test procedure number - sullivan uv

NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0

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


36 Gi lber t S t reet South • T in ton Fa l l s , New Jersey 07701 (732) 936-0800 • Fax (732) 936-0700

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REVISION PAGE

Rev. # Date Page # Para. # Description 0 06/18/09 Complete Document


SIGNATURES

Prepared By: Gary Freed Compliance Engineer Reviewed By: Mark Betts, Program Manager

Approved By: David Potpinka, Quality Manager


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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



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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

The Pancake Alternator & PMU was checked for damage, during and after testing as applicable.

1.1.3. Testing

Tests and Standard

Test Standard

Vibration Qualification Test Matrix for 315-025005-

009 Mil-Std-810D Method 514.3

Mechanical Shock Qualification Test Matrix for 315-025005-

009 Mil-Std-810D Method 416.3 Procedure V



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2.0 APPLICABLE DOCUMENTS

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.

3.0 TEST ITEMS

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

None



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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.



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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.



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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.



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Appendix A, Test Equipment List


Test Equipment

Asset No. Manufacturer Item Model S/N Cal. Date Cal. Due

nj1532 PCBDC

Accelerometer3711D1FA200

G 1889 12/30/08 12/30/09

nj1205Spectral

DynamicsVibration Controller 2405-9700-1 2400-2041 11/18/08 11/18/09

nj1127 Unholtz Dickie Shaker T1000 476 NCR NCR

nj1130 Unholtz Dickie AmplifierMA145A-130IAR 2418 NCR NCR


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Appendix B, Vibration Data


x: 122.5, y: 0.0169009 Locked

A PSD g²/Hz [CH 1] X Axis Random Vibration

NATIONAL TECHNICAL SYSTEMS

10 20 50 100 200 500 1000 2000

0.0002

0.0005

0.001

0.002

0.005

0.01

0.02

0.1

g²/H

z (L

og)

Hz (Log)

x: 122.5, y: 0.0187801 Locked

A PSD g²/Hz [CH 1] Y Axis Random Vibration


10 20 50 100 200 500 1000 2000

0.0002

0.0005

0.001

0.002

0.005

0.01

0.02

0.1

g²/H

z (L

og)

Hz (Log)

x: 122.5, y: 0.0187546 Locked

A PSD g²/Hz [CH 1] Z Axis Random Vibration


10 20 50 100 200 500 1000 2000

0.0002

0.0005

0.001

0.002

0.005

0.01

0.02

0.1

g²/H

z (L

og)

Hz (Log)


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Appendix C, Mechanical Shock Data


x: 0.0453906, y: 20.2872

A Time Trace g [Control]

NATIONAL TECHNICAL SYSTEMSX 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

-7.8

0

10

21

g

Sec

x: 0.0453906, y: -19.9794


NATIONAL TECHNICAL SYSTEMSX 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

-20

-10

0

7.9

g

Sec

x: 0.0453906, y: 20.208


NATIONAL TECHNICAL SYSTEMSY 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

-7.6

0

10

21

g

Sec


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x: 0.0453906, y: -20.0044


NATIONAL TECHNICAL SYSTEMSY 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

-21

-10

0

7.8

g

Sec

x: 0.0452734, y: 20.3063


NATIONAL TECHNICAL SYSTEMSZ 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

-8.1

0

10

21

g

Sec

x: 0.0452734, y: -20.6142


NATIONAL TECHNICAL SYSTEMSZ 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

-21

-10

0

8.4

g

Sec


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Appendix D, Photos


Vibration/Shock


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test procedure number - sullivan uv

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