QC/T 463-2022 PDF in English
QC/T 463-2022 (QC/T463-2022, QCT 463-2022, QCT463-2022)
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Technical requirements and bench test methods for automotive hydrodynamic torque converter assembly
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| QC/T 463-1999 | English | 399 |
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Motor vehicles. Hydrodynamic torque converter. The specifications
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QC/T 463-2022: PDF in English (QCT 463-2022) QC/T 463-2022
QC
AUTOMOBILE INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 43.040.50
CCS T 21
Replacing QC/T 29033-1991, QC/T 557-1999, QC/T 463-1999
Technical requirements and bench test methods for
automotive hydrodynamic torque converter assembly
ISSUED ON: APRIL 08, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: Ministry of Industry and Information Technology of PRC
Table of Contents
Foreword ... 6
1 Scope ... 9
2 Normative references ... 9
3 Terms and definitions ... 9
4 Technical requirements ... 10
5 Bench test method ... 18
6 Processing of test data ... 33
7 Test report ... 35
Appendix A (Informative) Example of characteristic curve of hydrodynamic torque
converter assembly ... 36
Technical requirements and bench test methods for
automotive hydrodynamic torque converter assembly
1 Scope
This document specifies the technical requirements and bench test methods for
automotive hydrodynamic torque converter assemblies (referred to as torque converter
assemblies).
This document is applicable to the hydrodynamic torque converter assemblies, which
are used in category M and category N vehicles. Other types of hydrodynamic torque
converter assemblies can make reference to this standard.
2 Normative references
The content in the following documents constitutes the essential provisions of this
document through normative references in the text. Among them, for dated references,
only the version corresponding to the date applies to this document; for undated
references, the latest version (including all amendments) applies to this document.
GB/T 2828.1-2012 Sampling procedures for inspection by attributes - Part 1:
Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot
inspection
GB/T 3858 Hydrodynamic drive - Terminology
3 Terms and definitions
The following terms and definitions, as defined in GB/T 3858, as well as the following
terms and definitions, apply to this document.
3.1
Transmission fluid
The working medium in the vehicle automatic transmission, which is composed of
the torque converter assembly and the mechanical transmission.
3.2
Speed ratio
d) The torque ratio of the highest efficiency working condition;
e) Maximum efficiency.
4.1.2 The hydrodynamic torque converter assembly for automobiles shall be able to
work normally, at the ambient temperature of -40 °C ~ 50 °C.
4.1.3 Painting and rust prevention shall meet the following requirements:
a) Internal runners and impellers on parts shall not be painted;
b) The work blank of cast iron and cast steel shells shall be cleaned by sandblasting
and then coated with anti-rust paint; the paint layer shall be even and smooth;
c) The exposed fasteners, joints and other parts shall be treated with anti-rust
treatment.
4.1.4 The internal cleanliness of the hydrodynamic torque converter assembly shall
meet the requirements of the technical documents.
4.1.5 The tests in this document, that need to be completed under lockup conditions, are
only applicable to torque converter assemblies, which have lockup clutches.
4.1.6 The unbalance of torque converter assembly and sub-assembly shall meet the
requirements of technical documents.
4.1.7 The auxiliary devices of the hydrodynamic torque converter assembly, such as
pressure regulating valve, safety valve, oil pump, lockup clutch and its operating parts,
etc., shall be able to work normally, under the conditions specified in the drawings or
technical documents, AND reach the specified service life. Valves shall be adjusted on
the test bench, according to the parameters specified in the design.
4.2 Performance requirements
4.2.1 Basic performance requirements
4.2.1.1 Traction performance
The traction performance can be tested, based on the product requirements, by selecting
one of the constant input speed or constant input torque methods. The product
performance indicators shall meet the following conditions.
a) According to the speed ratio points, which are required by the technical documents,
the variation of the K factor is within the range of ±5.0% of the design reference
value (the variation of the C coefficient or the torque coefficient of the pump is
within the range of ±10.0% of the design reference value);
b) The variation of the torque ratio, in the full speed ratio working condition, is
within the range of ±5.0% of the design reference value.
4.2.1.2 Stall performance
Stall performance indicators shall meet the following conditions.
a) The variation of K coefficient in stall condition is within the range of ±5.0% of
the design reference value (the variation of C coefficient or pump torque
coefficient is within the range of ±10.0% of the design reference value);
b) The variation of the torque ratio, in the stall condition, is within the range of ±5.0%
of the design reference value.
4.2.1.3 Reverse drag performance
Reverse drag performance indicators shall meet the following conditions.
The variation of K coefficient, in reverse dragging condition, is within the range of ±7.5%
of the design reference value (the variation of C coefficient or pump torque coefficient
is within the range of ±15.0% of the design reference value).
4.2.1.4 Lockup clutch's torque capacity
The torque capacity, which is transmitted by the lockup clutch, shall meet the
requirements of the technical documents. Under the rated pressure, the tested torque
capacity value is 1.07 times greater than the design value.
4.2.1.5 Lockup clutch response
To test the lockup response capability of the torque converter assembly, it is required
that there is no sticking during switching AND the response time is less than 1 s.
4.2.1.6 Torsional characteristics of the lockup clutch
The torsional characteristic indicator of the lockup clutch shall meet the requirements
of the technical documents of both the supplier and the buyer. It is required that the
design limit torque of the lockup clutch is not less than 1.2 times the maximum torque
of the engine.
4.2.1.7 Noise of hydrodynamic torque converter assembly
The noise shall meet the following requirements: When the input speed is 2000 r/min,
the sensor and the torque converter assembly are at the distance specified in 5.3.7.1,
meanwhile the noise test value shall not exceed 105 dB (A).
4.2.2 Reliability requirements
4.2.2.1 Pressure pulse reliability of hydrodynamic torque converter assembly
The test frequency is 1 Hz ~ 10 Hz; the total number of cycles shall not be less than 1
x 106; the test torque is set according to the following conditions:
a) Forward torque: 1.3 times the rated torque of the engine OR the design limit torque
of the shock absorber sub-assembly;
b) Reverse torque: 1 time the rated torque of the engine OR the design limit torque
of the shock absorber sub-assembly.
After the test, the following requirements shall be met:
a) Parts are free from cracks, damage, abnormal wear;
b) The change in the torsional characteristics of the shock absorber sub-assembly
shall not exceed the requirements of the technical documents.
4.2.2.5 Dynamic expansion reliability
The test speed is required to reach at least the rated speed of the engine; the data shall
be collected after the test conditions are stable for a single test.
After the test, the following requirements shall be met:
a) The deformation at the following test points shall meet the values, which are
required in the technical documents: The total elastic deformation and plastic
deformation -- from the pump wheel shaft sleeve (test point at S3) to the cover
handle (test point at S1); the elastic deformation and plastic deformation of the
test point at S1; the elastic deformation and plastic deformation of the cover
handle (test point at S1).
b) There is no oil leakage.
c) The functional requirements of the hydrodynamic torque converter assembly can
be guaranteed.
4.2.2.6 Static expansion reliability
The test oil pressure shall meet the requirements: 0.2 MPa shall be added, on the basis
of the maximum working pressure value, which is provided by the transmission
hydraulic system to the torque converter assembly; the test pressure shall be kept for no
less than 1 min.
After the test, the following requirements shall be met:
a) The elastic deformation and plastic deformation of the hydrodynamic torque
converter assembly shall meet the values, which are required by the technical
documents;
assembly shall not be fatigued and damaged; there is no interference between
internal parts;
c) The functional requirements of the hydrodynamic torque converter assembly can
be guaranteed.
4.2.2.9 Torsional durability reliability of connection block
The test torque shall not be less than 6 times of the maximum output torque of the
engine; the test frequency shall be 1 Hz ~ 10 Hz; the total number of cycles shall not be
less than 5 x 106.
After the test, it shall be satisfied that there are no cracks and damages in the cover,
connecting block, welding parts.
4.2.2.10 Durability reliability of eccentric load of pump impeller sub-assembly
Assess the welding strength of the pump wheel load in the pump wheel sub-assembly,
in which the test speed, applied force (or bending moment), number of tests shall meet
the requirements of the technical documents.
After the test, there are no cracks and tears in the welded part of the pump impeller
subassembly.
4.2.2.11 Durability reliability of eccentric load of cover sub-assembly
To examine the welding strength of the cover handle of the cover subassembly, the test
speed, applied force (or bending moment), number of tests shall meet the requirements
of the technical documents.
After the test, there are no cracks and tears in the welding part of the cover handle.
4.3 Inspection rules
4.3.1 Exit-factory inspection
4.3.1.1 Each hydrodynamic torque converter assembly shall undergo exit-factory
inspection, before leaving the factory.
4.3.1.2 The items of exit-factory inspection are as follows:
a) Product specification inspection;
b) Appearance quality inspection;
c) Completeness and packaging inspection;
d) Traction performance test at constant input speed;
e) Dynamic balance test;
f) Torque capacity test of the lockup clutch;
g) Cleanliness inspection.
4.3.1.3 In 4.3.1.2, items a ~ e are mandatory inspection items, whilst items f and g are
random inspection items. The inspection point of item d is determined through
negotiation between the supplier and the buyer. Regular sampling inspections shall be
carried out for batch products in stable production. The quantity of sampling inspection
of each batch of products shall be determined, through negotiation between the supplier
and the buyer.
4.3.2 Type inspection
4.3.2.1 In any of the following situations, type inspection shall be carried out, on
samples of products that have passed the exit-factory inspection.
a) Type identification of trial production of new products OR old products after
trans-plant production;
b) After the official production, if there is a major change in the design, manufacture,
process or materials used, which will affect the product performance;
c) During normal production, one inspection shall be carried out regularly OR after
accumulative production;
d) When the national quality supervision agency requests type inspection.
4.3.2.2 For the type inspection in 4.3.2.1, the quantity of random inspection of each
batch of products shall be determined, through negotiation between the supplier and the
purchaser. It should refer to the provisions of GB/T 2828.1-2012. The batch size and
sampling frequency plan shall be agreed upon, through negotiation by the manufacturer
and the user or the quality supervision organization.
4.3.2.3 Type inspection includes the following items:
a) Traction test at constant input speed;
b) Overspeed reliability of the hydrodynamic torque converter assembly;
c) Durability reliability of hydrodynamic torque converter assembly at low speed
ratio;
d) The torsional durability reliability of the shock absorber sub-assembly;
e) The static expansion reliability;
f) It is required that the control fluctuation of the equipment to the set torque shall
be less than 1%; the fluctuation of the set speed shall not exceed 2 r/min.
g) The range of the instrument, which is used in the test, shall be compatible with
the measurement range; meanwhile it shall be calibrated, according to the national
measurement standard before the start of the test, AND regular review is required.
h) During the test, there shall be no oil seepage or leakage on the surface of the parts
and the oil seal; there shall be no abnormal noise; there shall be no other
conditions that would cause the test to fail to proceed normally.
i) The basic performance tests and reliability tests, which are listed in this document,
are used to verify the design, process and manufacture of the hydrodynamic
torque converter assembly, from the stage of sample trial production to the formal
production stage, which is approved by the purchaser. Except for items with
special instructions.
5.3 Basic performance test methods
5.3.1 Traction test
5.3.1.1 Test device
The test device requirements are as follows:
a) See Figure 1, for the test device.
b) The test device shall meet the following requirements: the operating state,
operating range, measurement of test parameters specified in the test items, as
well as other requirements proposed by the test conditions.
c) Driving and loading equipment: The driving equipment generally uses an electric
dynamometer, DC motor or AC frequency-modulated motor; the loading
equipment generally consists of an electric dynamometer, DC motor or AC
frequency-modulated motor.
d) Installation and fixing device: Ensure that the hydrodynamic torque converter
assembly is reliably fixed on the bench.
e) Bench connection device: Ensure the power transmission of the bench; it is
required to avoid the energy loss of the accessories, as much as possible during
operation.
f) Compensation system: It shall be able to adjust the flow and pressure; have heating,
cooling, safety protection functions.
g) Torque sensor: If the torque measurement accuracy of the dynamometer cannot
meet the requirements, a torque sensor must be added; the torque sensor shall not
5.3.3 Reverse drag test
5.3.3.1 Test device
See Figure 1, for the test device.
5.3.3.2 Test procedure
To test under reverse drag conditions, first keep the value of the output (pump wheel
side) speed equal to zero or close to zero; increase the input (turbine side) speed, until
the input (turbine side) torque reaches the torque value specified in the test; then keep
the input (turbine side) torque remains unchanged; increase the output (pump wheel
side) speed gradually, at the set increment, until the predetermined value.
5.3.4 Torque capacity test of lockup clutch
5.3.4.1 Test device
The test device is as shown in Figure 1.
5.3.4.2 Test procedure
Carry out the test under the traction working condition. Gradually increase the input
speed and output speed, according to the set increment, until reaching the predetermined
value. Switch the hydrodynamic torque converter to run in the lockup working
condition. Adjust the oil pressure on the side of the pump wheel. Wait for the lockup
pressure difference reaches the set value. Keep the input speed unchanged. Gradually
reduce the output speed, according to the set increment, until the target speed difference
is reached.
Repeat the above test, according to the lockup differential pressure value, which is
required by the technical documents.
5.3.5 Lockup clutch response test
5.3.5.1 Test device
The test device is as shown in Figure 1.
5.3.5.2 Test procedure
Carry out the test under the traction condition. Gradually increase the input speed and
output speed, according to the set increment, until reaching the predetermined value.
Keep the speed ratio unchanged. Switch the hydrodynamic torque converter assembly
to run, under the lockup condition. Measure and record the time interval (response time),
FROM when the cover side pressure starts to drop TO when the output torque starts to
increase.
Figure 8 -- Schematic diagram of static expansion test device and test points
5.4.6.2 Test procedure
The static expansion reliability test procedure is as follows:
a) Install the hydrodynamic torque converter assembly on the test bench;
b) Set the corresponding test oil pressure; the oil pressure value and test duration
shall meet the requirements of 4.2.2.6; measure and record the elastic deformation
and plastic phase change of the test point of the hydrodynamic torque converter
assembly.
Repeat the above test, according to different test oil pressure values in technical
documents.
5.4.7 Sliding friction durability reliability test of lockup clutch
5.4.7.1 Test device
The test device is as shown in Figure 1.
5.4.7.2 Test procedure
The test is carried out under the lockup condition. The test conditions shall meet the
requirements of 4.2.2.7. The input and output speed difference reaches the set value.
The single cycle time and the total test duration meet the requirements of 4.2.2.7.
5.4.8 Load acceleration/deceleration reliability test
5.4.8.1 Test device
The test device is as shown in Figure 1.
5.4.8.2 Test procedure
Carry out test under traction conditions. Increase the input speed and output speed to
the idle speed of the engine, at the same time. Keep the output speed constant. Increase
the input speed, step by step according to the set increment, to reach the speed
corresponding to the maximum output torque of the engine. Then gradually reduce the
input speed to engine idle speed.
Carry out the above test process cyclically. The number of tests shall meet the
requirements of 4.2.2.8.
5.4.9 Torsional durability reliability test of connection block
5.4.9.1 Test device
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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