Test Report Number 41418-09.PPC Testing of Pancake Alternator & PMU PREPARED FOR: The Perfect Parts Company Sullivan Products 1 North Haven Street Baltimore, MD 21224 PREPARED BY: National Technical Systems 36 Gilbert Street South Tinton Falls, NJ 07701
REVISION PAGE Rev. # Date Page # Para. # Description 0 06/18/09 Complete Document Page 2 of 20
SIGNATURES Prepared By: Gary Freed Compliance Engineer Reviewed By: Mark Betts, Program Manager Approved By: David Potpinka, Quality Manager Page 3 of 20
TABLE OF CONTENTS 1.0 PURPOSE... 5 1.1 Test Program Sequence... 5 1.1.1. Receipt Inspection... 5 1.1.2. Functional Test... 5 1.1.3. Testing... 5 2.0 APPLICABLE DOCUMENTS... 6 2.1 Purchase Order Number 10548... 6 2.2 NTS Quotation Number 1519... 6 2.3 NTS Corporate Quality Policy Manual... 6 3.0 TEST ITEMS... 6 3.1 Description... 6 3.2 Security Classification of Items... 6 4.0 TEST DATE(S) AND EQUIPMENT... 7 4.1 Test Date(s)... 7 4.2 Test Equipment... 7 5.0 GENERAL TEST REQUIREMENTS... 7 5.1 Test Facility... 7 5.2 Test Sample Configuration... 7 5.3 Functional Pass/Fail Criteria... 7 6.0 TEST PROCEDURE... 8 6.1 Vibration... 8 6.1.1. Requirement... 8 6.1.2. Test Procedure... 8 6.1.3. Comments... 8 6.2 Mechanical Shock... 9 6.2.1. Requirement... 9 6.2.2. Test Procedure... 9 6.2.3. Comments... 9 Appendix A, Test Equipment List... 10 Appendix B, Vibration Data... 12 Appendix C, Mechanical Shock Data... 14 Appendix D, Photos... 17 Page 4 of 20
1.0 PURPOSE This test report describes the methods used for the Environmental and Dynamic Testing of the Sullivan Pancake Alternator tested for The Perfect Parts Company. This test program was conducted to determine the ability of the Pancake Alternator & PMU to successfully satisfy the requirements specified in the references listed in section 2.0 of this report. 1.1 Test Program Sequence 1.1.1. Receipt Inspection Upon receipt at NTS, the Pancake Alternator & PMU was visually inspected to ensure there had been no damage due to shipping/handling, and to confirm that the test model number and serial number coincide with those on the packing list. No discrepancies or damage was observed. 1.1.2. Functional Test 1.1.3. Testing The Pancake Alternator & PMU was checked for damage, during and after testing as applicable. Tests and Standard Test Vibration Mechanical Shock Standard Qualification Test Matrix for 315-025005- 009 Mil-Std-810D Method 514.3 Qualification Test Matrix for 315-025005- 009 Mil-Std-810D Method 416.3 Procedure V Page 5 of 20
2.0 APPLICABLE DOCUMENTS 3.0 TEST ITEMS None 2.1 Purchase Order Number 10548 2.2 NTS Quotation Number 1519 2.3 NTS Corporate Quality Policy Manual Revision 5, Dated June 13, 2008. 3.1 Description Qty Item P/N SN# 2 Pancake Alternator S675-400 1129 & 1115 2 PMU REG-300V 1134 & 1135 3.2 Security Classification of Items Page 6 of 20
4.0 TEST DATE(S) AND EQUIPMENT 4.1 Test Date(s) Test Date(s) Vibration 05/18/2009 Mechanical Shock 05/18/2009 4.2 Test Equipment A list of the test equipment to be used is included in Appendix A of this procedure. This equipment is calibrated according to ISO 10012-1 and calibration is traceable to the National Institute of Standards and Technology (NIST). Calibration records are maintained on file at National Technical Systems. 5.0 GENERAL TEST REQUIREMENTS 5.1 Test Facility The Pancake Alternators & PMU s were tested for The Perfect Parts Company at NTS test facilities located in Tinton Falls, NJ. 5.2 Test Sample Configuration The test item configurations are documented in the photographs contained in this test report. 5.3 Functional Pass/Fail Criteria Throughout the test program, there is no requirement for functional testing of the Pancake Alternator & PMU. At the completion of all testing the test items will be returned to The Perfect Parts Company. for further evaluation and functional testing. Page 7 of 20
6.0 TEST PROCEDURE 6.1 Vibration 6.1.1. Requirement The Pancake Alternator & PMU shall be subjected to the Source Dwell Vibration test described in Mil-Std-810D Method 514.3 Figure 514.3-28. Discrete Frequencies Vibration 10-2000 Hz 1 Hour Per Axis 6.1.2. Test Procedure The Pancake Alternator & PMU was placed in the vibration fixture and tested to the above stated specifications. 6.1.3. Comments The Pancake Alternator & PMU was tested in accordance with the Vibration Test requirements. Please reference Appendix B for test data. Page 8 of 20
6.2 Mechanical Shock 6.2.1. Requirement The Pancake Alternator & PMU shall be capable of withstanding mechanical shock testing of Mil-Std-810D Method 514.3 Section I-3.7 Procedure V. The peak value shall be 20G s for duration of 11 milliseconds. The shock pulse shall be applied 3 times each axes. The total number of shocks shall be 9. 6.2.2. Test Procedure The Pancake Alternator & PMU was mounted in the on the shock fixture/table and tested to the above stated specifications 6.2.3. Comments The Pancake Alternator & PMU was tested in accordance with the Shock Test requirements. Please reference Appendix C for test data and plots. Page 9 of 20
Appendix A, Test Equipment List Page 10 of 20
Test Equipment Asset No. Manufacturer Item Model S/N Cal. Date Cal. Due nj1532 nj1205 PCB Spectral Dynamics DC Accelerometer 3711D1FA200 G 1889 12/30/08 12/30/09 Vibration Controller 2405-9700-1 2400-2041 11/18/08 11/18/09 nj1127 Unholtz Dickie Shaker T1000 476 NCR NCR MA145Anj1130 Unholtz Dickie Amplifier 130IAR 2418 NCR NCR Page 11 of 20
Appendix B, Vibration Data Page 12 of 20
0.1 A PSD g²/hz [CH 1] x: 122.5, y: 0.0169009 Locked X Axis Random Vibration g²/hz (Log) 0.02 0.01 0.005 0.002 0.001 0.0005 0.0002 10 20 50 100 200 500 1000 2000 Hz (Log) 0.1 A PSD g²/hz [CH 1] x: 122.5, y: 0.0187801 Locked Y Axis Random Vibration g²/hz (Log) 0.02 0.01 0.005 0.002 0.001 0.0005 0.0002 10 20 50 100 200 500 1000 2000 Hz (Log) 0.1 A PSD g²/hz [CH 1] x: 122.5, y: 0.0187546 Locked Z Axis Random Vibration g²/hz (Log) 0.02 0.01 0.005 0.002 0.001 0.0005 0.0002 10 20 50 100 200 500 1000 2000 Hz (Log) Page 13 of 20
Appendix C, Mechanical Shock Data Page 14 of 20
g 21 10 0-7.8 A Time Trace g [Control] x: 0.0453906, y: 20.2872 X Axis Shock + 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec 7.9 0 A Time Trace g [Control] x: 0.0453906, y: -19.9794 X Axis Shock - g -10-20 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec g 21 10 A Time Trace g [Control] x: 0.0453906, y: 20.208 Y Axis Shock + 0-7.6 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec Page 15 of 20
7.8 0 A Time Trace g [Control] x: 0.0453906, y: -20.0044 Y Axis Shock - g -10-21 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec g 21 10 0-8.1 A Time Trace g [Control] x: 0.0452734, y: 20.3063 Z Axis Shock + 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec 8.4 0 A Time Trace g [Control] x: 0.0452734, y: -20.6142 Z Axis Shock - g -10-21 0 0.004 0.008 0.012 0.016 0.02 0.024 0.028 0.032 0.036 0.04 0.044 0.048 0.052 0.056 0.06 0.064 0.068 0.072 0.0799609 Sec Page 16 of 20
Appendix D, Photos Page 17 of 20
Vibration/Shock Page 18 of 20
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