Hainan Automobile Test Site - Automated Product Reliability Test Procedure

Hainan Automobile Test Site

Automotive product stereotype reliability test procedures

(Trial)

1 subject content and scope of application

This standard stipulates the test conditions, test procedures, driving specifications, inspection items and reliability evaluation of the automotive products in the Hainan Automobile Test Site.

This standard applies to all types of cars with more than 13t axles.

2 reference standard

General rules for GB/T12534 automotive road test methods

3 terms

3.1 Bus Class A

The total length of the vehicle is more than 3.5m. The main assembly is specially designed or used for the passenger car of the fixed assembly or the chassis of the unformed passenger car.

3.2 passenger car B

The total length of the vehicle is more than 3.5m, and the passenger car with the designed chassis is selected.

3.3 Car C

A car with a displacement of more than 1L.

3.4 sedan class D

A car with a displacement of less than or equal to 1L.

3.5 micro-customer

Passenger cars with a total length of less than or equal to 3.5m.

3.6 micro-goods

A truck with a maximum total mass of less than or equal to 1.8t.

3.7 mini car

The general term for micro-customers and micro-goods.

3.8 all-wheel drive car

Refers to an all-wheel drive vehicle designed for civilian purposes.

3.9 Light Truck I

Light-duty trucks with a maximum total mass of more than 2.5t.

3.10 Light Truck II

Light-duty trucks with a maximum total mass of less than or equal to 2.5t.

4 test conditions

4.1 Test road facilities and environment

For the test road facilities and environment, please refer to Appendix A, “Automobile Test Road Facilities and Environment of Hainan Automobile Test Site”.

4.2 test sample car

The number of test vehicles and their test implementation conditions shall comply with the provisions of the corresponding model test procedures and prepare the test vehicles in accordance with GB/T 12534.

4.3 Testers

The tester shall consist of the person in charge of the test, the technician, the driver of the car and the repairman. The tester shall correctly understand and master the procedures and conduct test operations as required.

4.4 Test main instruments

Drive recorder, engine tachometer, front wheel locator, ground balance, point thermometer, integrated weather meter, stopwatch, computer, etc.

5 test mileage and mileage distribution

5.1 Basic vehicle reliability The total mileage of driving test (excluding running-in mileage) and mileage distribution are shown in Table 1.

Table 1 Total mileage and mileage distribution of basic vehicle test

Serial number

Test road category

Mileage (km)

truck

Off-road

car

bus

car

miniature

car

A

B

C

D

1

General road

4000

4000

4000

3000

4000

4000

4000

2

Mountain road

6000

6000

5000

2000

4000

3000

4000

3

high way

12000

8000

15000

5000

18000

15000

12000

4

Strengthen bad road

(including steep slope)

8000

(1000)

9000 (1000)

6000

(1000)

5000

4000 (500)

3000

(500)

3000

(500)

5

Cross country road

3000

6

total

30000

30000

30000

15000

30000

25000

22000

Note: 1. The mountain road mileage of the articulated bus and double-decker bus is incorporated into the general road mileage.

2. All-wheel drive vehicles shall refer to the corresponding vehicle regulations, and the total mileage shall include a certain all-wheel drive mileage.

5.2 variant car (including chassis)

5.2.1 The total mileage of the reliability test of the modified vehicle (excluding the running-in mileage) and the mileage distribution are shown in Table 2. The mileage of the modified car on various roads does not exceed the mileage of the corresponding road of the basic car.

5.2.2 The total mass or axle load mass is increased by more than 5%, but not more than 10% (including 10%) according to the modified type, and more than 10% is treated according to the basic type.

The change items not listed in Table 2 can be referred to for execution.

Table 2 Total mileage and mileage allocation of modified car test

Serial number

Improve the appearance

Mileage (km)

Mountain area

highway

Strengthen bad road

(including steep slope)

high speed

track

total

1

bus

5000

3000

8000

Micro-customer

2500

2500

5000

2

Truck change cab

(not including local changes)

truck

5000

3000

8000

Micro-customer

2500

2500

5000

3

Truck change container

(does not include partial improvements)

truck

3500

1500

5000

Micro cargo

2500

2500

5000

4

2000

2000 (200)

3000

7000

5

3500

500 (500)

3000

7000

6

5000(500)

2000

7000

7

3000

1000

3000

7000

8

3000

3000(500)

1000

7000

9

4000

2000 (200)

6000

10

1000

5000

1000

7000

11

2000

7000

1000

10000

2000

5000

1000

8000

12

3000

5000

8000

13

2000

5000

7000

14

2000

5000

7000

5.2.3 If the variant car structure has more than one change listed in Table 2, the longest mileage of each road is combined.

5.3 special car

Special vehicles shall be implemented according to their structural characteristics and conditions of use with reference to Table 1, Table 2 or in accordance with relevant standards.

6 test procedure

6.1 The driving test shall be carried out in the order of general road → mountain road → high speed runway → enhanced bad road → off-road road. High-speed runways and intensive bad roads can also form a small cycle.

6.2 Strengthening the bad road is divided into four lanes. The applicable models and lengths are shown in Table 3.

Table 3 lanes applicable models and length

Lane

name

Applicable lane

Length (m)

Strengthen bad road

Connecting the road

Total length

One

number

car

Road

Heavy truck, heavy duty

Off-road vehicle, heavy duty

Dump truck, heavy duty

Traction car

5715

2225

7940

two

number

car

Road

Medium truck, medium sized

Off-road vehicle, medium-sized

Dump truck, medium-sized

Traction car

5715

2225

7940

three

number

car

Road

Light car I, light

Off-road vehicle, light

Dump trucks, large and medium passenger cars

4493

1592

6085

four

number

car

Road

Light truck II, air-suspended passenger car, light passenger car, various types of cars, mini cars

4140

1210

5350

7 driving specifications

7.1 General Highway

The car is driven under normal operating conditions.

7.2 Mountain Road

On the prefecture of the Haishu Middle Line, the road is driven at a relatively fast speed, and the uphill gear is not limited. In principle, the downhill slope is driven at a higher gear than the uphill slope. Service brakes, vehicles with exhaust brakes or auxiliary brakes should use exhaust or auxiliary brakes normally.

7.3 high speed runway

On the high-speed runway of Hainan Automobile Test Site, the average speed of the car is not less than 90% of the maximum designed speed, but not more than 140km/h. The maximum speed of the curve is no more than 140km/h. The duration of each driving is not less than 1.5h.

7.4 Strengthening bad roads

7.4.1 In the enhanced bad road of Hainan Automobile Test Site, the test vehicles will cycle according to the prescribed lanes. The average speed and the reference speed of various typical roads are shown in Table 4. The road speed without the specified speed is not limited.

7.4.2 During the steep slope driving, the test vehicles are respectively 20% slope on the lowest gear and 16% slope on the lower low gear. There is a sign at the middle of the ramp. Use the parking brake to release the service brake. After that, start to drive.

7.4.3 During each cycle, the test vehicle shall stop braking at the initial speed of 30km/h on the specified road section, and then continue to drive.

7.4.4 During each cycle, the test vehicle turns on the turn indicator or honk on each designated section.

7.4.5 After the end of each shift, the test vehicle will drive 20m at the designated location.

Table 4 Average speed and typical road reference speed km/h

Lane name

Stone road

Twisted road

Pebble road

Seesaw road

Fish scale pit road

Wave road

Stone road

Stone road

level

All

car

speed

A

B

C

A

B

C

A

B

C

A

B

First lane

twenty four

26

30

10

20

40

40

30

30

26~32

Second lane

twenty two

twenty four

30

10

20

40

40

30

30

28~36

Third lane

twenty four

45

10

52

55

44

32

38

40

32~42

Fourth lane

48

15

52

55

42

32

38

38

32~50

7.5 off-road road

When driving off-road vehicles on off-road roads, there should be a certain amount of mileage to engage the front sedan. And at a faster speed, under safe conditions.

7.6 All the mileage driving in the test site should be turned on.

7.7 During the entire driving test, the car shall not slide in the neutral position.

8 load

8.1 In the reliability driving test, if there is no special regulation, the loading quality is in accordance with the provisions of GB/T12534, the test vehicle is in the factory to determine the maximum total mass state, and the axle load quality meets the requirements of the instruction manual.

8.2 For vehicles that can be towed by the design task book, if conditions permit, they should consider a certain proportion of towing trailer mileage when driving on mountain roads, but not more than 50%.

9 inspection items

9.1 During the reliability driving test, the vehicle shall be inspected and maintained according to the regulations, and the vehicle stopping time and inspection and maintenance working hours shall be recorded.

9.2 During the reliability driving test, all faults shall be recorded in detail, including fault mileage, mode, troubleshooting measures, and fault shutdown time, and troubleshooting work hours.

9.3 During the reliability driving test, the mileage, time, fuel consumption and oil consumption are recorded according to different working conditions.

9.4 After the reliability driving test is completed, the main inspection assembly of the automobile may be disassembled according to the situation, and the obvious abnormal situation shall be handled according to the fault and included in the reliability evaluation.

10 reliability evaluation

10.1 Statistical analysis of faults.

According to the fault statistics table.

10.2 Reliability Evaluation Indicators

a, mean time between failures (MTBF);

b, inherent validity (A);

c, equivalent failure rate (D);

10.3 Reliability Statistics Indicators

d, mean fault repair time (MTTR);

e, average first fault mileage (MTTFF).

The fault statistics table and the calculation methods of each reliability evaluation and statistical indicators are shown in Appendix B.

Additional information:

This standard was proposed by China National Automotive Industry Corporation.

This standard is under the jurisdiction of the National Automotive Standardization Technical Committee.

This standard was drafted by Hainan Automobile Test Institute

The main drafters of this standard: Tan Gan, Mai Ruili, Gong Hongbing

Appendix A

Hainan Automobile Test Site Automotive Test Road Facilities and Environment

(Supplementary)

A1 range

Automobile test road facilities refer to various road surfaces and building facilities directly related to vehicle driving test, and do not involve instruments and auxiliary facilities for testing in road tests; environmental introduction refers to general natural conditions and meteorological data such as temperature and humidity. .

A2 car test road facility

The vehicle test road facility is divided into two parts: the reliability test road and the special test facility.

A2.1 Reliability Test Road

A2.1.1 High-speed ring test track (hereinafter referred to as high-speed runway)

The high-speed runway is in the form of a telephone receiver with a circumference of 6.042m. It consists of a straight section, a main curve section, a continuation curve section and a reverse curve section. The plan view is shown in Figure A1. The straight section has a roadbed width of 20m, a concrete pavement width of 7.5m, a length of 2.200m, and a longitudinal slope of less than one thousandth. The main curve segment at both ends has a radius of gyration of 150m and a lateral maximum slope of 43. The curve design has a maximum speed of 160km/h. The high-speed runway is suitable for high-speed continuous driving reliability assessment of various vehicles, and its straight line segment can also be used for various vehicle performance test projects.

A2.1.2 Rugged and intensified bad road (hereinafter referred to as strengthening bad road)

This road is specially built to meet the needs of rapid test of vehicle reliability. There are 13 types of typical roads with 27 parameters (excluding wading roads, salt water roads, and passing roads). The steep slope is mainly composed of standard ramps, which are both the intensified test pavement and the special test ramp. The names, lengths and widths of various pavements are shown in Table A1, and the floor plan is shown in Figure A1. The entire intensive road is designed according to the natural terrain, which is always 8,995m, of which 84% is fixed road and 16% is non-fixed road (sand road). In the total length, the weak road length is 63645m, accounting for 71%; the connecting road surface (asphalt road and concrete road) is 2630m long, accounting for 29%. Except for the steep slope road, the relative height difference of the strengthened bad road is 12.8m, the average slope is 2.8%, and the maximum slope is 15.8%. There are 15 corners with an average of 2 bends per kilometer and a minimum turning radius of 19m.

The intensive bad road is divided into four lanes, and its specific composition is as follows:

Lane 1: Start → Stone Road (A) → Stone Road (C) → Wave Road → Steep Road → Shatu Road → Fish Scale Road → Pebble Road (C) → Stone Road (B) → Cement Road → Beach Road (A) → Shishi Road → Shiban Road → Twisted Road → Asphalt Road → Yanban Road (A) → Pebble Road (A) → End point, a total length of 7,940 meters. Among them, the intensive roads accounted for 72%, and the connected roads accounted for 28%.

Lane 2: Change the pebble road (A) in the first lane to the pebble road (B), the rest are the same.

Lane 3: Starting Point→搓板路(B)→石块路(C)→Wave Road→Steep Road→Shatu Road→Fengxiankeng Road→ Pebble Road(C)→Shibang Road(B)→Cement Road→Beach Road (B) → Shishi Road → Shiban Road → twisted road (B) → asphalt road → end point, a total length of 6085 meters. Among them, 74% of the roads were strengthened and 26% were connected.

Lane 4: Start → 搓板路 (B) → Stone Road (C) → Wave Road → Steep Road → Shatu Road → Yucaikeng Road → Pebble Road (C) Shishi Road → Shiban Road → Twisted Road (C) → Asphalt road → end point, the total length is 5350 meters. Among them, 77% of the roads were strengthened and 23% were connected.

A2.1.3 Mountain road

The mountain road uses the Haitang midline (224 National Road) to cross the Atoling section of the altitude of 670m. The section is located between the 190-kilometer-long Maoyang Town and the 215-kilometer Tongshi City, with a total length of 25 kilometers and an asphalt pavement width of 6~7m. There are more than 150 corners on the road. Among them, there are 53 sharp bends and more than 10 bends, with an average of 6 bends per kilometer. The northern slope has a length of 14.1 km, a maximum slope of 9.6%, an average slope of 4.0%, a southern slope of 10.9 km, a maximum slope of 3,7%, and an average slope of 3.4%. The schematic diagram of the slope of the mountain road is shown in Figure A2.

A2.1.4 General road

The general road selects the Haitang East Line (223 National Road) Qionghai to Xinglong Section, with a length of 100 kilometers and asphalt pavement. The road section is wide and relatively straight, with a maximum slope of 4.0% and an average slope of less than 1.2%.

A2.1.5 off-road road

Off-road roads are made up of rugged and complex terrain such as hillsides, wilderness, sand, mud pits and shrubs. According to the test requirements, cyclic travel with different mileage can be formed.

A2.2 special test facility

A2.2.1 standard ramp

It consists of five kinds of ramps: 10%, 16%, 20%, 30%, 40%. The standard ramp width is 8m, and the lengths are 135m, 25m, 40m, 45m and 30m respectively. The total length of various ramps and their connecting roads is 1020m. In addition to performance tests such as car climbing ability and parking capacity, the ramp can also be used to connect the four ramps with the rugged and intensified bad roads to form a steep slope for the drive train, brake system and engine of the car. Reliability test.

A2.2.2 Passive test road

The pass-through test road with a total length of 200m is composed of wading roads, vertical obstacles, road trenches and trenches. It is a special facility for measuring the terrain passing ability of off-road vehicles.

A2.2.2.1 wading road

The wading road is divided into two types, A and B. The dimensions are 50x3.8x1m3 (length x width x height). The maximum water depth of the wading road is 0.8m. The maximum water depth of the wading road is 0.6m. The water depth is appropriately adjusted for the size and purpose of the test. It can be used to assess the inhalation of water in the car air filter, the infiltration of water in the components, the leakage of the body, and the strength of the fan. Also used for vehicle brake wading decline test.

A2.2.2 Vertical obstacles

Vertical obstacles are available in front side 900 and beveled 450. The top is made of a replaceable cross-beam structure that can be adjusted in height. Used to determine the ability of off-road vehicles to climb obstacles.

A2.2.2.3 Road ditch

The road ditch has a depth of 1.4m and a width of 8.4m, which is composed of 36.5% and 27% of the slopes. It is used to verify the adaptability of the off-road car's approach angle and departure angle.

A2.2.2.4 trench

The distance between the gully and the bank can be adjusted, and the adjustment range is 35~80cm. The ability of the off-road vehicle to cross the maximum gap without support can be measured by the gutter unit.

A2.2.3 Handling Stability Test Square

The steering stability test square has a total area of ​​20,000 m2 and a cement concrete structure. The longitudinal direction of the square is 300m long and the high-speed test track is inlaid. The slope is less than 0.1%, and the maximum cutting speed of the car is 120km/h. With a maximum lateral width of 100m and a slope of less than 0.3%, the square is a necessary facility for vehicle steering, steering, tire and suspension performance tests, and is a good venue for automotive characteristic parameters, noise and radio interference measurements.

A2.2.4 shower room

The space size of the shower room is 14.7x4.4x6.3 (length x width x height) m3, and the rain test equipment is configured according to the national standard. The top and rear rain nozzles are adjustable in height (long) to meet the requirements of various types of vehicles for rain sealing test.

A2.2.5 Dust hole

The dust hole space is 60x12x5.5 (length x width x height) m3. Natural materials with better temperature resistance are used as dust particles. The specifications and proportions of dust particles are strictly in accordance with relevant international standards. It is a special facility for the dust-tightness test of automobiles with stable test conditions and strong comparability.

A2.2.6 brine tank

The size of the brine tank is 30x6.4x0.4 (length x width x height) m3, the depth of the brine is easy to adjust, the deepest can reach 0.3m, and the brine concentration in the tank is kept within the range of 3%~5%. This tank is mainly used to assess the corrosion resistance of the car chassis, body and electrical appliances. The tank can also be connected in series with the enhanced bad road to become a salt water road for assessing the corrosion resistance of the vehicle in the reliability and durability test of the automobile.

A3 general natural conditions

The Hainan Auto Test scene is located in Qionghai City, Hainan Province, with a geographical position of 19014'57" north latitude and 110°26'13" east. The geographic location and traffic map are shown in Figure A3. Here, the sun has strong radiation, high temperature, relatively high relative humidity, abundant rainfall, and no obvious four seasons in a year. It is a typical wet tropical climate. The annual average temperature is 23.9 °C, the highest temperature in the hottest month is 33.9 °C, and the average temperature is 24.9 °C. The average temperature in the coldest month is 22.6 °C, and the average temperature is 14.5 °C. The average annual rainfall is 2,070mm and the maximum annual rainfall is 3,244mm. The annual average relative humidity is 85%, the annual average sunshine is 2,055 hours, and the annual average solar radiation is 130,047 cal/cm.

Hainan's unique wet tropical climate makes the test site provide services for various automotive tests throughout the year. It also provides an ideal natural test site for rubber parts, plastic parts, plated parts and various paint coatings. .

Table A1 strengthens the length and width of various roads

category

Road name

Length (m)

Width (m)

class

do not

Road name

Length (m)

Width (m)

1

搓板路(甲)

303

3.5

5

Beach Road (A)

50

4.0

搓板路(B)

200

3.5

Beach Road (B)

50

4.0

2

Stone Road (A)

310

3.5

6

Fish scale pit road

310

3.5

Stone Road (B)

303

3.5

7

Stone road

417

6~7

Stone Road (C)

200

3.5

8

Stone road

704

6~7

3

Pebble Road (A)

300

4.0

9

Asphalt road

317

6~7

Pebble Road (B)

30

4.0

10

Sandstone road

1434

6~7

Pebble Road (C)

300

3.5

11

Concrete road

2313

6~7

4

Twisted road (a)

50

3.5

12

Waveform road

84

4.0

Twisted road (B)

50

3.5

13

Steep slope

950

8~12

Twisted road (c)

50

3.5

Cumulative total length: 8995

Note: (1), each road surface in the table constitutes a four-lane enhanced bad road.

(2), the road shape of the fish scale pit road, according to the car track, the parameters are also different.

(3), steep slope route 10%, 16%, 20%, 30% and other four ramps and corresponding connection road and railway

Mouth composition.

Appendix B

Fault statistics and reliability evaluation index calculation method

(Supplementary)

B1 fault classification

Faults are classified according to QCn29008.4.

B2 fault record

B2.1 All faults in the styling test are recorded in detail in Table B1 "Fault Summary Table" in the order in which they appear.

B2.2 If the initial performance or re-test of the basic performance and safety of the vehicle fails to meet the technical requirements or specified indicators, and the retest value is more than 5% lower than the initial test and the technical requirements or specified indicators are not met, a serious fault is recorded; When the retest is reduced between 3% and 5% and the technical requirements or specified indicators are not met, a general fault is recorded. The fault mileage of the retest is the test cutoff mileage.

The obvious abnormal phenomenon during B2.3 dismantling is handled according to the fault, and the fault mileage is the test cut-off mileage.

B3 fault statistics

B3.1 is classified by subsystem according to the fault classification in Table B2 "Fault Statistics Table".

B3.2 The same pattern of the same part of the same part of the failure should be counted separately, but when calculating the reliability evaluation indicators and statistical indicators, only one calculation.

B3.3 induced faults only count one, and the most serious category is taken under normal circumstances.

B4 car maintenance

During the test, the car should be maintained according to the established maintenance card, and the maintenance time and maintenance time should be recorded.

B5 reliability evaluation index calculation

B5.1 Mean Time Between Interval (MTBF)

Nt

MTBF=——

r

among them:

n——Number of test vehicles

t —— test cut-off mileage (km);

r ——The total number of faults in the test vehicle (excluding 4 types of faults, when r=0, calculate by r=1)

B5.2 inherent validity (A)

N

∑U

i =1

A=—————

N

∑(U; G;)

i =1

among them:

U —— the running time of the i-th test vehicle (h);

G —— the sum of the failure time of the i-th test vehicle and the maintenance stop time (h);

N ——The number of test samples.

B3.3 equivalent failure rate (D)

1000 4

D= ——— ∑ε;r;

Nt i =1

among them:

n——Number of test vehicles

T——test cut-off mileage (km);

r——The total number of i-type faults in the test car

Ε——the equivalent failure factor of the i-th fault, the value of which is:

Class 1 fault ε1=100

Class 2 fault ε2=10

Class 3 fault ε3= 1

Class 4 fault ε4= 0.2

B5.4 Mean Time to Repair (MTTR)

r

MTTR=(∑ t;)/ r

i =1

among them:

t ——The ith fault maintenance work (including diagnosis, maintenance, adjustment)

r ——The total number of failures of the test sample car

B5.5 average first fault mileage (MTTFF)

1 n'

MTTFF=——[∑t; (nn')t]

N'i=1

among them:

n —— the number of test samples;

t —— test cut-off mileage (km);

n′——Number of vehicles that have failed (excluding 4 types of faults, when n′=0, calculated by n′=1);

T1——the first fault mileage of the i-th test vehicle (km);

The calculation results of the above indicators are filled in the table B3 "Reliability Evaluation Index Table Summary Table".

Table B3 Summary of Reliability Evaluation Indicators

car model:

project

Test vehicle number

No. 01

No. 02

malfunction

frequency

(times)

Class 1

2 types

Category 3

4 types

First failure mileage (km)

Test cut-off mileage (km)

Test vehicle running time (h)

maintenance

time

Parking time (h)

Working hours (h)

Exclude

Obstacle time

Parking time (h)

Working hours (h)

Table B1 Fault Statistics Table Car Model: Car Number:

Serial number

Subsystem name

Class 1 fault

Type 2 fault

Class 3 fault

Class 4 fault

1 ~ 3 types of faults

Total faults

Equivalent number of failures

Total (times)

ratio(%)

Total (times)

ratio(%)

Total (times)

ratio(%)

1

Engine body

2

Oil supply system

3

cooling system

4

Lubrication system

5

Intake and exhaust system

6

Engine suspension

7

clutch

8

Transmission (including transfer case)

9

transmission shaft

10

Rear axle

11

Front axle (or front axle)

12

Steering system

13