SAE_J2045-1998_燃油系统管路总成性能要求

SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243 TO PLACE A DOCUMENT ORDER; (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http://www.sae.org Copyright 1998 Society of Automotive Engineers, Inc. All rights reserved. Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 STANDARD Submitted for recognition as an American National Standard J2045 REV. FEB1998 Issued 1992-10 Revised 1998-02 Superseding J2045 OCT92 (R) Performance Requirements for Fuel System Tubing Assemblies TABLE OF CONTENTS 1. Scope ....................................................................................................................................................... 1 2. References ............................................................................................................................................... 2 3. Routing Recommendations ..................................................................................................................... 2 4. Technical Requirements ........................................................................................................................... 2 4.1 Leak Resistance ....................................................................................................................................... 2 4.2 Fitting Pull-Off........................................................................................................................................... 3 4.3 Flow Restriction........................................................................................................................................ 3 4.4 Internal Cleanliness.................................................................................................................................. 4 4.5 Internal Fuel Resistance........................................................................................................................... 5 4.6 Life Cycle.................................................................................................................................................. 5 4.7 Flame/Heat Resistance ............................................................................................................................ 6 4.8 Burst ......................................................................................................................................................... 6 4.9 Pressure Drop/Flow Resistance ............................................................................................................... 7 4.10 Electrical Resistance ................................................................................................................................ 7 4.11 Assembly Hydrocarbon Loss (Mini-S.H.E.D.) ........................................................................................... 8 4.12 Chemical Resistance................................................................................................................................ 9 5. Validation Testing Recommendations....................................................................................................... 9 1. Scope—This SAE Standard encompasses the recommended minimum requirements for non-metallic tubing and/or combinations of metallic tubing to non-metallic tubing assemblies manufactured as a liquid- and/or vapor-carrying systems designed for use in gasoline, alcohol blends with gasoline, or diesel fuel systems. This SAE Standard is intended to cover tubing assemblies for any portion of a fuel system which operates above –40 °C (–40 °F) and below 115 °C (239 °F), and up to a maximum working gage pressure of 690 kPa (100 psi). The peak intermittent temperature is 115 °C 239 °F). For long-term continuous usage, the temperature shall not exceed 90 °C (194 °F). It should be noted that temperature extremes can affect assemblies in various manners and every effort must be made to determine the operating temperature to which a specific fuel line assembly will be exposed, and design accordingly. The applicable SAE standards should be referenced when designing liquid-carrying and/or vapor-carrying systems which are described in this document. SAE J2045 Revised FEB1998 -2- Wherever possible or unless stated otherwise, systems tested to this document shall be in the final design intent configuration. 2. References 2.1 Applicable Publications—The following publications form a part of the specification to the extent specified herein. Unless otherwise indicated the latest revision of SAE publications shall apply. 2.1.1 SAE PUBLICATIONS—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001 SAE J30—Fuel and Oil Hoses, Sections 10 and 11 SAE J517—Hydraulic Hose SAE J526—Welded Low Carbon Steel Tubing SAE J1645—Fuel System Electrostatic Charge SAE J1681—Gasoline/Oxygenate Mixtures for Materials Testing SAE J1737—Procedure/Fuel Permeation Losses SAE J2027—Protective Covers for Non-metallic Gasoline Fuel Injection Tubing SAE J2044—Fluid Coupling for Gasoline Fuel Injection Fuel Supply & Vapor Systems SAE J2260—Non-metallic Fuel System Tubing with 1 or more layers 2.2 Other Publications Code of Federal Regulations Title 40 part 86 3. Routing Recommendations— Fuel tube/hose assemblies shall be routed and supported as to; a. Prevent chafing, abrasion, kinking, or other mechanical damage. b. Be protected against road hazards or provided with adequate shielding in locations that are vulnerable to physical and/or chemical hazards. c. Be protected where temperatures may exceed the limits of –40 °C to +90 °C by the addition of adequate insulation and/or shielding. d. To assure maintenance of design intent routings of liquid fuel and/or fuel vapor assemblies, appropri- ate retaining/mounting devices must be incorporated for proper assembly and subsequent vehicle ser- vice operation, maintaining interfaces for temperature and environmental control for durability. e. Route tube assemblies in an environment which minimizes heat input to the assemblies and the liquid fuel and/or fuel vapor which they contain. 4. Technical Requirements 4.1 Leak Resistance 4.1.1 TESTING DEVICE—A device capable of applying the recommended internal pressure specified for both liquid fuel and fuel vapor line assemblies. Test is intended to be performed on liquid fuel/fuel vapor assemblies that duplicate the design intended for vehicle application, including applicable end fittings and/or connections. 4.1.2 SAMPLE PREPARATION—All tests are to be conducted at room temperature. 4.1.3 PROCEDURE a. Attach tube assemblies to test fixture which simulates vehicle installation where at all possible. b. Apply internal pressure (see Appendix A) at one end of the assembly, allowing sufficient time for system to stabilize before determining leak rate. SAE J2045 Revised FEB1998 -3- c. At test completion, test media should be exhausted through opposite end of assembly to which it was pressurized to insure obstruction and/or blockage was not present in the liquid fuel/fuel vapor line assembly, as well as blowout any potential residue which may have been present. d. After test, remove assembly from test fixture. 4.1.4 ACCEPTANCE CRITERIA—Design target for maximum leakage allowed, are per specified guidelines (see Appendix A). Final acceptance criteria to be jointly determined by producer and end user. 4.2 Fitting Pull-Off—(room temperature and elevated temperature) 4.2.1 TESTING DEVICE—A device suitable for applying a tensile load at a constant rate of 50 mm/min, elongating tube or hose assemblies up to 400% of their initial length, and measuring the maximum load achieved up to a load of 900 N minimum. 4.2.2 SAMPLE PREPARATION—All tests are to be conducted at room temperature (room temperature fitting pull-off) and at 115 °C for high-temperature fitting pull-off. 4.2.3 PROCEDURE a. The test specimen shall consist of a direct connection coupling between the flexible tubing/hose and fitting or tube with enough length of hose and/or tube on either side of specimen to permit adequate gripping in the test apparatus. Specimens may be cut from the production intent part or made for this test utilizing production intent product and processes, such as component assembly devices and tube forming techniques. b. Grip the test specimen in the tensile-loading device and apply a tensile load at a speed of 50 mm/ min until one of the following events occur; 1. The fitting or tube separates from the flexible tubing 2. One of the test specimen components break, fracture, or rupture 3. A maximum load is reached whereby the flexible tubing reaches its maximum tensile/elongation load capability c. For elevated temperature pull-off tests, grip the test specimen in the tensile-loading device and heat test chamber to 115 °C (239 °F) prior to applying the 50 mm/min tensile load. Test chamber should be instrumented with a thermocouple to insure test environment reaches 115 °C prior to applying the tensile load. d. Measure and record the greatest load achieved before one of the events listed (2) occurs, and the type of event (failure mode). 4.2.4 ACCEPTANCE CRITERIA a. Room Temperature—450 N minimum (fuel assemblies) or 222 N minimum (vapor assemblies) b. 115 °C Temperature—115 N minimum (fuel assemblies) or 65 N minimum (vapor assemblies) 4.3 Flow Restriction 4.3.1 TESTING DEVICE—A spherical ball half the size of the nominal flexible tubing material inner diameter. 4.3.2 SAMPLE PREPARATION—Testing is to be performed at room temperature. SAE J2045 Revised FEB1998 -4- 4.3.3 PROCEDURE a. Bend or preform tubing, utilizing intended production processing method, to the shape and contour required by its design application. It is not recommended to include connectors or tubing ends for this test since geometry constraints of these components may interfere with performing this test (i.e., lack of flow through feature, restrictions, etc.) b. Pass the spherical ball through the preformed tube. 4.3.4 ACCEPTANCE CRITERIA—The spherical ball must pass freely through the preformed tube. 4.4 Internal Cleanliness 4.4.1 TESTING DEVICE(S)—Testing devices must be utilized which can safely and accurately flush the interior of the tubing assembly with solvent, effectively remove any contaminants and foreign material from the interior surface, and accurately measure that material and its weight. (See Figure 1.) FIGURE 1—EXAMPLE SAE J2045 Revised FEB1998 -5- 4.4.2 SAMPLE PREPARATION—Testing is to be performed at room temperature. 4.4.3 PROCEDURE a. Pre-dry filter device, then cool in a desiccant cabinet. b. Pre-weigh filter device which will be used in collecting potential contaminants and foreign material in fuel line assembly. Filter must be capable of collecting a contaminant which is 240 micron in size or larger. c. Set up test specimen in test device/apparatus. d. Turn on vacuum pump (if applicable or utilized). e. Pour an amount of solvent (equivalent to at least the volume of the assembly) through the tube assembly. Solvent which is dispensed into the fuel line assembly should be pre-filtered. f. Dispense solvent which has passed through the fuel line assembly into a pre-weighed filter, followed by a collection device to contain the solvent. Dry filter to dissipate solvent absorbed by filter. g. Weigh filter to determine weight gain, which is an indicator of contaminant and/or foreign material collected from tube assembly. Record value obtained in grams per tube. 4.4.4 ACCEPTANCE CRITERIA—Total contaminant collection should not exceed 0.15 g/s meter (flexible tubing assembly) or 0.25 g/s meter (flexible tubing assembly with steel tubing attached) of interior surface area. 4.5 Internal Fuel Resistance 4.5.1 TESTING DEVICE(S)—Apparatus capable of safely storing fuel filled test specimens at elevated temperature (up to 60 °C) and controlling the ambient temperature to within ±2 °C. 4.5.2 SAMPLE PREPARATION—Prepare samples and conduct testing to temperatures as described in SAE J2260, 7.7 and 7.8. 4.5.3 TEST PROCEDURE—Per SAE J2260, 7.7 and 7.8, except conduct on finished assemblies or samples which consist of design intent interfaces and components. 4.5.4 ACCEPTANCE CRITERIA—Assemblies must meet 4.1, 4.2 (room temperature only), 4.8, and 4.10 (conductive systems only) of SAE J2045 upon completion of internal fuel resistance exposures. End user should be consulted for any potential additional requirements beyond SAE J2260 baseline fuels. 4.6 Life Cycle 4.6.1 TESTING DEVICE—Life cycle test chamber capable of performing the pressure, vibration, and temperature cycles with test fluid as outlined in SAE J2044, 6.5. 4.6.2 SAMPLE PREPARATION—Prepare samples as described in 6.5 of SAE J2044 on finished assemblies or samples which consist of production intent interfaces and components. 4.6.3 TEST PROCEDURE—Per SAE J2044, 6.5 (both liquid-fuel and/or fuel-vapor applications) 4.6.4 ACCEPTANCE CRITERIA—Test assemblies must exhibit no fluid leaks through entire test duration. At comple- tion of test, visually inspect assemblies and components to insure no fractures, cracks, or unusual wear has occurred. Test assemblies must then meet the air leak test, 4.1 of SAE J2045. SAE J2045 Revised FEB1998 -6- 4.7 Flame/Heat Resistance 4.7.1 TESTING DEVICE—Device capable of performing the burn-through resistance test as outlined in SAE J2027, 5.2.8. 4.7.2 SAMPLE PREPARATION—Prepare samples and conduct testing to temperatures as outlined in 5.2.8 of SAE J2027. 4.7.3 TEST PROCEDURE—Per SAE J2027, 5.2.8 on finished test samples, which consist of design intent interfaces/ components. 4.7.4 ACCEPTANCE CRITERIA a. Flame/heat resistance of the assembly shall meet the burn-through resistance requirements of the individual coverstock material chosen for the design. b. Burn through of the assembly shall be no less than the time specified in the burn test referenced in SAE J2027. c. Insulating ability of the assembly can be altered or modified per SAE J2027 to attain desired end result. 4.8 Burst—(room temperature and elevated temperature) 4.8.1 TESTING DEVICE—A test apparatus capable of applying a pulse free hydrostatic pressure at a uniform rate of increase of 7000 kPa/min (1000 psi/min). For high-temperature burst testing, test apparatus must also be capable of heating test fluid to the test temperature of 115 °C (239 °F) and maintaining test temperature to within ±3 °C (±5 °F). Fluid bath (silicon oil or equivalent) or hot-air exposure are recommended means to employ in conducting this test. Test apparatus must also be capable of filling test specimens with hydraulic fluid to conduct room and high- temperature burst testing. 4.8.2 SAMPLE PREPARATION—Sample tubing, representative of the production design intent, shall be cut to a length 31 to 46 cm (12 to 18 in) and assembled with the proper, production design intent connectors. Test assemblies shall be processed and assembled in the manner applicable to the production design intent process. Samples are then conditioned for 24 h minimum at room temperature. 4.8.3 TEST PROCEDURE a. Room Temperature 1. Fill burst test apparatus and test specimen with burst fluid. 2. Secure test assembly to burst test apparatus in the same manner which the test assembly will be secured for end use. 3. Apply pressure at a 7000 kPa/min rate of increase until the test specimen fails. b. Elevated Temperature (115 °C) 1. Fill burst test apparatus and test specimen with burst fluid. 2. Secure test assembly to burst test apparatus in the same manner which the test assembly will be secured for end use. 3. Heat both the test specimen and test fluid to 115 °C (bath chamber or oven) and allow to stabilize at 115 °C. SAE J2045 Revised FEB1998 -7- 4. Once the test specimen and test fluid have reached a stabilized pressure of 115 °C, apply pressure at a 7000 kPa/min rate of increase until the test specimen fails. 4.8.4 ACCEPTANCE CRITERIA a. Room Temperature—Minimum burst value must equal 8 times the average vehicle system working pressure (vehicle application) b. 115 °C Temperature—Minimum burst value must equal 3 times the average vehicle system working pressure (vehicle application) 4.9 Pressure Drop/Flow Resistance 4.9.1 TESTING DEVICE—A device capable of applying an internal air pressure for fuel line and/or vapor line applications to ±7 kPa increment from a nominal set-point pressure which is to be jointly determined by producer and end user (as well as test need and applicability). Matched fittings that duplicate production design intent shall be used. 4.9.2 SAMPLE PREPARATION—All tests are to be conducted at room temperature. 4.9.3 TEST PROCEDURE a. Attach test assemblies to the test fixture. b. Apply air pressure at 1035 kPa (fuel) or 69 kPa (vapor) at one end of the assembly, allow flow to reach a steady state, then measure pressure drop across assembly. c. After test, remove assembly from test fixture and examine for cracking, deformation, or damage to connectors. 4.9.4 ACCEPTANCE CRITERIA—Maximum pressure drop allowed across entire assembly for fuel and /or vapor line assemblies must be determined by end user. 4.10 Electrical Resistance 4.10.1 BACKGROUND—SAE J1645 is a document that covers electrostatic charge issues as they pertain to the fuel system. It is a recommended practice that: 1. Explains the phenomenon, 2. Outlines design factors that can be used to mitigate a charging situation that may develop, 3. Describes general techniques to be followed to determine aspects of a fuel system assembly's performance in handling the electrostatic charge situation, 4. Identifies cautions that relate to the various testing elements, 5. Delineates specific test procedures that can be followed. That document should serve as a guideline for measurement of the electrical resistance of a fuel system assembly. Numerous other steps and tests may be pertinent to the performance of the assembly; the end user should be consulted for the various details of the document that should be followed. If there are no inputs from the end user for performance of a fuel system assembly (in the sense of handling electrostatic charge), then the following general steps should be completed. NOTE—These steps only relate to assemblies designed to handle liquid fuel. Electrostatic charge is not typically an issue for systems designed to handle fuel vapor. SAE J2045 Revised FEB1998 -8- 4.10.2 TESTING DEVICE—A device capable of measuring electrical resistance as described in 7.1 of SAE J1645 shall be used. Such a device should be capable of using a 9-V and 500-V source as the drive for the measurement of the level of ohms. 4.10.3 SAMPLE PREPARATION—All tests are to be conducted at 23 °C ± 2 °C and at 50% ± 5% relative humidity. Measurements are to be conducted on the liquid fuel line assembly which has completed all process steps per production design-intent application (including end fittings, attachment clips, etc.). 4.10.4 TEST PROCEDURE—Measure the D.C. resistance using the ohmmeter (referenced in 4.10.2) from one extreme end of the fuel systems assembly to the other end for each of the fuel lines involved. If at all possible, measurements of the assembly attached to the vehicle should also be done. 4.10.5 ACCEPTANCE CRITE