Sae j577 201509 實驗室跟108 一樣的衝擊測試

Downloaded from SAE International by Ashley Lei, Monday, May 13, 2019
SURFACE VEHICLE J577™ SEP2015
RECOMMENDED PRACTICE Issued 1940-01

Reaffirmed 2011-06
Revised 2015-09
Superseding J577 JUL2005
(R) Vibration Test Machine and Operation Procedure
RATIONALE
Vibration machine is designed to simulate worst case road inputs to lamps. The 2005 version of SAE J577 documented a
FMVSS compatible machine that could be suitable to qualify lamps. All lamps must also pass the FMVSS requirement but
technology advancements and styling progression has resulted in large lamps being used on vehicles. The larger lamp
with fixture cannot be contained within the platform on the SAE J577 2005 version (Example 1). Pre re-write FMVSS
requires that the fixture does not overhang the vibration machine adapter plate, which cannot be done with large lamps and
the current SAE J577 machine. To update SAE J577, an example of larger vibration machine (Example 2) is given in this
standard and a minimum Grms value is added to validate machine performance. The Grms value sets the minimum
performance of any size vibration machine. Enlarging the vibration machine is limited by the FMVSS requirement that during
calibration a force gauge must measure between 60 -70 pounds when lifting the platform over the hammer and anvil area
of the machine.
J577 Vibration Machine Differences

Vibration Machine Type and Bandwidth Comparison
7
6
5
4
Grms
3
2
Example 2, Grms(600Hz) Example 1, Grms (600Hz)
1
0
0 10 20 30 40
Fixture Weight
__________________________________________________________________________________________________________________________________________
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 revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
suggestions.
Copyright © 2015 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of SAE.
TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) SAE values your input. To provide feedback
Tel: +1 724-776-4970 (outside USA) on this Technical Report, please visit
Fax: 724-776-0790 http://www.sae.org/technical/standards/J577_201509
Email: [email protected]
SAE WEB ADDRESS: http://www.sae.org
SAE INTERNATIONAL J577™ SEP2015 Page 2 of 27
1. SCOPE
This SAE Recommended Practice provides procedures, and information to conduct vibration (impact) tests on lighting
devices and their components as well as other safety equipment used on vehicles.
Figure 1 - Example 1 vibration test machine
Figure 2 - Example 2 vibration test machine

2. REFERENCES
2.1 Related Publications
The following publications are provided for information purposes only and are not a required part of this SAE Technical
Report.
2.1.1 SAE Publications
Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA
and Canada) or +1 724-776-4970 (outside USA), www.sae.org.
SAE J575 Tests for Motor Vehicle Lighting Devices and Components
SAE J2139 Tests for Lighting Devices, Reflective Devices and Components Used on Vehicles 2032 mm or more in
Overall Width
SAE 861957 Headlight Vibration Testing for Heavy Duty Trucks
SAE 840501 Automotive Component Vibration: A Practical Approach to Accelerated Vibration Durability Testing
SAE 790747 Vibration Test for Motor Vehicle Lighting Devices and Components
2.1.2 FMVSS Publications
Available from the National Highway Traffic Safety Administration, 400 Seventh SW, Washington, DC 20024-0002.
FMVSS-108 Lamps Reflective Devices, And Associated Equipment (Available as 49 CFR 571.108)
2.2 Other Publications
U.S. Department of Agriculture General Technical Report FPL 22—An Assessment of the Common Carrier Shipping
Environment
3. DEFINITIONS
3.1 ANVIL
The member located at the front of the machine on the lower base plate, that is struck by the hammer when the top plate is
falling.
3.2 CAM FOLLOWER
A mechanism that contains a roller(s) that comes in contact with the cam(s) surface and thereby reduces the friction and
wear on the cam by rotating rather than rubbing.
3.3 HAMMER
The member located at the front of the machine on the upper plate, that strikes the anvil when the top plate is falling.
3.4 VIBRATION TEST FIXTURE
A fixture specifically designed to support the device under test in its designed operating position during the vibration test.
Size of fixture should not overhang the base plate of the vibration machine. Fixture overhang may result in excessive
vibration force and a false failure.
4. LIGHTING IDENTIFICATION CODE
Not applicable.
5. TESTS
5.1 Calibration Equipment and Instrumentation
Equipment listed is a guide for standardization only. Equivalent instrumentation equipment is available, however test results
should be checked for accuracy
5.1.1 Force Gage
5.1.1.1 Force/Torque Indicator with 50 x 0.02 kgf Capacity, 500 x 0.2 N, accuracy ± 0.2% of full scale ± 1 digit.
5.1.1.2 Force Sensor with 50 x 0.02 kgf Capacity, accuracy ± 0.15% of full scale ± 1 digit.
5.1.2 Go-No-Go Gages
5.1.2.1 Gage specified in Figures 3, below should be used to set the machine up and for recalibration.
5.2 Vibration Test
This test evaluates the ability of a device to resist damage from vibration-induced (impact-induced) stresses.
5.3 Vibration Test Procedures
5.3.1 A sample of the device, mounted in the specified vibration test fixture shall be bolted to the anvil end of the table on
the vibration test machine and vibrated at 12.5 ± .17 Hz (750 ± 10 cpm) through a vertical distance of 3.2 mm ± .25
mm. The table shall be spring mounted at one end and fitted with a steel hammer on the underside of the other
end. The hammer shall contact the steel anvil once during each cycle at the completion of the fall. The impact force
shall be 290 N ± 20 N as measured with a force gauge above the anvil.
6. VIBRATION MACHINE REQUIREMENTS
The vibration system shall consist of a vibration machine and the mounting base. For large lamps and fixtures a large
machine should be used to prevent the fixture from overhanging the mounting base.
NOTE: Deviation from the specifications as listed could compromise the performance of the vibration test.
6.1 A mounting base for the vibration machine should meet the specifications in drawing 230050, which can be found in
the appendix of this document.
6.2 The designed machine mounting plate size for Example 1 machine is recommended to be 152.4mm x 304.8mm and
12.7mm thick. Example 2 machine shows a usable mounting plate size of 457.2mm x 660.4mm and 9.5mm thick.
Any mounting plate size can be used as long as it meets the Grms energy requirement and upward force requirement.
Machine mounting plate material shall be steel and be sufficiently thick to prevent flexure during the impact cycle..
a. The raising and dropping of the fixture shall be accomplished with use a CAM. Dimensions of the cam are shown
in Figure 4.
b. Impact vibration energy is imparted to the DUT when the Hammer (located on the moving base plate) is accelerated
downward and contacts the stationary Anvil.
c. Motion of vibration machine is intended to be Z axis only. A mechanism, such as V block or roller bearing, shall be
used to restrict motion side to side.
d. Vibration machine shall use spring(s) at front and rear or midsection of the machine to set gap, levelness, and
impact force.
e. Force to lift the table at the anvil must be 290N + 20N as measured with a force gauge.
f. Resultant energy imparted to the DUT shall be a minimum of 4.0 Grms as measured with a 200G accelerometer
with a signal processing bandwidth of 600Hz.
g. An electronic motor controller shall be used to provide accurate frequency control for the impact cycle. (12.5Hz +
0.17Hz)
h. Fixtures mounted on the vibration machine should not be larger than the mounting plate and not weight in excess
of 27 kg.
i. The mounting base should be equipped with vibration isolation feet to reduce the coupling of vibration energy into
the floor.
7. MACHINE SET-UP AND CALIBRATION
7.1 The vibration isolator system on the mounting base should be pressurized to a minimum of 275.6 kPa
7.2 Rear Spring Set-Up - Displacement is adjusted by changing the tension of the rear springs (opposite the anvil). Be
sure to verify the base plate is level when adjusting the rear springs
7.3 Calibration Procedure
7.3.1 Cam Set-Up
7.3.1.1 Care should be taken to assemble the cams on the machine correctly. When viewing the cams from the pulley
side of the machine, the cams should rotate clockwise.
7.3.1.2 Manually rotate the cams to Top-Dead-Center (TDC). This will provide the largest gap between the hammer and
anvil.
7.3.1.3 Check the gap using the “GO-NO-GO” gage in Figure 3. Adjust the cantilevered cam followers until the “GO”
portion of the gage fits between the hammer and anvil.
7.3.2 Spring Force Calibration
7.3.2.1 Rotate the cam from TDC backwards until the highest point on the cam stops at the cam follower. This is the
lowest point on the cam and the hammer should be touching the anvil.
7.3.2.2 Place the calibration frame ( Π shaped) in the receptacles as shown in Figure 1 and Figure 2.,. Install the lifting
hook in the accelerometer-mounting hole in the fixture mounting plate directly over the center of the anvil.
7.3.2.3 Attach the force gage specified to the calibration frame and attach it to the hook installed on the fixture plate.
Tighten the screw on top of the calibration frame until the gap between the hammer and anvil fits the “GO-NO-
GO” gage in Figure 3.
7.3.2.4 Adjust the front spring(s) until the calibration gage indicates 290 N ± 20 N
8. TEST FIXTURE DESIGN
8.1 The weight of the DUT and the fixture shall be a maximum of 27.0 kg The center of gravity of the fixture and the DUT
should be centered as near as practicable over the anvil.
Figure 3 - Gap gage
9. GUIDELINES
9.1 Preventive Maintenance and Re-calibration
9.1.1 Calibration of the machine should be checked after 150 hours of tests or per the companies re-calibration schedule,
which ever is less . Repair or replacement of worn machine components requires recalibration.
9.1.2 The machine should be inspected before and after each test to see if there is any wear appearing on the
components and that all of the springs are functioning properly.
9.1.3 The machine should be lubricated on a quarterly basis or per the companies preventive maintenance schedule,
which ever is less.
10. NOTES
10.1 Revision Indicator
A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not
editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title
indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original
publications, nor in documents that contain editorial changes only.
PREPARED BY THE SAE TEST METHODS AND EQUIPMENT STANDARDS COMMITTEE

Figure 4 - CAM details

APPENDIX A
A.1 MOUNTING BASE MACHINE DRAWINGS
Table 1 - Mounting base bill of material
ITEM ASY SHT DTL SHT QTY MATERIAL FINISH SIZE OR NAME
1 2 1 PUR CARR LANE, SWING BOLT #CL-2-SB
2 2 4 PUR FIRESTONE, AIRMOUNTS STYLE #16
3 2 1 PUR McMASTER-CARR, DRAWER & DOOR

PULLS #187A64
4 2 3 PUR McMASTER-CARR, HEX THIN (JAM)

NUT #91847A520
5 2 3 PUR McMASTER-CARR, LARGE O.D. FLAT

WASHER #91090A118
6 2 3 PUR & ALT McMASTER-CARR, THREADED ROD

#98847A033
7 3 5 1 WELDMENT BASE WELDMENT ASEMBLY
8 3 6 1 WELDMENT MOUNTING PLATE SUB-ASSEMBLY
9 3 7 2 STEEL TUBE MOUNTING PLATE CROSSMEMBER
10 3 8 1 1018 WEIGHT RACK COVER
11 3 9 4 1018 WEIGHT
23050-01
Mounting base assembly

Mounting base assembly

Rod weight clamp

Base weldment
Mounting base crossmember

Weight rack cover

Weight
A.2 TYPE 1 MACHINE DRAWINGS
Table 2 - J577 Machine bill of material
BILL OF MATERIALS
QTY Part No. Description
1 251942-01 Main Assembly
1 251942-02 Weldment Detail #2
1 251942-04 Weldment Detail # 4
1 251942-08 1.000 X 15.000 X 45.000 CRS
2 251942-09 1.670 DIA X 10.250 LG CRS
1 251942-12 1.250 SQ X 6.000 LG. # 4140 STL.
1 251942-13 1.250 X 1.500 X 6.000 LG. CRS
1 251942-14 0.750 X 1.000 X 4.125 LG. CRS
2 251942-15 FAFNIR PILLOW BLOCK #G1012KRRB, RAK 3/4
1 251942-16 0.500 X 6.000 X 26.625 LG. CRS
1 251942-17 0.750 X 2.000 X 11.000 CRS
1 251942-18 1.250 DIA X 13.375 LG. D2 58/62Rc STL.
1 251942-21 1.250 SQ. X 2.500 LG. #4140 STL.
1 251942-22 1.250 SQ. X 4.500 LG. CRS
2 251942-23 1.625 X 1.750 X 6.500 LG. CRS
1 251942-24 1.250 X 2.750 X 6.000 LG. D2 STL.
1 251942-25 1.000 X 2.875 X 11.875 LG. CRS
4 251942-26 Century Spring #11996
1 251942-27 Electric Motor, Baldor # CDP3320
1 251942-28 Bushed Gearbelt Pulley, Browning # 18LG075
1 251942-29 Bushed Gearbelt Pulley, Browning # 40LH075
1 251942-30 Timing Belt, Gates # 600L075
2 251942-31 Cam Follower, Roller Bearing Co. of America # S40L
2 251942-32 Cam follower # S32LW & Lube Fitting #36235 Roller Bearing Co. of America
4 251942-33 1.810 DIA X 0.344 LG. Tool STL
4 251942-34 1.810 DIA X 0.564 LG. Tool STL
1 251942-35 0.500 DIA X 2.250 X 4.000 LG CRS
2 251942-37 0.250 SQ. X 1.360 LG. Key
2 251942-38 E-Ring, McMaster Carr #98407A156
2 251942-40 1/8" Grease Zerk, McMaster Carr # 1095K11
2 251942-41 2.000 DIA X 1.500 LG Hardened D2 STL
1 251942-42 0.500 X 6.000 X12.000 LG. CRS
2 251942-43 2.000 SQ. X 14 GA. Tubing X 3.000 LG
2 251942-44 1.500 SQ X 0.125 Wall Tubing X 18.000 LG.
1 251942-45 1.500 SQ X 0.125 Wall Tubing X 11.250 LG.
1 251942-46 12GA. X 17.605 X 40.908 LG. CRS
Table 2 - J577 Machine bill of material (continued)
BILL OF MATERIALS
QTY Part No. Description
1 251942-47 Inline Force/Torque Indicator Mark -10, Model BGI, Series SSM100
2 251942-49 0.125 SQ. X 2.000 LG. Key
1 251942-50 Red Oak Quarter Sawn 1.625 X 15.000 X 45.000 LG.
3 251942-52 Hook, Purchased W/ P/N 251942-47
2 251942-53 0.125 X 1.000 X 1.000 Angle X 1.250 LG.
1 251942-54 2.250 X 2.188 X 7.500 LG. CRS
1 251942-56 1.250 X 4.500 X 6.000 LG. CRS
2 251942-61 1.250 SQ. X 8.000 LG. CRS
1 251942-62 Sub-Assembly
1 251942-63 1.000 X 2.000 X 3.000 LG. CRS
1 251942-66 Hinge, McMaster Carr # 16175A15
1 251942-67 0.750 X 1.000 X 4.125 LG. CRS
4 251942-68 0.125 X 1.000 X 1.000 Angle X 1.000 LG.
2 251942-69 1.250 DIA X 0.437 LG. Hardened Tool STL
1 251942-71 0.250 X 1.750 X 2.125 LG. CRS
1 251942-72 Honda ATV Valve Spring #14751-KCY-670
1 251942-73 Bushing, Browning # H 3/4
1 251942-74 Bushing, Browning # G 5/8
1 251942-75 Dart Tachometer #MDIOP
1 251942-76 Dart Pulse Generator # PU2E
2 251942-77 0.125 X 1.000 X 1.500 Angle X 1.000 LG.
2 251942-78 0.250 X 1.380 X 3.000 LG, CRS
1 251942-79 0.500 X 2.375 X 2.000 Angle X 1.500 LG.
1 251942-80 1.000 DIA X 1.500 LG. ROD
1 251942-81 0.250 DIA X 4.000 LG. ROD
1 251942-82 1/4-20UNC SHCS X 1.250 LG
1 251942-83 0.093 DIA X 1.250 LG. ROD
Vibration test machine assembly

Vibration machine top and side views

Vibration machine with calibration frame

Vibration machine cross sections

Weldment details and base sub-assembly

Component details
Component details
Component details
Component details
Component details

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Downloaded from SAE International by Ashley Lei, Monday, May 13, 2019

SURFACE VEHICLE J577™ SEP2015

RECOMMENDED PRACTICE Issued 1940-01

Superseding J577 JUL2005

(R) Vibration Test Machine and Operation Procedure

J577 Vibration Machine Differences

SAE INTERNATIONAL J577™ SEP2015 Page 2 of 27

Figure 1 - Example 1 vibration test machine

Figure 2 - Example 2 vibration test machine

SAE INTERNATIONAL J577™ SEP2015 Page 3 of 27

2.1 Related Publications

2.1.1 SAE Publications

SAE 861957 Headlight Vibration Testing for Heavy Duty Trucks

2.1.2 FMVSS Publications

2.2 Other Publications

3.2 CAM FOLLOWER

3.4 VIBRATION TEST FIXTURE

SAE INTERNATIONAL J577™ SEP2015 Page 4 of 27

4. LIGHTING IDENTIFICATION CODE

5.1 Calibration Equipment and Instrumentation

5.1.1 Force Gage

5.1.2 Go-No-Go Gages

5.2 Vibration Test

5.3 Vibration Test Procedures

6. VIBRATION MACHINE REQUIREMENTS

SAE INTERNATIONAL J577™ SEP2015 Page 5 of 27

7. MACHINE SET-UP AND CALIBRATION

7.3 Calibration Procedure

7.3.1 Cam Set-Up

7.3.2 Spring Force Calibration

SAE INTERNATIONAL J577™ SEP2015 Page 6 of 27

8. TEST FIXTURE DESIGN

Figure 3 - Gap gage

9.1 Preventive Maintenance and Re-calibration

10.1 Revision Indicator

PREPARED BY THE SAE TEST METHODS AND EQUIPMENT STANDARDS COMMITTEE

SAE INTERNATIONAL J577™ SEP2015 Page 7 of 27

Figure 4 - CAM details

SAE INTERNATIONAL J577™ SEP2015 Page 8 of 27

A.1 MOUNTING BASE MACHINE DRAWINGS

Table 1 - Mounting base bill of material

2 2 4 PUR FIRESTONE, AIRMOUNTS STYLE #16

3 2 1 PUR McMASTER-CARR, DRAWER & DOOR

4 2 3 PUR McMASTER-CARR, HEX THIN (JAM)

5 2 3 PUR McMASTER-CARR, LARGE O.D. FLAT

6 2 3 PUR & ALT McMASTER-CARR, THREADED ROD

7 3 5 1 WELDMENT BASE WELDMENT ASEMBLY

8 3 6 1 WELDMENT MOUNTING PLATE SUB-ASSEMBLY

9 3 7 2 STEEL TUBE MOUNTING PLATE CROSSMEMBER

10 3 8 1 1018 WEIGHT RACK COVER

SAE INTERNATIONAL J577™ SEP2015 Page 9 of 27

Mounting base assembly

SAE INTERNATIONAL J577™ SEP2015 Page 10 of 27

Mounting base assembly

SAE INTERNATIONAL J577™ SEP2015 Page 11 of 27

Rod weight clamp

SAE INTERNATIONAL J577™ SEP2015 Page 12 of 27

SAE INTERNATIONAL J577™ SEP2015 Page 13 of 27

Mounting base crossmember

SAE INTERNATIONAL J577™ SEP2015 Page 14 of 27