ENGINEERING AND TEST DIVISION CHURCH STREET, BOHEMIA, LONG ISLAND, NEW YORK (631)

Transcription

1 DAYTON T. BROWNINC. Founded 1950 ENGINEERING AND TEST DIVISION CHURCH STREET, BOHEMIA, LONG ISLAND, NEW YORK (631) TEST REPORT NO: DBT04R DAYTON T. BROWN, INC. JOB NO CUSTOMER: U.S. AUTO PARTS MANUFACTURER 1410 ANY STREET SOMEWHERE, USA SUBJECT: PRODUCTION VERIFICATION TEST PROGRAM CONDUCTED ON ROOF RAIL AIR BAG MODULES SERIAL NOS PURCHASE ORDER NO.: ATTENTION: PRODUCTION SUPERVISOR THIS REPORT CONTAINS: FIVE PAGES AND EIGHT ENCLOSURES TEST ENGINEER DEPARTMENT SUPERVISOR OPERATIONS MANAGER QUALITY DEPARTMENT P. DOLAN J. BULL J. DOE J.Q. PUBLIC DATE 26 JANUARY 2002 THE DATA CONTAINED IN THIS REPORT WAS OBTAINED BY TESTING IN COMPLIANCE WITH THE APPLICABLE TEST SPECIFICATION NOTED

2 TABLE OF CONTENTS Subject Paragraph Page No. Abstract References Administrative Information Test Program Outline Number Number Enclosures of Pages of Photos (1) Service Durability (Pre) Test and Results 4 1 (2) Heat Age Dry Test and Results 5 1 (3) Storage Test and Results 5 1 (4) Thermal Shock Test and Results 4 - (5) Thermal Humidity Test and Results 6 1 (6) Salt-Spray Test and Results 4 1 (7) Service Durability (Post) Test and Results 4 - (8) A2LA Scope of Accreditation Pg 1

3 1.0 ABSTRACT This test report details the results of the production verification test program conducted on the USA Motor Company Roof Rail Air Bag Modules, under reference (a) to the requirements of reference (c). Results of the tests are detailed in the following text. The test items were nonoperating during testing. The operation of the test items was the sole responsibility of U.S. Auto Parts, Inc. personnel, and all operational data was retained by same. Test data pertinent to this program will remain on file at Dayton T. Brown, Inc. for 90 days. The test results recorded in this report relate only to those items tested. This test report shall not be reproduced, except in full, without the written approval of Dayton T. Brown, Inc Pg 2

4 2.0 REFERENCES (a) Customer Purchase Order No.: (b) Dayton T. Brown, Inc. Job No.: (c) Test Specification: U.S. Auto Parts, Inc. Specification B Pg 3

5 3.0 ADMINISTRATIVE INFORMATION Customer: U.S. Auto Parts, Inc U.S. Highway West Somewhere, USA Test Item Description: Roof Rail Air Bag Modules Quantity Received: 38 Units Serial Nos.: 1-38 Testing Sequence: Service Durability (Pre) Test Heat Age Dry Test Storage Test Thermal Shock Test Thermal Humidity Test Salt-Spray Test Service Durability (Post) Test Date Received: 18 October 1999 Test Performance Dates: 19 October through 30 December 1999 Date Shipped: 3 January Pg 4

6 4.0 TEST PROGRAM OUTLINE Test Test Item Description Results Service Durability (Pre) Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 1. Heat Age Dry Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 2. Storage Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 3. Thermal Shock Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 4. Thermal Humidity Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 5. Salt-Spray Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure 6. Service Durability (Post) Roof Rail Air Bag Modules, Serial Nos Refer to Enclosure Pg 5

7 Enclosure 1 Service Durability (Pre) Test and Results

8 TEST REQUIREMENT The service durability (pre) test shall be conducted in accordance with reference (c). TEST RESULTS A pretest visual inspection of the test items revealed that there were missing screws on the cushion of Serial No. 32. All testing was performed in accordance with the referenced specification. Below are the measurements for the bridge wire resistance, shunt resistance, and insertion forces. All M6 fasteners were torqued to a value of 88 inch-pounds. The test items completed all phases of testing. A post-test visual inspection of the test items revealed no anomalies due to testing Enc 1 Pg 1

9 Electrical Resistance Measurements Service Durability (Pre) Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 1 Pg 2

10 Service Durability (Pre) Test Insertion Forces (lb) Serial No. Trial #1 Trial #2 Trial # Enc 1 Pg 3

11 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: SERVICE DURABILITY (PRE) ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE Push/Pull Scale Chatillon DFGS ±0.15% FS 11/19/ Digit Digital Voltmeter Hewlett-Packard 3456A 9-21 Mfr 7/23/2000 Torque Wrench Proto 6064A ±4% CW 7/30/2000 ±6% CCW Enc 1 Pg 4

12 TESTED FOR U.S. AUTO PARTS, INC. ITEM: ROOF RAIL AIR BAG MODULES TEST ITEM SETUP FOR THE CONNECTOR FORCE INSERTION MEASUREMENT IN THE SERVICE DURABILITY (PRE) TEST JOB NO FILE NO DTB04R ENCLOSURE 1 PHOTO 1

13 Enclosure 2 Heat Age Dry Test and Results

14 TEST REQUIREMENT The heat age dry test shall be conducted in accordance with reference (c). TEST RESULTS A pretest visual inspection of the test items revealed that there were no new anomalies. All testing was performed in accordance with the referenced specification. The test items completed all phases of testing. Refer to the post-heat age dry test bridge wire and shunt resistance measurements. A post-test visual inspection of the test items revealed that the metal fill tubes showed signs of discoloration turning the tubes a dark color blue Enc 2 Pg 1

15 Enc 2 Pg 2

16 Enc 2 Pg 3

17 Electrical Resistance Measurements Post-Heat Age Dry Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 2 Pg 4

18 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: HEAT AGE DRY ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE Temperature Chamber Dayton T. Brown, Inc. 22 Ft Temperature Controller Honeywell UDC ±2.0EF 3/26/2000 Temperature Recorder Honeywell DRT ±0.7EF 4/9/2000 Truline ±0.2% RH %RH Transmitter Rotronics HT255D ±2% RH 1/7/ Enc 2 Pg 5 %RH Transmitter Rotronic HT255D ±2% 7/9/2000 Probe

19 TESTED FOR U.S. AUTO PARTS, INC. ITEM: ROOF RAIL AIR BAG MODULES HEAT AGE DRY TEST SETUP JOB NO FILE NO DTB04R ENCLOSURE 2 S/N 1-38 PHOTO 1

20 Enclosure 3 Storage Test and Results

21 TEST REQUIREMENT The storage test shall be conducted in accordance with reference (c). TEST RESULTS A pretest visual inspection of the test items revealed that the metal fill tubes showed signs of discoloration turning the tubes a dark color blue. All testing was performed in accordance with the referenced specification. The test items completed all phases of testing. Refer to the post-storage test bridge wire and shunt resistance measurements. A post-test visual inspection of the test items revealed that there were no new anomalies due to testing Enc 3 Pg 1

22 Enc 3 Pg 2

23 Enc 3 Pg 3

24 Electrical Resistance Measurements Post-Storage Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 3 Pg 4

25 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: STORAGE ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE 20-Foot Temperature Atmosphere Unlimited 20 Ft Altitude Chamber Temperature/Altitude JC Systems ±1.08 F 8/13/2000 Controller Temperature Altitude Honeywell DR ±0.7 F 8/13/2000 Recorder Enc 3 Pg 5

26 TESTED FOR U.S. AUTO PARTS, INC. S/N 1-38 ITEM: ROOF RAIL AIR BAG MODULES TEST ITEMS SETUP FOR THE STORAGE TEST JOB NO FILE NO DTB04R ENCLOSURE 3 PHOTO 1

27 Enclosure 4 Thermal Shock Test and Results

28 TEST REQUIREMENT The thermal shock test shall be conducted in accordance with reference (c). TEST RESULTS A pretest visual inspection of the test items revealed that the metal fill tubes showed signs of discoloration turning the tubes a dark color blue. The test items completed all phases of testing. All testing was performed in accordance with the referenced specification. Refer to the post-thermal shock test bridge wire and shunt resistance measurements. A post-test visual inspection of the test items revealed that all the test items showed that there was slight corrosion around the initiator and some discoloration of the cushion and tether Enc 4 Pg 1

29 Enc 4 Pg 2

30 Electrical Resistance Measurements Post-Thermal Shock Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 4 Pg 3

31 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: THERMAL SHOCK ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE 20-Foot Temperature Atmosphere Unlimited 20 Ft Altitude Chamber Temperature/Altitude JC Systems ±1.08 F 8/13/2000 Controller Enc 4 Pg 4 Temperature Altitude Honeywell DR ±0.7 F 8/13/2000 Recorder Temperature Chamber Dayton T. Brown, Inc. 22 Ft Temperature Controller Honeywell UDC ±1.7EF 5/7/2000 Temperature Recorder Honeywell DR ±0.7EF 4/9/2000 Temperature Humidity Thermotron 24 Ft Chamber 24 Ft Temperature JC Systems ±1.08 F 7/2/2000 Humidity Controller Chart Recorder Honeywell DR ±0.5 F 7/2/2000

32 Enclosure 5 Thermal Humidity Test and Results

33 TEST REQUIREMENT The thermal humidity test shall be conducted in accordance with reference (c). TEST RESULTS For the pretest visual inspection, refer to the thermal shock test post-inspection. All testing was performed in accordance with the referenced specification. The test items completed all phases of testing. Refer to the post-thermal humidity test bridge wire and shunt resistance measurements. A post-test visual inspection of the test items revealed that all the inflators, inflator mounting brackets, initiator ends, and fill tube mounting tabs were covered with a white powdery substance and showed signs of rust. The following test items had white powder on the fill tube: Serial Nos. 2, 4, 9, 10, 11, 14, 20, 24, 30, 32, 34, 35, 36, and 38. The remaining test items had rust on the fill tube Enc 5 Pg 1

34 Enc 5 Pg 2

35 Enc 5 Pg 3

36 Enc 5 Pg 4

37 Electrical Resistance Measurements Post-Thermal Humidity Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 5 Pg 5

38 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: THERMAL HUMIDITY ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE Temperature/Humidity Webber/Thermotron 10 Ft Chamber Digital Control JC Systems ±1.08 F 9/24/2000 Indicator ±1.06% RH Temperature & %RH Honeywell DR45AT ±0.5 F 9/24/2000 Chart Recorder ±0.2% RH Enc 5 Pg 6 % RH Probe Vaisala HMP ±1% 0 90% 7/2/2000 ±2% %

39 TESTED FOR U.S. AUTO PARTS, INC. S/N 1-38 ITEM: ROOF RAIL AIR BAG MODULES TEST ITEMS SETUP FOR THE THERMAL HUMIDITY TEST JOB NO FILE NO DTB04R ENCLOSURE 5 PHOTO 1

40 Enclosure 6 Salt-Spray Test and Results

41 TEST REQUIREMENT The salt-spray test shall be conducted in accordance with reference (c). TEST RESULTS For the pretest visual inspection, refer to the thermal humidity test post-inspection. All testing was performed in accordance with the referenced specification. The test items completed all phases of testing. Refer to the post-salt-spray test bridge wire and shunt resistance measurements. A post-test visual inspection of the test items revealed the following: - Inflator mounting bracket showed signs of oxidation and very slight amounts of rust. - Inflator showed signs of oxidation. - Fill tube showed signs of rust and oxidation Enc 6 Pg 1

42 Enc 6 Pg 2

43 Electrical Resistance Measurements Post-Salt-Spray Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) , Enc 6 Pg 3

44 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: SALT-SPRAY ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE Salt-Fog Chamber Industrial Filter and 21 Ft Pump Mfg. Co. Temperature Honeywell UDC ±2.0EF 9/17/2000 Controller/Indicator Pressure Gauge Weiss Instruments 0 to psi Enc 6 Pg 4 Pressure Gauge Weiss Instruments 0 to psi Petri Dish Fisher Corning 100 x % Indefinite 50 mm -10% Graduate Nalgene 50 ml ±0.5 ml 4/8/2001 Hydrometer Fisher F 39-9 Mfr 10/1/2000 ph Meter Cole-Palmer ±0.10 ph Each Day Temperature Recorder Doric ±1EF 6/11/2000 Resistivity Meter Myron L. Co ±1% FS 9/10/2000

45 TESTED FOR U.S. AUTO PARTS, INC. S/N 1-38 ITEM: ROOF RAIL AIR BAG MODULES SALT-SPRAY TEST SETUP JOB NO FILE NO DTB04R ENCLOSURE 6 PHOTO 1

46 Enclosure 7 Service Durability (Post) Test and Results

47 TEST REQUIREMENT The service durability (post) test shall be conducted in accordance with reference (c). TEST RESULTS For the pretest visual inspection refer to the salt-spray test post-inspection. All testing was performed in accordance with the referenced specification. Below are the measurements for the bridge wire resistance, shunt resistance, and insertion forces. All M6 fasteners were torqued to a value of 88 inch-pounds. The test items completed all phases of testing. A post-test visual inspection of the test items revealed that there were no new anomalies due to testing Enc 7 Pg 1

48 Electrical Resistance Measurements Service Durability (Post) Test Serial No. Bridge Wire Resistance (Ω) Shunt Resistance (Ω) Enc 7 Pg 2

49 Service Durability (Post) Test Insertion Forces (lb) Serial No. Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Trial 6 Trial Enc 7 Pg 3

50 Test equipment utilized for the program reported herein was within its assigned interval of calibration. Details are on file at Dayton T. Brown, Inc. and will be made available upon request. TEST: SERVICE DURABILITY (POST) ITEM MANUFACTURER MODEL DTB NO. ACCURACY CAL DUE DATE Digital Volt/Ohm Meter Hewlett-Packard 3456A 9-22 Mfr 6/11/2000 Push/Pull Scale Chatillon DFGS ±0.15% FS 11/19/2000 Torque Wrench Proto 6064A Data 12/17/ Enc 7 Pg 4

51 Enclosure 8 A2LA Scope of Accreditation

52 Enc 8 Pg 1

53 Enc 8 Pg 2