test procedure number - sullivan uv
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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
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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REVISION PAGE
Rev. # Date Page # Para. # Description 0 06/18/09 Complete Document
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
SIGNATURES
Prepared By: Gary Freed Compliance Engineer Reviewed By: Mark Betts, Program Manager
Approved By: David Potpinka, Quality Manager
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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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.
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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.
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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.
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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Appendix A, Test Equipment List
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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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Appendix B, Vibration Data
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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
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: 0.0187546 Locked
A PSD g²/Hz [CH 1] Z 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)
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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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Appendix C, Mechanical Shock Data
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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
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
-20
-10
0
7.9
g
Sec
x: 0.0453906, y: 20.208
A Time Trace g [Control]
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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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
x: 0.0453906, y: -20.0044
A Time Trace g [Control]
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
A Time Trace g [Control]
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
A Time Trace g [Control]
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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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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Appendix D, Photos
NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
Vibration/Shock
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NATIONAL TECHNICAL SYSTEMS NTS Test Report Number: 41418-09.PPC Revision 0
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