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GB/T 12678-1990 English PDF (GBT12678-1990)

GB/T 12678-1990 English PDF (GBT12678-1990)

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GB/T 12678-1990: Reliability running test method for automobiles

This Standard specifies the reliability running test method of automobile. This Standard is applicable to the reliability running test of the whole vehicle during the finalization and quality assessment of various types of vehicles.
GB/T 12678-1990
GB
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
GB/T 12678-90
Replacing GB 1334-77
Reliability Running Test Method for Automobiles
ISSUED ON: DECEMBER 30, 1990
IMPLEMENTED ON: OCTOBER 01, 1991
Issued by: State Bureau of Technical Supervision
Table of Contents
1 Subject Contents and Applicable Scope ... 3
2 Normative References ... 3
3 Terms ... 3
4 Test Conditions ... 4
5 Preparation of Test Vehicle ... 5
6 Test Method ... 5
7 Test Data Processing and Evaluation Index Calculation ... 12
8 Test Report ... 16
Appendix A (Supplement) Records and Statistics Form ... 19
Appendix B (Reference) The Coefficient by which MTBF shall be Multiplied when the Lower Limit of Confidence is Calculated by Fixed-Time Truncation 24 Additional Information: ... 25
Reliability Running Test Method for Automobiles
1 Subject Contents and Applicable Scope
This Standard specifies the reliability running test method of automobile. This Standard is applicable to the reliability running test of the whole vehicle during the finalization and quality assessment of various types of vehicles.
2 Normative References
GB 7031 Mechanical Vibration ?€? Road Surface Profiles ?€? Reporting of Measured Data
GB/T 12534 Motor Vehicles???General Rules of Road Test Method
3 Terms
3.1 Routine reliability test
Reliability test that is carried out in accordance with certain specifications under highway and general road conditions.
3.2 Fast reliability test
A reliability test with a certain fast coefficient that is carried out on the road of the test filed.
3.3 Maintenance after failure
Maintenance that is performed after the vehicle is broke down.
3.4 Preventive maintenance
Maintenance and curing that is carried out according to the cycle and items specified in the vehicle manual.
3.5 Potential failure
A failure that has occurred but has not been discovered, or is discovered during preventive maintenance and disassembly.
4.2.2 Reliability test road of test yard
The reliability test road of the test yard shall generally include: special reliability roads with a fixed road shape (such as: stone road, pebble road, fish scale pit road, washboard road, twisted road, bump road, sand trough, pool, salt water pool, etc.), high-speed runways, ramps, sandy roads, etc.
4.3 Meteorology
Generally, a variety of meteorological conditions shall be selected for testing; and vehicles that are used in special areas or vehicles for special purposes shall be tested under corresponding special meteorological conditions (such as severe cold, damp heat, etc.).
4.4 Test instruments and equipment
Driving condition recorder, weather meter, stopwatch, semiconductor thermometer, engine tachometer, slope meter, pavement meter, etc.
4.5 Tire pressure, fuel, lubricating oil (grease) and brake fluid shall be in accordance with the provisions of Articles 2 and 3 in Clause 3 of GB/T 12534.
5 Preparation of Test Vehicle
The preparation of test vehicle shall be in accordance with Article 1 in Clause 4 of GB/T 12534.
6 Test Method
6.1 Vehicle driving and maintenance (preventive maintenance)
The driving and technical maintenance of the test vehicle shall be in accordance with the provisions of the vehicle's instruction manual.
6.2 Running-in driving
The running-in driving of the vehicle is in accordance with the provisions of Article 2 in Clause 4 of GB/T 12534.
6.3 Reliability driving
6.3.1 The test mileage and the mileage distribution of various roads are specified in the corresponding test procedures.
6.3.2 Test specifications, unless otherwise specified (for example, Test Specification e. Regular maintenance and inspection: In maintenance operations, in addition to item-by-item maintenance as required, attention shall also be paid to check for abnormal phenomena, such as wear, cracks, and deformation of the parts. f. Performance test and vehicle dismantling and inspection.
6.3.3.3 Troubleshooting
a. If the vehicle breaks down, stop immediately. After checking and determining the cause, in principle, the fault must be eliminated in time.
b. If the fault does not affect the driving safety and basic functions, and will not cause an induced fault, the test and observation may be continued, until it needs to be repaired. The fault level and mileage shall be calculated according to at the most serious time.
6.3.4 Vehicle maintenance
6.3.4.1 Maintenance after failure
a. Maintenance scope: limited to the parts directly related to the failure. b. Maintenance method: According to the specific situation, take the fastest and most economical maintenance method, including replacing parts, but the
replaced parts shall be the same batch of qualified products.
c. Maintenance time: including fault diagnosis time, maintenance preparation time, actual repair time, commissioning and site cleaning time.
d. Maintenance costs: including costs for materials, equipment and working hours. 6.3.4.2 Preventive maintenance
a. Preventive maintenance content: including tightening, adjustment, lubrication, cleaning and replacement of the wearing parts.
b. Preventive maintenance time: the time from the beginning of preparation work to the end of all work. The fixed number of maintenance personnel is two persons per vehicle. When the fixed number is less than or exceeded, the maintenance time is converted to the standard number of man-hours.
c. Preventive maintenance costs include costs for materials, equipment and working hours.
d. When carrying out preventive maintenance, if any non-preventive maintenance items are found to be faulty, follow the procedures in 6.3.3 and 6.3.5.3. 6.3.5 Test record
??2 min.
6.3.5.4 Preventive maintenance records
The preventive maintenance that is carried out during the test must be carefully filled in the preventive maintenance record card (see Table A4 in Appendix A). 6.4 Automobile performance test
6.4.1 Automobile performance tests are carried out at the beginning and after the end of the reliability driving test to determine whether it meets the design requirements or the limits and stability set by the state.
6.4.2 Test contents (according to test category, increase or decrease according to test regulations) include:
a. Power: maximum speed, minimum stable speed, acceleration performance; b. Fuel consumption: fuel consumption for constant speed driving, fuel consumption for multiple working conditions and fuel consumption for driving under limited conditions;
c. Braking performance: braking distance, braking speed, braking stability and parking brake;
d. Noise and concentration of emissions;
e. Handling stability;
f. Ride comfort and body airtightness, etc.
6.4.3 The test method shall be in accordance with the corresponding national standard or professional standard.
6.4.4 Before the performance test, no other maintenance and adjustments are allowed except for the specified adjustment items.
6.5 Disassembly and inspection of automobiles
6.5.1 After the automobile test, in order to check the wear and other abnormal phenomena of the internal structure of each assembly, the main assembly (including engine, clutch, transmission, steering gear, drive axle, etc.) shall be partly or wholly dismantled and inspected.
6.5.2 The main content of the dismantling and inspection is shown in Table 1. The table only lists the dismantling and inspection items of the general structure of the automobile. For other special structures, the disassembly and inspection items may be specified separately depending on the vehicle type.
7.2 Failure statistics
7.2.1 All failures are counted in the failure statistics table (Table A5 in Appendix A) in the order of the mileage in which the failures are found.
7.2.2 The types of failures in the table shall be filled in: "essential failures" and "misuse failures".
7.3 Reliability data statistics
According to the calculation requirements of the evaluation index, conduct the statistics of various types of failure frequency and first failure mileage, equivalent failure number, actual mileage, average technical speed, failure maintenance time, preventive maintenance time and maintenance costs, etc. (see Table A6 in Appendix A). 7.3.1 Principles of failure statistics
7.3.1.1 Only essential failures are considered, and misuse failures are not counted as failures.
7.3.1.2 The failure that has not been eliminated only counts once. The failure category is classified according to the most serious situation; and the corresponding mileage is the failure mileage.
7.3.1.3 The failures of different parts of the same mileage shall be counted separately. Different modes of failures on the same part shall also be counted separately; if several failures of the same mode occur on the same part, they shall be counted only once, and the failure category shall be classified according to the most serious condition. 7.3.2 The equivalent number of failures are calculated as follows:
Where:
rD ?€? equivalent number of failures;
??i ?€? the ith failure coefficient; the values of which are ??1 =100, ??2 =10, ??3 =1, ??4 =0.2; ri ?€? the number of ith failures.
7.4 Automobile reliability evaluation index and its calculation method
7.4.1 Mean time to first failure (MTTFF)
7.4.1.1 When the number of test vehicles is less than 5, it is estimated as follows: factory date, initial driving mileage, certificate number and serial number, etc. 8.4 Test conditions
Including vehicle, load, road, weather and other conditions, as well as the used fuel and mileage distribution.
8.5 Test instruments and equipment
8.6 Test date and procedure
8.7 Test results
8.7.1 Statistics of driving conditions.
8.7.2 Statistics of failure and maintenance.
8.7.3 Reliability evaluation index calculation results.
8.7.4 Disassembly inspection results.
8.8 Analysis of reliability test results
Perform the necessary reliability analysis according to the requirements of the test purpose, for example:
8.8.1 The histogram of the failure frequency or failure rate distribution of each subsystem.
8.8.2 Failure criticality analysis and failures sorted by importance.
8.8.3 Special analysis of important failures (failures with large hazards and high frequency), and propose a failure analysis report.
8.8.4 The graph of the cumulative number of failures versus the total test time. 8.8.5 Maintainability evaluation and analysis.
8.9 Conclusions and recommendations
8.10 Test organization
Including the name, title, organization and labor division of the test personnel. 8.11 Appendix
8.11.1 Failure maintenance statistics.
8.11.2 Performance test records.

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