音箱可靠性測試規(guī)范

HARMANINTERNATIONALRELIABILITYTESTPLANforAUTOMOTIVEAUDIOSPEAKER

harmanconsumergroupCentralQualityGroupReleaseDate:2/1/98RevisionLevel:KReleaseDate:2/1/98RevisionLevelDate:03/31/050PurposeThepurposeofthistestplanistodescribetheenvironmentalandfunctionalperformancerequirementstowhichthespeakerwillundergoinordertobevalidated.Theintentofthevalidationprogramistoexposethespeakertoanacceleratedagingprocess.2.0TestPlanThistestplandetailsthetypeoftestsandthenumberofunitsrequiredforeach.ThesamplesizeoutlinedbelowmaychangedependingonReliabilityTarget.TestImplementationThefullqualificationtestprogramconsistsofthegroupslistedbelow.Thisisaparalleltestsequencesuchthateachgroupisrunindependently.Thistestplanmustbeperformedonatleastonememberofa“ProductFamily”.Themostcomplexorhighestpowermodelshouldbechosen.FullQualificationTestSequenceGroupV^/U-U-llLlLJDVPVTestNameSpec.Sect.FunctionalTestNo.RequirementsA26LifeCycle5.14.4and4.5B26PowerTest5.44.4and4.5UVExposureTest5.8ImpactTest5.5C26HumidityTest5.34.4and4.5RandomVibrationTest5.64.4and4.5D2*6PackagingTest(ASTM)5.74.4and4.5ForPackagesupto150lbs(ASTM4169)Handling(Drop),FirstSequenceand4.5CompressionTest(VehicleStackingAssuranceLevelII)and4.5LooseLoadVibrationand4.5VehicleVibrationand4.5Handling(Drop),SecondSequenceand4.5TemperatureTest5.24.4and4.5(1)ForMasterPackShippingOption(ifavailable)5.7.9HumidityStorageTestLooseLoadVibration5.7.3VehicleVibration5.7.4*Ifpackagingisavailable.Note1:Unlessotherwisespecified,allunitsshallbetestedintheorientationthatunitwillbemountedinthecar.Note2:TheperformancelimitsoftheunitsundertestwillbespecifiedintheHCGapprovedEngineeringTestSpecification(ETS)[seeSection6].AbbreviatedQualificationTheabbreviatedtestprogramconsistsofthegroupslistedbelow.Thisisaparalleltestsequencesuchthateachgroupisrunindependently.Thesetestsmustbeperformedonallmembersofa“ProductFamily”notsubjectedtotheFullQualificationfoundinsection2.1.AbbreviatedQualificationTestScheduleGroupTestNameSpec.Sect.FunctionalTestDVPVNo.RequirementsA26LifeCycle5.14.4and4.5B26PowerTest5.44.4and4.5HandlingDropTest5.5C2*6PackagingTest(ASTM)5.74.4and4.5ForPackagesupto150lbs(ASTM4169)Handling(Drop),FirstSequenceand4.5CompressionTest(VehicleStackingAssuranceLevelII)and4.5LooseLoadVibrationand4.5VehicleVibrationand4.5Handling(Drop),SecondSequenceand4.5*Ifpackagingisavailable.Note1:Unlessotherwisespecified,allunitsshallbetestedinthenormalcarmountingorientation.Note2:TheperformancelimitsoftheUUTwillbespecifiedintheEngineeringTestSpecification.3.0StandardTestConditions3.0.1SignalSourceUnlessotherwisespecified,alltestsshallbeconductedwiththeAudioSignalGenerator/Amplifieroutputconfiguredtobebalanced,lessthanorequalto50-ohmsourceimpedance,andfloating.ThesignalsourceGNDshallbeconnectedtothespeakerPWRGNDatthespeaker.3.0.2PositionUnlessotherwisespecified,thespeakershallmeetallrequirementsinthe“normalmountingposition”.ItisdefinedontheProductSpecificationastothehorizontalorverticalpositionofthemountingsurface.3.0.3RoomTemperatureUnlessotherwisespecified,allmeasurementsshallbemadeatroomtemperature.Roomtemperatureisspecifiedas23oC+/-3oC.3.0.4FrequencyRangeThefrequencyrangeisspecifiedfromthe-3dBpointattheupperandloweroperatingrangeofthedriver.ThisrangeandthelimitswithinthatrangeshallspecifiedontheProductSpecification.3.0.5NoiseTheproductsaredividedintothreegroups,fullrange(multi-element),mid-bass,andsubwoofer.ThetypeofproductshallbespecifiedontheProductSpecification.FullRangewillusetrack13ontheCarAudioTestDiscVersion2.0:IECnoisewithacrestfactorof9dB.Mid-basswillusetrack14ontheCarAudioTestDiscVersion2.0:adecadeofpinknoise,50to500Hz(-3dBpoints)12dBslopes,withacrestfactorof9dB.Sub-wooferwillusetrack15ontheCarAudioTestDiscVersion2.0:adecadeofpinknoise,30to300Hz(-3dBpoints),12dBslopes,withacrestfactorof9dB.3.0.6MusicSignalTheproductsaredividedintotwogroups:1)fullrange(multi-element)andmid-bass,2)subwoofer.ThetypeofproductshallbespecifiedontheProductSpecification.FullRangeandMid-bass—track16ontheCarAudioTestDiscVersion2.0:“BeatIt”byMichaelJacksonSub-woofer—track17ontheCarAudioTestDiscVersion2.0:“CrimeStories”byMCHammer4.0FunctionalRequirementsFunctionalrequirementsaretobetestedinaccordancewithanHCGapprovedproductengineeringspecification(ETS).4.0.1PolarizationWiththedriverfacedownandtheterminalfacingtowardyoutheProductSpecificationshallidentifythepositiveterminal,whichshallbelabeledPin1or“+”.Whenapositivepotentialisappliedtothepositiveterminal,theconeshallmoveoutwardfromthebasketproducingpositivepressure.Ref.IEC268-24.0.2DCResistanceEnsurethatthetestleadresistanceisfactoredoutofthismeasurement.ConnectthetestleadstothespeakerandmeasuretheresistanceinohmswithanaveragingohmmetertoensurethatambientnoiselevelsdonotproduceanEMFatthemeteryieldingfalseresistancereadings.TheDCRshallbewithinthelimitsspecifiedontheProductSpecification.4.0.3ImpedanceRigidlysuspendthespeakerfromthemotorstructureinfreeairatleast50cmfromthenearestreflectingsurface.Mountingmeansmustbeminimalinbulksuchthattheairmovementduringtestingissubstantiallyunrestricted.MeasurethedeviationfromtheReferenceSampleSpeakerimpedanceateachofthedefinedfrequencies.ThedeviationatallfrequenciesshallbewithinthelimitsspecifiedontheProductSpecification.4.0.4FrequencyResponseApplyasteppedsinewavesweeporaCaneticssignaloverthespecifiedfrequencyrange,usingthespecifiedfrequencyspacing,withthespecifiedbandwidthsmoothingpertheProductSpecification,andanalyzethemicrophoneoutput.Calibratethemeasurementsystemtodisplaythe1Watt1MeterequivalentsensitivitybasedonZnomasspecifiedontheProductSpecification.DisplaytheSPLandtheFrequencyinISOstandard25dB/decadeaspectratio.Theresultantgraphofamplitudevs.frequencyisdefinedasthefrequencyresponse.MeasurethedeviationfromtheReferenceSampleSpeakersoundpressurelevelateachofthedefinedfrequencybands.ThedeviationatallfrequenciesshallbewithinthelimitsspecifiedontheProductSpecification.ToverifythatnodamagehasoccurredtotheReferenceSampleSpeakerandthatthetestequipmentisfunctioningproperly,thefirstprocessshallbetotesttheReferenceSampleSpeakeragainstthestoreddatafromthepreviousproductionruns.Ifthereisachangeofmorethanonestandarddeviationatanyfrequency,boththeReferenceSampleSpeakerandtestequipmentshallbere-calibrated.4.0.5ExtraneousNoiseThespeakerassemblyshallnotproduceextraneousnoisewhenadynamictestisperformed.Thefollowingtypesofdeficienciesaresometypicalcausesofextraneousnoise:Buzz:Anynoiseproducedbyaloosenessofcomponentsvibratingagainstothercomponents.Rub:Anynoiseproducedbythevoicecoilslidingorrubbingagainstothercomponents.Bottoming:Thenoiseproducedbythecontactofthemovingsystemwiththespeakerstructure.Rattle:Therandomnoiseproducedbyanobjecttrappedwithinthespeakerstrikingmovingcomponentsoranyintermittentnoisecausedbylooseelectricalconnectionsorcontrols.FrozenCoil:Absenceoffreeexcursioncausedbyadhesiveinthemagneticgaporanoffset(loose)componentofmagneticcircuit.AirNoise:Thenoiseproducedbyhighvelocityairflowthroughasmallleak.5.0QualificationTestingThereliabilitytargetforallcarspeakerproductsiszerodefectsat50,000milesoperation.Successfulcompletionofthetestisintendedtodemonstrate90%reliabilitywith90%confidence.LifeCycleEachspeakershallwithstand5cycles(totaling215hours)oftheenvironmentalconditionsoutlinedbelow.Thespeakersshouldbecheckedonceadayonaregularbasis.Afullfunctionaltestshouldbeperformedonallunitsattheendofthesecondandfifthcycles.LifeCycleCalibrationThesuppliedCarAudioTestDiscVersion2.0facilitatesaccuratetestlevelcalibrationandtestingconsistencybyincorporatingsinewavetesttones(firstthreetracks)thatarecalibratedtothemusictracksspecifiedfortesting.UsingtheRMSnumberfromtheProductSpecificationunderthe“LifeCycle”column,thelevelwillbecalibratedwiththeappropriatetesttone(track1forsubwoofers,track2formidbass,andtrack3formulti-elementfullrange).Thenskiptotrack16“BeatIt”forfullrangeandmid-bassortrack17“CrimeStories”forsubwooferandrepeatforthespecifiedduration.Thelevelofthemusicsignalisalreadycalibratedtothetesttone.(Seegraphonnextpage)(Seegraphonnextpage)Overa30-minuteperiod,raisethetemperatureto40°Cwitharelativehumidityof95%.Stabilizethetemperatureat40°Cwitharelativehumidityof95%for16hours.After6%hours,applythedesignatedmusicsignalat1/8ththespecifiedRMSvoltage(section3.0.6).Attheendofthe16-hourperiod,removethesignal.Overa30-minuteperiod,raisethetemperatureto90°Cwitharelativehumidityof<20%.Stabilizethetemperatureat90°Cwitharelativehumidityof20%for8hours.After3hours,applythedesignatedmusicsignalat1/8ththespecifiedRMSvoltage.Attheendofthe8-hourperiod,removethesignal.Overa30-minuteperiod,lowerthetemperatureto25°C.Stabilizethetemperatureat25°Cfor2hours.Overa30-minuteperiod,lowerthetemperatureto-35°C.Stabilizethetemperatureat-35°Cfor5hours.After2hours,applythedesignatedmusicsignalat1/8ththespecifiedRMSvoltage.Attheendofthe5-hourperiod,removethesignal.Overa1-hourperiod,raisethetemperatureto90°C.Stabilizethetemperatureat90°Cfor5hours.After2hours,applythedesignatedmusicsignalat1/8ththespecifiedRMSvoltage.Attheendofthe5-hourperiod,removethesignal.Overa30-minuteperiod,lowerthetemperatureto25°C.Stabilizethetemperatureat25°Cfor3.5hours.Thisistheendofonecycle.Ref.ChryslerPF950Damp/DryCycling&TemperatureTestRef.ChryslerPF950Damp/DryCycling&TemperatureTestCarProductLifeCycleRef.ChryslerPF950Damp/DryCycling&TemperatureTestRef.ChryslerPF950Damp/DryCycling&TemperatureTestONECYCLE(43hours)Temperature(ONECYCLE(43hours)Temperature(°C)Humidity(%RH)CarLifeCycleFunctionalIntervals3.60daysfor50%functional(2cycles)5.38daysfor100%functional(3cycles)Temperature(Non-Operational)TestEachspeakershallwithstand24hoursofexposureto-35oCand24hoursto90oCinsidetheenvironmentalchamber.Thetestdurationshouldbe24hoursateachtemperaturewithaminimumof4hoursbetweentemperatureconditions.Letthespeakerscooldowntoanormalroomtemperaturebeforeanypost-testevaluationisperformed.Thespeakershouldbetestedattheendofeach24-hourperiod.Ref.ChryslerPF950TemperatureTestHumidity(Non-Operational)TestEachspeakershallwithstandexposureto40oCat95%relativehumidityfor16hours,then90oCat20%relativehumidityfor8hourswith15minutesrampbetweenthetwotemperatureandhumidityconditions.Thisisconsideredonecycle.Thetotaltestis5cycleslongtotaling122hours.Leavethespeakersforaminimumof4hoursatroomtemperaturebeforeanypost-testevaluationisperformed.Ref.ChryslerPF950Damp/DryCyclingOperatingPower(Noise)TestEachspeakershallwithstand100hoursofapplicationofnoisesignalspecifiedinsection3.0.5.Thenoisesignalshouldbecalibratedto100%oftheRMSvoltageratingasspecifiedontheProductSpecification.Leavethespeakersforaminimumof4hoursatroomtemperaturebeforeanypost-testevaluationisperformed.PowerTestCalibrationProcedureThesuppliedCarAudioTestDiscVersion2.0facilitatesaccuratetestlevelcalibrationandtestingconsistencybyincorporatingsinewavetesttones(firstthreetracks)thatarecalibratedtothenoisetracksspecifiedfortesting.UsingtheRMSnumberfromtheProductSpecificationunderthe“PowerTest”column,thelevelwillbecalibratedasfollows:Subwoofer—usetrack1:50Hz0dBMid-bass—usetrack2:100Hz0dBFullrange(multi-element)—usetrack3:1kHz0dBThenskiptotheappropriatenoisetrack(Subwoofer—track15,Mid-bass—track14,Fullrange—track13)andrepeatforthedesignated100-hourdurationofspeakertesting.Thelevelofthetestsignalisalreadycalibratedtothetesttone.NOTE:Theamplifierusedinthetestset-upmustbecapableofslightlyhigherPEAKvoltagethanthelevelrequiredfortesting.Anoscilloscopewillbeusedtoverifytheabsenceofaclippedoutputsignal(whichcouldcausedamagetothetransducerandprematurefailure).Impact(Non-operational)TestEachspeaker(withoutthepackaging)shallwithstandone(1)dropfromaheightof1meterontoaconcretebase.Eachspeakershallbedroppedonceforeachside.Atotalof6unitsareneededtocoverallsix(6)sides.

Eachspeakershallbevisuallyinspectedforanylooseorbrokenpartsandcomponents.Resultsofthetestshouldbetreatedforinformationpurposesonlyandnotpartoftheacceptancecriteria.5.6RandomVibration(Non-operational)TestEachunitshallwithstand2hoursperaxisoftheRandomVibrationoutlinedbelow:Z一AxisBreakpoint(Hz)510602001000Magnitude(G2/Hz)0.00550.059Eachspeakershallbevisuallyinspectedforanylooseorbrokenpartsandcomponents.Resultsofthetestshouldbetreatedforinformationpurposesonlyandnotpartoftheacceptancecriteria.5.6RandomVibration(Non-operational)TestEachunitshallwithstand2hoursperaxisoftheRandomVibrationoutlinedbelow:Z一AxisBreakpoint(Hz)510602001000Magnitude(G2/Hz)0.00550.0590.0350.00070.00004TotalSpectralContent=1.8GrmsY-AxisBreakpoint(Hz)58121000Magnitude(G2/Hz)0.00920.0760.0760.0003TotalSpectralContent=1.685GrmsX-AxisBreakpoint(Hz)5101903701000Magnitude(G2/Hz)0.00540.05120.00270.000230.00023TotalSpectralContent=1.4GrmsPostTestTestunitsshallbevisuallyinspectedforanylooseorbrokenpartsandcomponents,followedbyfunctionaltesting.Ref.ChryslerPF98Vibration5.7PackagingTest(ASTM)ScheduleA—ManualHandling,FirstSequenceForpurposesofthisprocedure,thebottomofasmallparcelisthesurfaceonwhichtheparcelrestsinitsmoststableorientation.Recommendeddropheights,thenumberofdrops,thesequenceofdrops,andtheshippingunitorientationatimpactareasfollows:ShippingWeight,lb(kg)0to20(0to9.1)20to40(9.1to18.1)40to60(18.1to27.2)60to80(27.2to36.3)80to100(36.3to45.4)100to200(45.4to90.7)DropHeight,in.(mm)24(610)21(533)ShippingWeight,lb(kg)0to20(0to9.1)20to40(9.1to18.1)40to60(18.1to27.2)60to80(27.2to36.3)80to100(36.3to45.4)100to200(45.4to90.7)DropHeight,in.(mm)24(610)21(533)18(457)15(381)12(305)10(254)NumberofImpactsAtSpecifiedHeightOnetopTwoTwoOnebottomRef:ASTMD4169—99ImpactOrientation-FirstSequenceofDistributionCycleadjacentbottomedgesdiagonallyoppositebottomcornersPostTestTheunitsshouldbecheckedforfunctionalperformanceandexternalappearanceafterthetest.Noimpairedfunctionorconcealeddamageispermitted.Endpadsmaybecrackedwithnoseparation.Cartonsshouldhavenotearingorde-bondingoftheseamedge.CompressionTest:VehicleStackingAssuranceLevelIIScheduleB-WarehouseStackingandVehicleStackingThistestisintendedtodeterminetheabilityoftheshippingunittowithstandthecompressiveloadsthatoccurduringwarehousestorageorvehicletransport.Theformulacalculatesthecompressiveloadoverthelargestfootprintofthepackageusingashippingdensityfactor.Asafetyfactorisusedtotakeintoeffecttimeinstorage,stackingpattern,variablesincontainerstrengthandatmosphericconditions(temperature,humidity).Thetestistobeconductedbyloadingtheshippingunittothecomputedloadvalue,ascalculatedbelow.Thecompressiveloadistobeuniformlydistributedaboutitslargestfootprint.Removetheloadwithin3secondsafterreachingthespecifiedvalue.Formula:Formula:L=Mf*J*((l*w*h)/K)*((H-h)/h)*FL=MinimumRequiredTestLoad=lborNMf=ShippingCargoDensityfactor=10.0lb/ft3or160kg/m3J=conversionfactor=1lbf/lbor9.8N/kgl=lengthofshippingunit=inormw=widthofshippingunit=inormh=heightofshippingunit=inormK=conversionfactor=1728in3/ft3or1m3/m3H=maximumstackheight=108.0inor2.7mF=factortoaccountforindividualfactorsdescribedabove=7AcceptanceCriteria:NovisibledamageProductintactinternallyPackagingcomponentsabletoprovidefurtherprotectionCompressiontestcannotcausetheoutershippingcontainertocrease,splitortearatthejoint.TestConditioning:73.4oF(+/-2oF)[23oC(+/-1oC)]and50%(+/-2%)relativehumidityinaccordancewithpracticeD4332.Ref:ASTMD4169LooseLoadVibrationMethodA1—RepetitiveShockTestPlacethetestspecimenonthetestmachineplatforminitsnormalshippingorientation.Attachrestrainingdevicestotheplatformtopreventthespecimenfrommovinghorizontallyofftheplatformandtopreventexcessiverockingwithoutrestrictingtheverticalmovement.Adjusttherestrainingdevicestopermitfreemovementofthespecimenofapproximately10mm(0.4in.)inanyhorizontaldirectionfromitscenterposition.Startthevibrationoftheplatformatafrequencyofabout2Hzandsteadilyincreasethefrequencyuntilsomeportionofthetestspecimenrepeatedlyleavesthetestsurface.Toensurethatthetestspecimenreceivesacontinuingseriesofrepetitiveshocks,ashimwitha1.6mm(1/16-in.)thicknessandawidthof50mm(2.0in.)shallbeusedtodeterminewhenthetestspecimenisleavingthetestplatform.Theshimshouldbeinsertedunderthepackageaminimumof100mm(4.0in.)andmovedintermittentlyalongoneentirelengthofthepackage.Continuethetestatthisfrequencyforaperiodof1hour.Thetestmaybestoppedmomentarilytoinspectfordamage.Ifthecontainermightpossiblybetransportedinanyotherorientations,testatleastonecontainerineachpossibleorientationforthefull-specifiedtestduration.Inspectthecontaineranditscontentsandrecordanydamageordeteriorationresultingfromthetest.Ref:ASTMD4169—99,ASTMD999—96ScheduleE-VehicleVibrationPerformthetestforeachpossibleshippingorientation.Recommendedintensitiesanddurationsfortherandomtestsaregivenbelow.RandomTest:Thefollowingpowerspectraldensities(asdefinedbytheirmodeoftransport,frequencyandamplitudebreakpoints)andtestdurationsarerecommended:Air:AssuranceLevelIFrequency,HzPowerSpectralDensityLevel,g2/Hz20.0004TOC\o"1-5"\h\z120.021000.023000.00002Overall,grms1.49Duration,minB180BForvehiclevibrationtestsinmultipleshippingunitorientations,thetotaldurationshouldbedistributedevenlybetweentheorientationstested.Ref:ASTMD4169-99ScheduleA—ManualHandling,SecondSequenceForpurposesofthisprocedure,thebottomofasmallparcelisthesurfaceonwhichtheparcelrestsinitsmoststableorientation.Recommendeddropheights,thenumberofdrops,thesequenceofdrops,andtheshippingunitorientationatimpactareasfollows:ShippingWeight,lb.(kg)0to20(0to9.1)ShippingWeight,lb.(kg)0to20(0to9.1)20to40(9.1to18.1)40to60(18.1to27.2)60to80(27.2to36.3)80to100(36.3to45.4)100to200(45.4to90.7)DropHeight,in.(mm)24(610)21(533)18(457)15(381)12(305)10(254)NumberofNumberofImpactsAtSpecifiedHeightOneTwoTwoOneImpactOrientation-SecondSequenceofDistributionCycleverticaledgeadjacentsidefacesonetopcornerandoneadjacenttopedgethedropshouldbeintheimpactorientationmostlikelyforadroptooccur,usuallythelargestfaceorthebottom.Fordistributioncycleswhereanydroporientationispossible(i.e.,smallparcelenvironment),thisdropshouldbeinthemostcriticalordamage-proneorientation.Ref:ASTMD4169—99PostTestTheunitsshouldbecheckedforfunctionalperformanceandexternalappearanceafterthetest.Noimpairedfunctionorconcealeddamageispermitted.Endpadsmaybecrackedwithnoseparation.Cartonsshouldhavenotearingorde-bondingoftheseamedge.5.7.9MasterPackShippingOption(ifavailable)Thistestisintendedtodeterminetheabilityoftheindividualbeautyboxesinamastershippingcartontowithstandthepotentiallyabrasiveenvironmentthatcouldoccurduringvehicletransportfollowingwarehousestorage.Amasterpackisconsideredtobeatleastsixunitsinalargercarton.Iftheproductmasterpackislessthanthisnumber,thenadditionalmast