15, when measured cold versus hot after being energized for 30 minutes in the lamp assembly, and then measured cold again.

4.8 Accelerated Corrosion. Lamps completely located inside the passenger compartment such as

CHMSLs with no external exposure are excluded from this procedure.

4.8.1 Purpose. To primarily determine the corrosion and humidity resistance of lamp assemblies and to secondarily determine stress levels are acceptable in welded assemblies and in lamps with snap fit attachments.

4.8.2 Sample Size. The sample size for all corrosion testing is three pair or six samples through each test.

4.8.3 Procedure.

4.8.3.1 Perform pre-test requirements 4.3.3, 4.3.5, and 4.3.6.

4.8.3.2 For lamps with snap fit attachments, test attached to the mating component or a representation of it. For other attachments to the body, represent the fastener, torque, and interface as close as possible.

4.8.3.3 Cyclic Corrosion Testing GMW14872. See Data Sheet A4. Test all parts as assemblies in cyclic corrosion per GMW14872 for validation.

4.8.3.3.1 For coatings and substrates test as assemblies in cyclic corrosion per GMW14872.

4.8.3.3.2 For headlamps, side repeaters, front fog lamps and under hood (UH) areas.

4.8.3.3.2.1 UH, All, Method 1/2, Exposure B + D.

4.8.3.3.3 For all other lamps.

4.8.3.3.3.1 Exterior (EXT) Applications, All, Method 1/2/3, Exposure C + D.

Note: After exposure B and C, all metal surfaces shall fulfill cosmetic requirements as defined in GMW15272. After exposure D, there shall be no loss of function.

4.8.3.4 Painted metal external parts on lamps must perform to GMW14669, Type A2.

4.8.3.5 Painted metal internal parts on lamps must perform to GMW14669, Type B2.

4.8.3.6 Chrome plated external plastic components must perform to GMW14668 (48 h) plus four thermal cycles per GMW14668.

4.8.4 Perform post-test requirements 4.6.3, 4.6.5, and 4.6.6 as noted above.

4.8.5 Acceptance Criteria.

4.8.5.1 Headlamps, Side Repeaters, and Front Fog Lamps. After exposure B all metal surfaces shall fulfill cosmetic requirements as defined in Table A1, Cosmetic Corrosion Resistance Requirements, of GMW15272. Samples shall pass post-test requirements in 4.6.3, 4.6.5, and 4.6.6. No cracks near attachments or interfaces of welded components are permissible.




4.8.5.2 All Other Lamps: After exposure C, all visible metal surfaces shall fulfill cosmetic requirements as defined in Table A1, Cosmetic Corrosion Resistance Requirements, of GMW15272. Surfaces visible when hoods, decklids, liftgates, etc., are in the open position are classified as visible surfaces. Samples shall pass post-test requirements of 4.6.5. No cracks near attachments or interfaces of welded components are permissible.

4.8.5.3 Functional. After Exposure D there shall be no loss of function per GMW15272 (Reference section titled: Functional Corrosion Resistance). The samples shall pass post-test requirements of 4.6.3 and 4.6.6.


4.9 Weatherability. This test is required on all lamps with externally visible multi-color and overlay interfaces, adhesive bonded lens to housing joints, and externally visible unpainted and uncoated plastics. See Data Sheet A5.

4.9.1 Purpose. To determine if molded lighting subsystems will incur damage when subjected to simulated sunlight, heat, and moisture.

4.9.2 Sample Size. Samples are to be plaque-sized sections cut from production representative or production lamps containing the interface to be tested. One sample of each condition outlined in 4.9.

4.9.3 Procedure. For exterior mounted lamps test to GMW14650 (Reference section titled: Weather-Ometer Resistance) Class 3 (>2500 kJ/m

2 to SAE J2527 or >3000 kJ/m

2 to

ISO 4892-1/2. For interior CHMSLs and other interior mounted lamps, test to GMW14651 and exposure requirements per GMW14444. Interior painted plastic shrouds shall also be tested to GMW14444. Inspect samples biweekly.

4.9.4 Acceptance Criteria. Samples shall pass post-test requirements in 4.6.5.


4.10 Internal and External Heat. See Data Sheet A6.

4.10.1 Internal Heat.

4.10.1.1 Purpose. To determine the effect of extreme heat with light sources activated. This procedure applies to all lamps.

4.10.1.2 Equipment.

4.10.1.2.1 Thermal chamber capable of maintaining +100 C without air circulation.

4.10.1.2.2 Power supply capable 9 V to 16 V and be able to maintain a constant supply of power at 16 V to all lamps.

4.10.1.3 Sample Size. Three (3) pair of headlamps. Two (2) pair or three samples of all other lamps.

4.10.1.4 Test Procedure.

4.10.1.4.1 Perform and pass all pre-test requirements in 4.3.

4.10.1.4.2 For headlamps and front fog lamps, uniformly apply by brush or spray to the lamp lens surface normally exposed to road dirt a mixture of fine powdered cement and water in accordance with ASTM C150 or equivalent composition and particle size. For all rear lighting do not apply this mixture to the lens. Reduce the photometric output at the horizontal-vertical (H-V) test point of the upper beam, the 0.5D-1.5R test point of the lower beam, the H-2D point of the fog lamp, to 25% 2% of the clean lens photometric output (equal to a 75% 2% reduction). Determine the reduction under the same conditions as the original measurement. AFL headlamps shall be tested with the movable beam contributor in the nominal position, only.

4.10.1.4.3 Mount lamps in the chamber in vehicle orientation.

4.10.1.4.4 Set temperature to 39 C 1.0 C with air circulation. Place the lamp in the chamber in vehicle orientation and maintain the temperature for 60 minutes allowing the lamp to stabilize.

4.10.1.4.5 Shut off air circulation and seal off chamber. Ensure that the lamp does not raise the oven temperature more than 5 C. Note decrease or increase in chamber temperature on the data sheet.

4.10.1.4.6 Activate the lamp functions that draw the highest wattage. Additionally, test to the conditions in 4.10.1.4.6.1 through 4.10.1.4.6.5, as applicable.

4.10.1.4.6.1 If a turn signal is part of the lamp assembly, activate it at 90 flashes/minute with a 50% 2% current on time.

4.10.1.4.6.2 If a headlamp option includes both a halogen and high intensity discharge (HID) light source, test the halogen light source only.

4.10.1.4.6.3 If a headlamp system consists of a four-bulb upper and lower beam, perform the test with the low or dipped beam source first, then the high beam source per the vehicle mechanization.

4.10.1.4.6.4 If a lamp assembly contains other lighting functions, including a dedicated DRL, activate the other lighting functions at the maximum wattage possible per the vehicles mechanization. Visually inspect the lamp. Then continue test with the DRL activated continuously for an additional 90 minutes.




4.10.1.4.6.5 For rear combination lamps, activate the stop, backup and other functions that can be energized with the stop and backup according to the first hour in the Lamp Activation Profile (LAP) in Figure 2.

4.10.1.4.7 Maintain set temperature plus tolerance for 60 minutes while lamps are being cycled. If the lamp contains a dedicated DRL, dwell for 90 minutes while the lamps are being cycled.

4.10.1.4.8 Remove the samples to ambient and clean the lens.

4.10.1.4.9 Perform post-test requirements in Data Sheet A6.

4.10.1.4.10 Re-test steps 4.10.1.4.1 through 4.10.1.4.9 on a new set of lamps with the temperature in 4.10.1.4.4 set at 50 C instead of 39 C. If three samples are being tested, test the second and third samples at 50 C.

4.10.2 External Heat Test.

4.10.2.1 Purpose. To determine the effect of extreme heat with light sources activated; including the effects of elevated ambient temperatures at the front of lamp and back side of lamp, exposed to engine compartment temperatures. This procedure applies to all headlamps, fog lamps, and other lamps mounted to the front of the vehicle and extending into the engine compartment.

4.10.2.2 Equipment.

4.10.2.2.1 Thermal chamber with baffle capable of maintaining +100 C with air circulation on the back side of lamp and +50 C with air circulation on the front side of lamp.

Note: The thermal chamber equipment specified in the internal heat test is for a thermal chamber without air circulation.

4.10.2.2.2 Power supply capable 9 V to 16 V and be able to maintain a constant supply of power at 16 V to all lamps.

4.10.2.3 Sample Size. One additional pair of lamps with clean lens.


4.10.2.4.1 Secure the lamp in vehicle orientation in the chamber. Construct a baffle of insulating material around the periphery of the assembly and use tape to seal off air flow at the housing to lens interface. This setup must expose the lens to ambient air temperature at 50 C and the housing to ambient air temperature at 100 C. Tool access to housing mounted sockets shall be considered, as noted in the procedure below. Reference Figure B1 for a simple test setup alternative to using a dual chamber.

4.10.2.4.2 Set the front side chamber temperature to 50 C and the back side chamber temperature to 100 C and allow the chamber temperatures to stabilize.

If the lamp contains an independent DRL, fog lamp or, both; test to sections 4.10.2.4.3 daytime mode activation and then 4.10.2.4.4 nighttime mode activation.

If the lamp is a dedicated DRL, fog lamp or, combination DRL/fog lamp using the same light source; test to section 4.10.2.4.3 daytime mode activation.

For all other lamp types, test to section 4.10.2.4.4 nighttime mode activation.

Note: The same set of lamps is to be used for daytime and nighttime testing, if both test modes are required.

4.10.2.4.3 Daytime Mode Activation. Activate the function(s) allowed by the vehicles mechanization in daytime mode (i.e., for dedicated DRL activate the DRL; for dedicated fog lamp activate fog; for combination DRL/fog lamp activate DRL). Allow lamp to dwell for 4 h with chamber temperatures maintained at 50 C and 100 C as specified above.

4.10.2.4.3.1 For lamp types noted in 4.10.2.4.2 that contain a socket or heat sink that directly connects to the housing and holds an active light source in daytime mode, perform the following:

4.10.2.4.3.1.1 At 100 C, with the lamp in the chamber, apply a 10 N load normal to the socket or external heat sink (if exposed) of the active light source for 20 s. See Figure B2 for a sample photo displaying load direction and load tip.

4.10.2.4.3.1.2 After loading, remove the lamp from the chamber, cool to ambient temperature, and evaluate according to 4.10.4.

4.10.2.4.3.2 For all lamp types noted in 4.10.2.4.2 that do not contain a socket or heat sink that directly connects to the housing, remove the lamp from the chamber and evaluate according to 4.10.4.

4.10.2.4.4 Nighttime Mode Activation. Activate the highest wattage light source(s) allowed by the vehicles mechanization in nighttime mode. Allow lamp to dwell for 4 h with chamber temperatures maintained at 50 C and 100 C as specified above.

4.10.2.4.4.1 For lamp types noted in 4.10.2.4.2 that contain a socket or heat sink that directly connects to the housing and holds an active light source in daytime mode, perform the following:




4.10.2.4.4.1.1 At 100 C, with the lamp in the chamber, apply a 10 N load normal to the socket or external heat sink (if exposed) of the active light source for 20 s. See Figure B2 for a sample photo displaying load direction and load tip.

4.10.2.4.4.1.2 After loading, remove the lamp from the chamber, cool to ambient temperature, and evaluate according to 4.10.4.

4.10.2.4.4.2 For all lamp types noted in 4.10.2.4.3 that do not contain a socket or heat sink that directly connects to the housing, remove the lamp from the chamber and evaluate according to 4.10.4.

4.10.3 External Heat Test for Headlamp Bulb Connector Terminals.

4.10.3.1 Purpose. To verify that heat generated by the lamp subsystem does not exceed thermal properties of the headlamp bulb connector(s). This procedure applies to all headlamps.

4.10.3.2 Equipment. Reference equipment noted in the External Heat Test of this section.

4.10.3.3 Sample Size. One sample that has completed the Internal Heat Test of this test section.


4.10.3.4.1 Instrument test sample bulb connector(s) as instructed in the Headlamp Bulb and Connector Temperature Cycle Test.

4.10.3.4.2 Perform the External Heat Test in Nighttime Mode Activation. During entire test, measure and record the temperature of each connector terminal at a minimum of every 30 minutes.

4.10.3.4.3 Record maximum rated terminal temperature as defined by the manufacturer.

4.10.3.4.4 Remove the lamp from the chamber and evaluate according to 4.10.4


4.10.4.1 Lamps tested at 39 C shall pass all post-test requirements in 4.6.

4.10.4.2 Lamps tested at 50 C shall pass all of the post-test requirements in 4.6 except that lens deformation up to 1.0 mm is acceptable. Review any lamp with slight deformation with the GM Validation Engineer and GM Designing Engineer.

4.10.4.3 Lamps tested at 50 C front side and 100 C back side shall pass all of the post-test requirements in 4.6 except that outer lens deformation up to 1.0 mm is acceptable. Review any lamp with slight deformation with the GM Validation Engineer and GM Designing Engineer.

4.10.4.4 Measured temperatures shall not exceed the maximum rated temperature for terminal

substrate and plating materials as provided by the terminal supplier.


4.11 Light Up. See Data Sheet A7.

4.11.1 Purpose. To determine the effects of long term lamp activation on lamp components.

4.11.2 Equipment.

4.11.2.1 An area where three pair or six samples can be positioned in vehicle position spaced >300 mm apart horizontally and vertically edge to edge (to minimize heating affects) with minimal airflow less than 3 km/h at an ambient temperature of 23 C 5 C.

4.11.2.2 Direct Current (DC) power supply capable of supplying 9 V to 16 V DC.

4.11.2.3 Controller capable of energizing all lamp functions contained in the sample following the cycles specified in the LAP in Figure 2.

4.11.3 Sample Size. Three (3) pair or six samples.

4.11.4 Procedure.

4.11.4.1 Perform and pass pre-test requirements in 4.3.3, 4.3.5, and 4.3.6.

4.11.4.2 Mount lamps in vehicle orientation.

4.11.4.3 Unless otherwise specified, activate the highest wattage light source(s) as electrically mechanized by the vehicle and for the durations shown in Figure 2.

4.11.4.4 Lamp Assemblies Without Dedicated DRL. Activate all light sources according to Figure 2, repeating the 180 minute cycle continuously for 12 days. During the last hour of each 24 h, turn off all lamp functions to completely cool the lamp. Begin the next cycle at the beginning of the LAP. Reduced Intensity Low Beam (RILB) DRL is not evaluated in this test.

Note: Lamp assemblies with an independent DRL source as an integral part of the assembly shall also be tested to section 4.11.4.8, for the DRL function only. The DRL function is not active during Section 4.11.4.4.

4.11.4.5 Signal Functions. Activate signal functions at 90 flashes 30 flashes per minute with 50% 20% current on-time. Do not flash a red signal function when combined with the stop function or an amber signal when used as a DRL.

4.11.4.6 Fog Lamps. Activate front fog lamp functions as indicated in Figure 2 unless the function is contained within the headlamp. In that case, activate the front fog lamp with the low beam only. For fog lamps combined with DRL activate each function as independent functions.




4.11.4.7 Unswitched Lamps. If a lamp function does not have a switching mechanism that allows the function to be on continuously such as puddle lamps, assist step lamps, etc., then activate the function on and off at the vehicle time out duration at a cycle of 1 h activated and 1 h off. If the vehicle time out duration is not provided, activate the function for 1 minute on and 1 minute off.

4.11.4.8 Dedicated DRL and Stand Alone DRL. Separately test lamp assemblies containing a dedicated DRL (including H15 bulb or other two filament executions) with three pair of unique samples for 23 h on and 1 h off with the DRL activated for 28 days. LED dedicated DRL stand alone lamps are not required to complete this test and shall fulfill the LED Light Source Requirements.

4.11.4.9 Inspections. A visual inspection is required after the first 4 h and then once after every 24 h cycle until complete. Inspect the lamp with functions activated and off. Monitoring can be suspended for a period of up to 72 h to account for weekends. Document the onset of visual incidences, contact the GM Validation Engineer and GM Designing Engineer, and continue the test the full 12 or 28 days.

4.11.4.10 Perform post-test requirements 4.6.3, 4.6.5, and 4.6.6.

4.11.4.11 Acceptance Criteria. Lamps shall pass post-test requirements specified. No outgassing on dedicated DRLs is permissible.


4.12 Weld Joint and Snap Attach Stress. See Data Sheet A8.

4.12.1 Purpose. To determine if the stress levels within a welded lamp assembly, multi-color lens assembly, and over-molded lens assembly are within acceptable levels. Alternately, to determine if the stress levels within snap attachment features are within acceptable limits when tested in a nominal deflected state.

4.12.2 Equipment.

4.12.2.1 Ethanol.

4.12.2.2 Methanol.

4.12.2.3 Ethyl Acetate.

4.12.2.4 Isopropanol.

4.12.2.5 Reagent Grade Ethanol (>97%).

4.12.3 Sample Size. Two (2) pair of lamps or three samples for each specific test. When testing snap attachment features, two pair of samples or three samples from each tool cavity shall be tested.

4.12.4 Procedure.

4.12.4.1 Lamps require production representative molding stress levels of the bonded materials and production representative bonding between the joints to be tested. Snap features shall be tested in their installed design nominal position and orientation, requiring a mounting plate or fixture. Annealing shall also be representative of the production process with the time and temperature noted in the test report.

4.12.4.2 Solution Preparation. Prepare solutions as follows:

Solution Number 1, 34% ethyl acetate in methanol

Solution Number 2, 50% ethanol in water

Solution Number 3, 50% methanol in water

Solution Number 4, 50% isopropanol in water

Solution Number 5, reagent grade ethanol

4.12.4.3 Apply the applicable solution from Table 4 to the lamp welded joint and/or snap features with a cotton ball, cotton swab, or cheesecloth. Thoroughly saturate the housing, housing and lens joint, entire lens surface, and snap features. Allow to evaporate.

Note: Use a well ventilated area and personal protective equipment to apply solvent in all 4.12 tests.

4.12.5 Acceptance Criteria. Inspect weld joint and/or snap feature for stress cracks on the lens and housing and snap features usually shown in the form of white cracks perpendicular to the weld joint or other feature line. No cracks may form on either the lens or housing within 10 minutes of application.


4.13 LED Light Source Requirements. See Data Sheet A9.

4.13.1 LED Lamp Actuation Cycle.

4.13.1.1 Purpose. To verify the LED lamp assembly meets long-term requirements.

4.13.1.2 Sample Size. Three (3) pair or six samples.

4.13.1.3 Procedure.

4.13.1.3.1 Perform pre-test requirements 4.3.3, 4.3.4, 4.3.5, and 4.3.6.

4.13.1.3.2 Activate lamps at 90 flashes 30 flashes per minute with 50% current on-time for 1 500 000 on activations (approximately 12 days duration).

4.13.1.3.3 Lamps designed to function with dual current shall be tested with 20% of activations at high current, and 80% at low current values.




Table 4: Weld Joint Stress Test Solutions by Lamp Material

4.13.1.4 Acceptance Criteria.

4.13.1.4.1 Lamps shall pass post-test requirements 4.6.3, 4.6.4, 4.6.5, and 4.6.6.

4.13.1.4.2 All circuitry shall function; all LEDs shall function with no more than 25% change in photometric output.

4.13.1.4.3 Record All Results per 3.5.

4.13.2 LED Continuous Activation.

4.13.2.1 Purpose. To determine the photometric degradation of the lamp system after long-term continuous activation conditions.

4.13.2.2 Sample Size. Three (3) pair or six lamp samples.

4.13.2.3 Procedure.

4.13.2.3.1 Perform pre-test photometric testing 4.3.4.

4.13.2.3.2 Set ambient temperature to 23 C 5 C.

4.13.2.3.3 Activate light source and circuit assembly.

4.13.2.3.4 Activate for 2000 h continuously without interruption.

4.13.2.3.5 Perform post-test photometric testing per 4.6.4.

4.13.2.4 Acceptance criteria. All circuitry shall function; all LEDs shall function with no more than 25% change in photometric output.


4.14 Condensation for Lamps with Oleophobic Membranes. See Data Sheet A10.

4.14.1 Purpose. To determine if condensation will form inside a lamp after exposure to high humidity and temperature change conditions with water spray. This procedure is applicable to lamps with and without anti-fog coating applied to the interior surface of the lens. Lamps with anti-fog coating shall be tested with and without the coating applied.

4.14.2 Equipment.

4.14.2.1 DC power supply capable of 12 V to 16 V DC.

4.14.2.2 Forty eight (48) h timer.

4.14.2.3 Dual water spray and thermal chamber(s) capable of temperatures from 20 C to 85 C with circulating air and humidity levels of 50% to 100% relative humidity (RH) on one half of the chamber.

4.14.2.4 Water spray capability from simple shower manifold to deliver a solid conical spray at approximately 18 L/minute at 3 bar and capable of temperatures from 15 C to 25 C.

4.14.2.5 Baffle to separate front and rear environments of the lamp.

4.14.3 Sample Size. Two (2) pair or three (3) samples. If initial samples include anti-fog coating an additional two (2) pair or three (3) samples without anti-fog coating are required.

4.14.4 Procedure.

4.14.4.1 Pre-condition the test lamp at 80 C 2 C and




4.14.4.2 Cool to ambient temperature, re-install bulbs and bulb access covers and mount the lamp in the thermal chamber in vehicle position; pre-conditioned at 20 C 4 C and 70% 10% RH on the back side of lamp. The front side environment shall be at 20 C 4 C and 75% 25% RH. Install a baffle around the lamp to separate the front and rear of lamp. Pre-condition the lamp for at least 24 h.

4.14.4.3 For headlamps, fog lamps, and other lamps mounted to the front of the vehicle only: Increase ambient temperature of the back chamber at > 2 C per minute to 80 C 2 C and 10% 5% RH until the ambient temperature reaches 80 C. Activate all functions mechanized with low beam and begin continuous spray of the lamp lens, uniformly across the lens surface.

4.14.4.4 For rear lamps, side lamps, and other lamps not mounted to the front of the vehicle: Increase ambient temperature of the back chamber at > 2 C per minute to 50 C 2 C and 10% 5% RH until the ambient temperature reaches 50 C. Activate the lamp functions that draw the highest wattage per the vehicles mechanization. Activation shall be approved by the responsible GM Engineer. If a turn signal is part of the lamp assembly, activate it 90 flashes/minute with a 50% 2% current on time. Begin continuous spray of the lamp lens, uniformly across the lens surface.

4.14.4.5 Continuously monitor the lamp for the formation of condensation.

4.14.4.6 Record the time duration to form condensation from the start of water spray. Record ambient conditions on the front and back side of lamp.

4.14.4.7 After 60 minutes, shut off water supply and turn off lamp functions. With an indelible marker, mark the areas where condensation is visible on the lens or interior surfaces of the lamp, if condensation is present. Photograph the marked areas. Attach labeled photographs to the test data sheet for each sample.


4.14.5.1 Lamps shall pass post-test requirements 4.6.3, 4.6.5, and 4.6.6.

4.14.5.2 The time to form visible condensation shall be greater than 20 minutes. If the production intent design includes anti-fog coating and the test sample is tested without the anti-fog coating, the time to form visible condensation shall be greater than 15 minutes.


4.15 High Humidity Environments. See Data Sheet A11.

4.15.1 Purpose. To determine if the lamp is resistant to extended humidity exposure.

4.15.2 Sample Size. Two (2) pair or three (3) samples.

4.15.3 Equipment. Thermal chamber capable of temperatures from 20 C to 50 C with circulating air and humidity levels of 50% to 97% RH.

4.15.4 Procedure.

4.15.4.1 Perform and pass pre-test requirements in 4.3.3, 4.3.5, and 4.3.6.

4.15.4.2 Test to GMW14729, 97% 3% RH exposure at 40 C for 240 h with all bulbs and bulb access covers removed. After the test, install all service gaskets and covers, and store the samples for 24 h at +70 C 3 C, 10% 5% RH.


4.15.5.1 Lamps shall pass post-test requirements 4.6.3, 4.6.5, and 4.6.6.

4.15.5.2 No test samples shall show any dripping moisture or any degradation of aluminized components.

4.16 High Pressure Water. See Data Sheet A12.

4.16.1 Purpose. To verify the seal integrity of externally mounted lamps whose rear components extend into the interior of the vehicle.

4.16.2 Sample Size. Two (2) pair or three (3) samples.

4.16.3 Procedure.

4.16.3.1 Perform and pass pre-test requirements 4.3.3, 4.3.5, and 4.3.6.

4.16.3.2 Test body-sealed lamps to the requirements of GMW3172 IPX9K installed in vehicle orientation with a test distance of 300 mm. Lamps shall be mounted to a fixture which represents a nominal body sealing condition.

4.16.4 Acceptance Criteria. No ingress of water into the body cavity or lamp assembly is permitted. Lamps shall pass post-test requirements 4.6.3, 4.6.5, and 4.6.6.

4.17 Leak Check for Production Processing Determination. See Data Sheet A13.

4.17.1 Purpose. To determine the LTP and Pressure Decay Rate (PDR) parameters for the production samples during the production process.

4.17.2 Equipment.

4.17.2.1 Pressure system capable of delivering air pressure from 0 kPa to 70 kPa in 1.75 kPa increments.




4.17.2.2 Mass Flow equipment capable of measuring a decay rate accurate to 1 Standard Cubic Centimeter per Minute (SCCM) at the above pressures.

4.17.3 Sample Size. Fourteen (14) samples are required for LTP determination and 30 samples for the PDR.

Note: Forty four (44) unique samples are required. Do not reuse samples.

4.17.4 Procedure.

4.17.4.1 Determine minimum pressure failure limit for each lamp. All samples shall be fully production representative and include all boots, sockets, sealing grommets, etc., with all adhesives cured. Body sealed lamps shall be mounted to a rigid fixture using production mounting features and fasteners, only. The lamp seal to fixture interface shall represent the nominal seal surface. The fixture shall be sealed at all joints and surfaces where the body sealed lamp does not mount and also allow for lamp pressurization through a sealed port.

4.17.4.2 Install all mating electrical connectors and pressurize the lamp the same way the production facility will test it.

4.17.4.3 Guidelines for Pressurization Techniques.

4.17.4.3.1 Use the vent opening to pressurize the lamp.

4.17.4.3.2 If the lamp has multiple vents, use one of the vents for pressurization and plug the other openings.

4.17.4.3.3 If the lamp has no vents, remove the bulb socket or connector and pressurize through that opening.

4.17.4.4 Submerse the lamp completely under 2.5 cm of water and pressurize in 1.75 kPa increments below 10.5 kPa and 3.5 kPa increments above 10.5 kPa. Dwell for a minimum of 1 minute at each increment until a leak is detected.

4.17.4.5 Leak Definition. A leak is any visible bubble under water or trail of bubbles emanating from the lamp assembly. Bubbles emanating from a wire harness lead at the connector shall not be considered a leak if the connection is made inside the vehicle.

4.17.4.6 Record the pressure failure limit and leak locations for each lamp.

4.17.4.7 Statistically determine using normal distribution analysis the 3 (three standard deviations) pressure leak Lower Control Limit (LCL). Statistically, this is the maximum lamp

pressure that will not exceed its pressure failure limit.

4.17.4.8 The LTP is 80% of the LCL calculated above. The LTP shall be at least 7.0 kPa. Any pressure above 28.0 kPa shall be tested at 28.0 kPa.

4.17.5 Pressure Decay Rate (PDR) Determination.

4.17.5.1 Measure all decay rates in Standard Cubic Centimeters per Minute (SCCM) using a Mass Flow Decay system with a minimum stabilization time of 10 s.

4.17.5.2 During a production representative run of the lamp, measure the PDR of each lamp at the LTP determined in 4.17.4.7.

4.17.5.3 After the run, verify each lamps seal using the 2.5 cm test specified in 4.3.3. If the adhesive is not totally cured during the production process, also measure the PDR of each lamp at the LTP determined in 4.17.4 with the adhesive fully cured.

4.17.5.4 Statistically determine using normal distribution analysis the 3 (three standard deviations) maximum PDR Upper Control Limit (UCL) which can occur without the lamp leaking. This PDR shall be used during the production process.

4.17.5.5 Also, calculate the minimum PDR LCL for the same lamps. If during production, the mean of accepted parts drops below the calculated PDR LCL, recalibration of the PDR is required. In all cases the PDR shall be < 35 SCCM at 7.0 kPa.

4.17.6 LTP and PDR. The LTP from 4.17.4.7 and the PDR from 4.17.5.4 are the parameters that shall be used to set up the production leak test equipment. The Supplier shall determine the specific fill time, stabilization time, and test time based on repeatedly being able to measure a lamp's leak rate.

Note: The adhesive may not be totally cured when leak tested in the production process. If a lower LTP than determined in 4.17.4.7 is necessary, demonstrate there is correlation between the uncured LTP and PDR to the LTP determined in 4.17.4.7 and the PDR determined in 4.17.5.4. The GM Validation Engineer and GM Designing Engineer and supplier quality engineer shall approve this correlation.

4.18 HID Component Ignition Reliability. See Data Sheet A14.

4.18.1 Purpose. This test verifies high intensity gas discharge igniter assemblies reliability under extreme temperatures.




4.18.2 Sample Size. Seven (7) pair or 14 HID igniter assemblies.

4.18.3 Procedure.

4.18.3.1 HID High Temperature Test. Pre-soak igniter assemblies at 100 C 3 C for 2 h. Activate as in Table 5, eight times sequentially for a total of 16 h at 100 C 3 C, monitoring for correct ignition throughout.

4.18.3.2 HID Low Temperature Test. Pre-soak the same igniter assemblies at -40 C 3 C for 2 h. Activate as in Table 5, eight times sequentially for a total of 16 h at -40 C 3 C, monitoring for correct ignition throughout.

4.18.4 Acceptance Criteria. Lamps shall pass post-test requirements 4.6.6.

Table 5: HID Ignition Cycling Activation Times

On time (seconds)

Off time (seconds)

1200 12

480 300

300 180

180 180

120 180

60 180

30 180

18 18

1200 282

1200 900

4.19 Adaptive Forward Lighting and Dynamic Headlamp Leveling System.

If a headlamp is so equipped, requirements and methods of GMW14570, GMW14571, and GMW14572 apply. Complete tests in this section in the order defined. See Data Sheet A15.

4.19.1 Mechanical Fatigue Test Procedure.

4.19.1.1 High Temperature Degradation. Conduct this test on an Adaptive Forward Lighting (AFL) and/or Dynamic Headlamp Leveling (DHL) lamp module, bracket and motor system according to test methods of GMW3172 and the environmental codes defined in the respective specification document. The test period is 2000 h at the maximum operating temperature of the headlamp. During and after the test, functional status classification A is required. AFL and DHL

operation shall be from the full inboard to full outboard positions for a total number of movements equal to 10% of total movements required during the Component Reliability Test defined in 4.19.3.

4.19.2 AFL/DHL Component Mechanical Shock. Conduct this test according to test methods of IEC 60068-2-27 Ea or as included in GMW3172. Use samples tested to High Temperature Degradation, only. With the mechanism securely mounted in vehicle orientation, apply successive shocks in each direction of the three principle perpendicular axes for six directions total. See Table 6.

Table 6: Mechanical Shock Parameters

Description Test

Acceleration 25G

Nominal shock duration 10 ms

Nominal shock shape Half sine

Total number of shocks 400 6 = 2400

4.19.3 Component Reliability Requirements and Test Procedure. The reliability requirement is R97/C50 (97% reliability with 50% confidence). Test seven pair or 14 lamp assembly samples to two lives (8 000 000 movements/life or approximately 14.7 weeks/life) for success-based testing. Use Figure 3 for the required swivel range or the respective part drawing. A 0.5 s dwell follows each movement. Repeat the 40 s cycle continuously. If the operating angle extremes are different than shown in Figure 3, use a proportionally similar 40 s cycle approved by the GM Validation Engineer and GM Designing Engineer.

4.19.3.1 AFS/DHL Combined Movement Requirements.

4.19.3.1.1 All lamp illumination functions are off during this test.

4.19.3.1.2 Test 10% at 100 C; 10% at -30 C; 80% at 25 C.

4.19.3.1.3 Test 25% of AFS movements with maximum DHL movements, 25% of AFS movements with two-thirds () maximum DHL movements, 25% of AFS movements with one-third () maximum DHL movements, and 25% of movements with no DHL movement. See Table 7. Test complete table, then repeat, if time allows.




4.19.3.1.4 Measure accuracy in degrees to the nominal (photometric) position and response time every 1.0 million cycles. Systems designed to interface with vehicle Local Interconnect Network (LIN) shall also be tested and monitored for functionality using the corresponding AFS/DHL electronic control module. LIN communication shall be replicated in the test setup and used to control movements and diagnose potential incidents.

4.19.3.1.5 Calculate reliability at 8.0 million movements with Weibull analysis of failure data.

4.19.3.1.6 Test to failure or stop when schedule requires. At least one life is required. Two (2) lives are preferred. If no failures, use degradation analysis to predict when accuracy or response time would have reached an unacceptable value. Apply Weibull analysis to the predicted degradation to estimate reliability at 8.0 million movements.

4.19.3.2 DHL (no AFS) Movement Requirements.

4.19.3.2.1 All lamp illumination functions are off during this test.

4.19.3.2.2 Test 10% at 100 C; 10% at -30 C; 80% at 25 C. See Table 7, DHL System Only cycles. Test complete table, then repeat, if time allows.

4.19.3.2.3 Measure accuracy in degrees to the nominal (photometric) position and response time every 1.0 million cycles. Systems designed to interface with vehicle LIN shall also be tested and monitored for functionality using the corresponding AFS/DHL electronic control module. LIN communication shall be replicated in the test setup and used to control movements and diagnose potential incidents.

4.19.3.2.4 Calculate reliability at 8 millio

GMW14906Feb2012.pdf

Documents

Transcript of GMW14906Feb2012.pdf