uscar3-2v002

SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBSTheresearchdata,analysis,conclusion,opinionsandothercontentsofthisdocumentaresolelytheproductoftheauthors.NeithertheSocietyofAutomotiveEngineers,Inc.(SAE)northeUnitedStatesCouncilforAutomotiveResearch(USCAR)certifiesthecomplianceofanyproductswiththerequirementsofnormakesanyrepresentationsastotheaccuracyofthecontentsofthisdocumentnortoitsapplicabilityforpurpose.Itisthesoleresponsibilityoftheuserofthisdocumenttodeterminewhetherornotitisapplicablefortheirpurposes.Copyright2002,USCARAllrightsreserved.PrintedinU.S.A.LandSeaAirandSpaceForAdvancingMobilityTheEngineeringSocietyINTERNATIONAL®400CommonwealthDrive,Warrendale,PA15096-0001IssuedAugust1997RevisedApril2002SAE/USCAR-3Revision2QUESTIONSREGARDINGTHISDOCUMENT:(724)772-8545FAX(724)776-0243TOPLACEADOCUMENTORDER:(724)776-4970FAX(724)776-0790SUMMARYOFCONTENTS1.SCOPE*........................................................................................................................32.REFERENCESTANDARD..........................................................................................53.DIAGRAMSANDDEFINITIONS*................................................................................53.1Appendices*.................................................................................................................54.GENERALREQUIREMENTS......................................................................................64.1RecordRetention..........................................................................................................64.2SampleDocumentationsandRetention*......................................................................64.3PowerSources.............................................................................................................74.4EquipmentTolerances..................................................................................................74.5MeasurementAccuracy................................................................................................84.6TestRepeatabilityandCalibration................................................................................84.7TestDefaultConditions*...............................................................................................94.8TestSharingWithinBulbFamilies................................................................................94.9TestFailureProcedure.................................................................................................94.10ControlPlans*.............................................................................................................104.11ReliabilityProgramsandMethods..............................................................................104.12HazardousMaterialRestriction...................................................................................105.PHYSICALPERFORMANCE....................................................................................115.1PhysicalDimensions...................................................................................................115.2MeanSphericalCandela............................................................................................115.3ExternalVisualExamination.......................................................................................12SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-2-5.4CrushStrength...........................................................................................................135.5ThermalShock............................................................................................................145.6BayonetBaseRetention.............................................................................................155.7PinRemoval...............................................................................................................165.8WedgeBaseRetention...............................................................................................175.9LeadWireBend..........................................................................................................185.10LeadWirePull............................................................................................................185.11Color*..........................................................................................................................195.12ColorMaintenanceandCoatingDurability*................................................................205.13ColorChemicalResistance*.......................................................................................235.14ResonantFrequency*.................................................................................................245.15AgedResonantFrequency.........................................................................................255.16SaltSpray...................................................................................................................265.17WireLoopPull............................................................................................................275.18Outgassing/Heat.........................................................................................................276.DURABILITY..............................................................................................................286.1LaboratoryLife*..........................................................................................................286.2AcceleratedLife*.........................................................................................................296.3LuminousIntensityMaintenance*...............................................................................296.4VibrationDurability*....................................................................................................306.5Shock..........................................................................................................................326.6AgedVibrationDurability............................................................................................336.7Reliability....................................................................................................................347.QUALITY/RELIABILITYPROGRAMS.......................................................................357.1ReliabilityGrowth........................................................................................................357.2OngoingQualityImprovements..................................................................................367.3Quality/ReliabilityImprovement..................................................................................368.REPORTREQUIREMENTS.......................................................................................378.1CalibrationSheets......................................................................................................378.2DataRequirements.....................................................................................................37APPENDIXAGLOSSARYOFTERMS*...........................................................................38APPENDIXBGRAPHICS,CHARTS,ETC.......................................................................40APPENDIXCREVISIONS................................................................................................56SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-3-1.SCOPE*Theprocedurescontainedinthisspecificationcoverthelaboratorytestingofminiatureincandescentbulbsforuseinautomotiveilluminationandsignalingapplications.Thefollowingtestsshallberunwheneverthefollowingoccurs:•Newbulbdesign•Designorprocesschangemadetoanexistingbulb,whichcouldaffecttheoutcomeofthetest.•ThecompletionofonecalendaryearasnotedinthefollowingTestScheduleTable.Processcontroldataisacceptable.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-4-TestScheduleTableTestTitleYearlyPhysicalDimensionsXMeanSphericalCandelaXExternalVisualExaminationXCrushXThermalShockXBayonetBaseRetentionXPinRemovalXWedgeBaseRetentionXLeadWireBendXLeadWirePullXNaturalAmberColorXCoatedAmberColor•IntegratedColor•VisualColor•PointColor•ColorMaintenanceandCoatingDurability•AmberCoatingChemicalResistanceXXXResonantFrequencyAgedResonantFrequencySaltSprayWireLoopPullXOutgassing/HeatLaboratoryLifeAcceleratedLifeXLuminousIntensityMaintenanceVibrationDurabilityShockAgedVibrationDurabilityReliabilitySAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-5-2.REFERENCESTANDARDDaimlerChrysler,Ford,andGeneralMotorsAdvancedProductQualityPlanningandControlPlanReferenceManualMeasurementSystemsAnalysisReferenceManual(AIAG)PotentialFailureModeandEffectsAnalysisReferenceManual(SAEJ1739)DaimlerChrysler,Ford,andGeneralMotorsProductionPartApprovalProcessManualANSI(C78.390)ASTMB117(StandardPracticeforOperatingSaltSpray[Fog]TestingApparatus)DaimlerChrysler,Ford,andGeneralMotorsQualitySystemRequirementsQS-9000ManualSAEJ573,MiniatureLampBulbsSAEJ1330,PhotometryLaboratoryAccuracyGuidelinesSAEJ578,ColorSpecificationUnlessotherwisespecifiedorrequiredbylaw,suppliersshouldusethemostrecentversionsofanyapplicablereferencedocumentsorstandards.3.DIAGRAMSANDDEFINITIONS*3.1Appendices*Diagramsareprovidedattheendofthisstandardtoclarifythedetailsofthetestprocedures.AppendixA-GlossaryofTermsAppendixB-Graphics,Charts,etc.FigureB1-FilamentOrientationFigureB2-CrushTestFixturesFigureB3-PinRemovalTestFixture(B-1,B-2,andC-2BaseTypes)FigureB4-PinRemovalTestPlate(B-1,B-2,andC-2BaseTypes)FigureB5-WedgeBaseRetentionFixtureFigureB6-PointColorFigureB7-ResonantFrequencyTestFigureB8-ShockTester(SideView)FigureB9-ShockTester(TopView)FigureB10-ShockTester-S-8WedgeBaseLampMountingDetailFigureB11-ShockTesterCamFigureB12-ShockTesterDetectionCircuitFigureB13-ShockTesterCounterCircuitSAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-6-FigureB14-HeatTestEnclosuresFigureB15-NormalProbabilityPlotFigureB16-WeibullLifePlotAppendixC-Revisions4.GENERALREQUIREMENTS4.1RecordRetentionSuppliermustmaintainafileforthestorageoflaboratoryreportsandcalibrationrecords,andestablisharecordretentionpolicyconcerningtheserecords.Theserecordsneednotfollowastandardformatbutmustpresenttherequireddatainanorderlyprofessionalmanner.Thefilemustbemadeavailabletoanyandallcustomerpersonneluponrequest,includingbutnotlimitedtorepresentativesfromthefollowingfunctions:productengineering,purchasing,quality,andreliability.4.1.1ObjectivesofRecordRetentionThefollowingarethemainobjectivesforretentionoftestdocumentsorrecords:1.Retainrecordsthatwillevidencecompliancesothatthesuppliercanappropriatelyrespondwhenorifproductcomplianceischallenged.Filesmustexistforthestorageofalllaboratoryrecords,data,andcalibrationrecords.Thefilesmustbeavailableatanytimeforauditorinspection.2.Retainrecordsasneededtoassistinevidencingtheexerciseof“duecare”inmattersrelatingtoproductcompliance,governmentrequirements,orproductliability.3.Complywithstatutoryrequirementsforthemaintenanceandretentionofspecificrecords.4.1.2RetentionMethodsMethodsofretentionmayincluderetentionoforiginaldocuments,theuseoffilm,orelectronicstorageequipment.Storerecordssothattheyareaccessibleinareasonableamountoftime.Storageareasshouldprovideadequateprotectionfromunauthorizedaccess,moisture,andfire.4.2SampleDocumentationsandRetention*EngineeringtestsamplesmustbeidentifiedbyANSITradeNumberandserialnumberunlessotherwisenoted.Documentationmustidentifythetypeoftestperformedanddescribespecialteststhatarenotapartofthisspecification.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-7-4.2.1RequiredDataPackageSuppliermustsubmitthedatapackagefortheappropriatelevelofsubmissiontothecustomer’sresponsibleengineerandpurchasingdivisionforapprovalsignatures.4.2.2SampleSelectionTestbulbsreferencedinthisspecificationaretobeselectedfromthesame"TestLot".Theminimum“TestLot”isdefinedasonehourofproduction.Testbulbsaretobesubjectedtoproductionintentprocessing,includingfinalpackaging.Note:Atestsamplesizeof10wouldconsistofonesamplepiecebeingremovedfromthetestlot,everysixminutesofproduction,foraone-hourproductionrun.Itisimportantthatthetestsamplesbeidentifiedastolocation,withinthetestlot,throughoutalltesting.4.2.3SampleRetentionSamplestestedtoattainpartapprovalmustberetainedbythebulbmanufacturerforaperiodoftimespecifiedinthePPAPManual.4.3PowerSourcesSuppliermustusevoltageregulateddirectcurrent(DC)powersourcesforallteststosimulateanautomotivebatteryandchargingsystem.4.3.1OutputCurrentThepowersourcemustbecapableofsupplyingacontinuousoutputcurrentasrequiredbythedesignloads,includinginrushcurrent.Whererequiredtosimulateautomotiveinrushcurrentconditions,anautomotivebatteryorbatterieswithsufficientcoldcrankingampsmaybeconnectedinparallelwiththepowersupply.4.3.2OutputVoltageThepowersourcemustbecapableofsupplyinganoutputvoltagethatmustnotdeviatemorethan1.0voltfromthenominalsettingovertheentireloadrange(includingsurges).Thepowersourcemustrecover63%ofitsmaximumexcursionwithin5.0milliseconds.Ripplevoltagemustnotexceed300mVpeaktopeak.PowersuppliesusedforphotometricmeasurementsmustconformtoSAEJ1330.4.4EquipmentTolerancesSuppliermustusetestsetupsandequipmentcapableofmeasuringtestparameters(expressedinnominals)withinthelimitsfoundintheEquipmentTolerancesTable.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-8-EquipmentTolerancesTableTestChamberTemperaturenominal±3°CTimenominal±0.5%Forcesnominal±0.01NDistancesnominal±0.01mmVoltagesnominal±0.01Vforphotometricsnominal±0.1VforallothertestsMeanSphericalCandelanominal±2.0%NOTE:Nottobeusedforperformancedependentvariable(seeMeasurementAccuracysection).4.5MeasurementAccuracyMetersandgagesusedtoassesstheperformancedependentvariable,asdefinedbythebasicfunctionofthetestsample,mustbecapableofmeasuringtoonecountlessthanthespecifiedvalue.Forexample,eventhougha0.1mmand0.10mmwiremightbethesamediameter,caliperscapableof0.01mmresolutionmaybeusedtomeasurethefirstwire,butamicrometerwith0.001mmresolutionisneededforthesecondwire.4.6TestRepeatabilityandCalibration4.6.1EquipmentRepeatabilityAllmeasurementequipmentusedforproductevaluationmustberepeatabletowithin20%oftheparttoleranceaccordingtoDaimlerChrysler,Ford,andGeneralMotorsMeasurementSystemsAnalysisReferenceManual(AIAG).4.6.2EquipmentCalibrationEquipmentusedformeasurementorverificationofmeasurementmustbeperiodicallycalibratedtoknownstandards.Calibrationintervalmustbeconsistentwithindustrypracticesbutmaynotbemorethan18months.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-9-4.6.3LaboratoryMastersBulbswhicharetraceabletoknownstandardsarelaboratorymasters.Eachsuppliermustuselaboratorymastersforcomparisonmeasurements,calibrationoftestequipment,andforevaluatinglong-termdriftintestequipment.4.7TestDefaultConditions*Whenspecifictestconditionsarenotgiven,thefollowingbasicconditionsapply:•TestthebulbwiththebaseandfilamentparalleltothegroundasshowninfigureFilamentOrientation.•Performtestsormeasurementsatthefollowingambientconditions:RoomTemperature.....................................≥20°CAtmosphericPressure......…………………..650−800mmMercury•ConducttestsormeasurementsusingthebulbsdesignvoltageaspublishedbytheAmericanNationalStandardsInstitute,Inc.,(ANSI)inSpecialReport25,ANSIAssignedMiniatureLampCodes.•Seasonthebulbsfor1%oftheaveragelife,10hoursmaximumatdesignvoltage,oranequivalentperiodatahigher(forced)voltageasdefinedinAcceleratedLifesection.Notetheseasoningmethodusedonthetestreport.•Wheneverbulbsareoperatedathigherthandesignvoltages,switchthemonattheirdesignvoltageforatleast50millisecondsandthenstepuptotheappropriatedesignvoltage.Thiswilllimittheinrushcurrenttothedesignlevel.4.8TestSharingWithinBulbFamiliesTheresultsoftestsperformedononebulbtypemay,insomecases,beusedtoindicatethecapabilityofanotherbulbtypewithinthesamebulbfamily.Forexample,acrushtestperformedonaclear,S-8,wedgebulbtypemaybeusedasademonstrationoftheglassstrengthofallclear,S-8,wedgebulbtypesmadebythesameprocessfromthesameglassfromthesamesource.Soundjudgmentmustguidethispractice.Bulbswithinthesamebulbfamilythatsharecomponentssuchasglassenvelopes,leadwires,filaments,bases,fillgases,etc.,maybeabletosharetestresults.Thecustomerwillbethefinalauthorityonwhetherthissurrogatedatamaybeused.4.9TestFailureProcedureShouldatestfail,contacttherequestingpartytodetermineifthetestistobecontinuedtogainadditionalproductexperienceoriftestingistobesuspended.Whencontactcannotbeimmediatelymade,stopthetestuntiltherequestingpartycanbecontacted.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-10-4.10ControlPlans*Suppliermustmaintainacontrolplan,consistentwithDaimlerChrysler,Ford,andGeneralMotorsAdvancedProductQualityPlanningandControlPlanReferenceManual,foreachbulbtype(orbulbfamily),thatcontainsappropriatecontrolstoensurethatallthesignificant/criticalcharacteristicscoveredbythetestsinthisspecificationaremet.4.11ReliabilityProgramsandMethods4.11.1ReliabilityGrowthandOngoingQualityImprovementsBulbsuppliersmustestablishandimplementaplantoimprovedemonstratedproductqualityandreliability.Theymustestablishproceduresforanalyzingandcorrectingend-of-linedefectsandpredominantfailuremodesidentifiedbythefieldreturnprogram.Truereliabilitygrowthoccurswhendesignchangestothebulbormanufacturingprocessaremadetoeliminatethefailuremodes.4.11.2NotificationofProcessChangesSuppliersmustnotifythecustomerofmanufacturingprocess,material,ordesignchangestodetermineifresubmissionforPPAPapprovalisrequired.4.11.3Quality/ReliabilityImprovementToolsSuppliersmustuseappropriatemethodstoimprovethequalityandreliabilityoftheirproductsinaccordancewithQS-9000.ExamplesofsuchmethodsareFieldReturnPrograms,DesignFailureModeEffectsAnalysis(DFMEA),ProcessFailureModeEffectsAnalysis(PFMEA),andFaultTreeAnalysis(FTA)orFishboneDiagrams.FurtherinformationonthesemethodsisavailablefromtheAutomotiveIndustryActionGroup(AIAG).4.12HazardousMaterialRestrictionAnyregulatedsubstancethatisidentifiedbyanyfederal,state,provincial,orlocalgovernmentunitorautomotivemanufacturer,shallnotbeusedinthemanufacturingprocessofanybulb.AnybulbmanufacturerthatiscurrentlysupplyinghazardousmaterialinacomponentwillsubmitatimelinetoGeneralMotors,Ford,andDaimlerChryslerfortheremovalofsaidproduct.Interimapprovalsforbulbswillbehandledonanindividualbasisdesignatedbytheindividualautomotivemanufacturer.SAE/USCAR-3Revision2RevisedApril2002SPECIFICATIONFORTESTINGAUTOMOTIVEMINIATUREBULBS-11-5.PHYSICALPERFORMANCEThesetestsareintendedtomeasuretheinnatecharacteristicsofthebulbs.AlldatamustberecordedaccordingtoRecordRetentionsection.5.1PhysicalDimensionsThepurposeofthisexaminationistoverifyallofthephysicaldimensionsofthebulb.5.1.1TestandMeasurementApparatusTheequipmentusedforthisexaminationmustbecapableofdeterminingtheactualdimensionswithinthetolerancelimitsspecifiedinMeasurementAccuracysection.Thisequipmenttypicallyincludesmicrometers,calipers,gages,andopticalprofileprojectors.5.1.2ProcedureSuppliermustmeasureaminimumof10selectedbulbsusingtheappropriateequipment.RecordthedataaccordingtoRecordRetentionsection.5.1.3FailureCriteriaAnybulbwithadimension(s)outsidethespecifiedlimitsconstitutesafailure.NOTE:LightCenterLength(LCL)LCLismeasuredfromthegeometriccenterofthelightsourcetoareferencepointonthebulbbase(Ref.SAEJ573).Thebasereferencepointsforthetwomostcommontypesofautomotivebulbsareasfollows:•BayonetBase.......................topofbasereferencepins•WedgeBase...........................................centerofnotchControloftheLCLisrequiredtoensureconsistentanduniformlightoutputfromthevariousbulbapplicationsonthevehicle.5.2MeanSphericalCandela5.2.1TestandMeasurementApparatusAnintegratingopticalspherewiththeappropriatepowersupply,opticaldetector,photometer,andtraceablestandardlightsourcearerequired.Thefollo