Bsr shaker process description 03012012

IP/SEAT SQUEAK & RATTLE PREVENTION

Jurgen Smets

S&R Body Engineering, FoE

January 03, 2012

IP/SEAT S&R SHAKER PROCESS

IP & SEAT S&R SHAKER PROCESS

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Dare : January 10, 2012

Jurgen Smets, S&R Body Engineering, FoE

1. Why S&R shaker testing

■ to support S&R DV/PV testing as earliest as possible

(when vehicle is not available yet)

■ to support S&R Root Cause Investigation

( can not evaluate with head in IP or underneath seat during drive or on hydropuls )

■ to support S&R ICA/PCA validation

( to validate Interim Containment and Permanent Corrective Action before being introduced in Production )

■ to support S&R Quality control

( to allow the cockpit supplier/assembler prove that IP/SEAT S&R quality is under control )

( to find new S&R issues earlier and before being shipped to Ford and to the End-customer)

( to focus on system level ilo vehicle level S&R testing )

( to realise condensed durability testing )


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2. Objective

No component shall produce any annoying buzz, squeak and rattle

( buzz, hum, squeak, chirp, creak, grind, squeal, crack, ring, snap, tick, click,

knock, rustle, rumble, hiss, whistle, chafe, whine, chatter, chuckle, clatter,

cluck, chuck,…..)

audible from a distance of 25 cm around the whole IP/centre console outer surface,

during the IP/centre console S&R shaker evaluation.


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3. 1. Facility Set up – external view inside JIT plant

Airco-condensor unit

L W H

5000 X 4000 X 4000

Shaker

Amplifiers

(outside room)


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3. 2. Facility Set up – internal view inside acoustic room

front view

side view

Acoustic chamber with max 40dBA background noise


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3. 3. Facility Set up – acoustic room requirements

The acoustic chamber has max 40dBA background noise

One Custom Industrial Noise Control Test Enclosure with measurements of 5m (inside length)

by 4m (inside width) and roughly 4m (inside height) to….

A. allow enough space around shaker, as shaker is often used as demonstrator tool;

B. include shaker facility controller unit;

C. include operator desk and quality data storage;

D. include assembly tools storage;

E. include nominal buck for static S&R evaluation (ref seats static S&R eval);

D. allow the IP manipulator feed/install/remove the test IP to/from the test fixture;

F. include IP fixture (components) if IPs for multiple vehicle lines being are tested


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3. 4. Facility Set up – acoustic room requirements

Doors will be butt hinged and will have a dual sealed of (1) 3/4" magnetic and (1) neoprene gasket, to maintain the same acoustical performance of the wall panels. Doors will be supplied with door closers which have a hold door open feature for both doors.Inside of the door there will have one door plunger to release the latch. All doors will have (1) 12” x 12” windows.

Windows will be double glazed, 1/4" safety glass mounted in tight sealing steel with neoprene gasket frame. Double glazed windows provide the acoustical performance as required by ASTM E90-75. Windows will be (1) 12” x 12” on each door leaf.

Lighting consist of (4) surface mounted self seal pendent lights and will be turned off and on by the switch supplied with this enclosure.

Ventilation system provided for this enclosure. Ventilation will also contain (2) noise attenuators inside of each vent system.

Acclimatisation ( silent airconditioner unit) is required as well, as inside temperature get reasonably highdue to the heat radiation of the shaker facility and human body heat (certainly when crowded) andthe sealed acoustic room.

Enclosure will have (1) 2” cable feed thru for air lines, electrical or other audio or equipment cabling.


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IP S&R SHAKER – COLOGNE JIT IP S&R SHAKER – SAARLOUIS JIT

IP S&R SHAKER – GENK JIT IP S&R SHAKER – VALENCIA JIT


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4. S&R Shaker capability – 5D Pitch and Roll system

Required module response directions are : vertical, pitch, fore/aft, roll and lateral


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5. Prefered S&R shaker specification


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6. Installation requirements


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7. WHY 5D Pitch and Roll system ?

Single axis shaker is not capable of reproducing S&R issues, that have

been detected on Ford Global S&R track

Single axis shaker with pivot table is more capable

of reproducing S&R issues, but requires double test timeAND can not fully approximate in vehicle testing conditions


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8. GLOBAL S&R SHAKER TEST PROFILES

Track surface Nr 1 – Harsh Road ( 25 mph / 40 kmph)

Track surface Nr 2 – Belgian Blocks ( 25 mph / 40 kmph)

Track surface Nr 3 – Tarr patch ( 45 mph / 72 kmph)

Track surface Nr 4 – Cobble Stones ( 5 mph / 8 kmph)

Track surface Nr 5 – Rough Brick ( 25 mph / 40 kmph)


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9. GLOBAL S&R SHAKER TEST PROFILES (car segment specific RLD)

Track surface Nr 1 – Harsh Road ( 25 mph / 40 kmph)

Track surface Nr 2 – Belgian Blocks ( 25 mph / 40 kmph)

Track surface Nr 3 – Tarr patch ( 45 mph / 72 kmph)

Track surface Nr 4 – Cobble Stones ( 5 mph / 8 kmph)

Track surface Nr 5 – Rough Brick ( 25 mph / 40 kmph)

Right A-Pillar Vertical Random PSD Profile for Be lgian Blocks @ 25 mph

0,0E+00

1,0E-03

2,0E-03

3,0E-03

4,0E-03

5,0E-03

6,0E-03

7,0E-03

8,0E-03

5 15 25 35 45 55 65 75 85 95 Hz

g2/Hz

LAP Composite RAP Composite PSD Profile

Right A-Pillar Ve rtical Random PSD Profile for Hars hnes s @ 45 mph

0,0E+00

2,0E-03

4,0E-03

6,0E-03

8,0E-03

1,0E-02

1,2E-02

5 10 15 20 25 30 35 40 45 50

Hz

g2/Hz


Grms = .34

Right A-Pillar Vertical Random PSD Profile for Belgian Blocks @ 25 mph

0,0E+00

1,0E-03

2,0E-03

3,0E-03

4,0E-03

5,0E-03

6,0E-03

7,0E-03

8,0E-03

5 15 25 35 45 55 65 75 85 95 Hz

g2/Hz


Left A-Pillar Vertical Random PSD Profile for Cobblestones @ 5 mph

0,0E+00

1,0E-03

2,0E-03

3,0E-03

4,0E-03

5,0E-03

6,0E-03

7,0E-03

8,0E-03

5 10 15 20 25 30 35 40 45 50

Hz

g2/Hz

LAP Composite RAP Composite PSD Prof ile

Grms = .20

Left A-Pillar Vertical Random PSD Profile for Rough Brick @ 25 mph

0,0E+00

5,0E-04

1,0E-03

1,5E-03

2,0E-03

2,5E-03

3,0E-03

5 15 25 35 45 55 65 75 85 95 Hz

g2/Hz

LAP Composite RAP Composite PSD Prof ile

Grms = .19

Pitch = 0,33 GrmsRoll (if MISO) = 70% 0,33 = 0,23 Grms






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10. GLOBAL S&R SHAKER TEST MODES

S&R Test/evaluations to be executed in pitch and roll mode,

pending shaker controller type

Multi-In/Single-Out (MISO) controller

Multi-In/Multi-Out (MIMO) controller

Recommendation : to use MIMO controller

Why ? Pitch and roll mode run simultaneously which will reduce

test time by more than half.

With MISO, pitch and roll mode need to be tested in

a sequencial way. Additionally, the system needs re-

callibration time between modes


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11. GLOBAL S&R SHAKER TEST SEQUENCE

Part One : Static S&R testing (10 min)

ALL STATIC TESTING IS TO BE PERFORMED TO THE FOLLOWING SPECIFICATIONS:

FOR IP :

Test is performed while IP / centre console is fixed in shaker jig;Open and close all storage-, top & glove boxes, bins, ashtrays;Adjust all airvent registers in all possible positions/directions;

Adjust/push all HVAC, Radio,…. buttons/controls

FOR SEATS :

Test is performed while seat is fixed in nominal buck/fixture;Evaluate noises during occupant load in 27 seat positions :

Factors : seat position (in x) = design position, fully forwards, fully rearwardsseat position (in z) = design position, fully up, fully downback rest = design position, tilted forwards, tilted rearwards headrest = in highest position


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12. GLOBAL S&R SHAKER TEST SEQUENCE

Part TWO : DYNAMIC S&R testing (30 min)

Loosen up - TRACK No 6 : Harsh Road (+/-5min)

Start detection :

TRACK No 1 : Tarr patch ( 45 mph / 72 kmph) (+/-5min)

TRACK No 2 : Rough Brick ( 25 mph / 40 kmph) (+/-5min)*

TRACK No 3 : Cobble Stones ( 5 mph / 8 kmph) (+/-5min)*

TRACK No 4 : Belgian Blocks ( 25 mph / 40 kmph) (+/-5min)TRACK No 5 : Harsh Road ( 25 mph / 40 kmph) (+/-5min)

Note 1 : if MISO controller , then all tracks to be applied in pitch and roll mode (2x 5min = 10min)

Note 2 : in order to increase the test rate (=number of test units), recommendation is toeliminate testing on rough brick and cobble stone surfaces* after PP build.

Note 3 : for seats 20% occupied driver’s seat – 80% unoccupied passenger’s seat can be applied.

Note 4 : number of seating test positions can be reduced pending seat type and occurrence rate


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13. Recommended Test Rates

VP BUILD >>> 100% of IP/SEATS

TT BUILD >>> MIN 50% of IP/SEATS

PP BUILD >>> MIN 20% of IP/SEATS

As of MP1 BUILD >>> MIN 10x IPs/SEATS when 2 production shift

MIN15x IPs/SEATS when 2 production shift

NOTE : cockpit build up and Issue detection takes +/- 1 hour.

Above given test rates can only be achieved if no new

issue have been found. If new issues have been found,issue demonstration, rootcause analysis, ICA and PCA

validation get priority over further testing


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14. IP shaker issue severity rating to set resolution priorities

FOR STATIC IP BSR EVALUATION (PART I)

>> If issue is NOK operational noise (eg cheap sound) >>> SCORE = 20 points

>> If issue is squeak/rattle during operational noise >>> SCORE = 60 points

FOR DYNAMIC IP BSR EVALUATION (PART II)

>> If issue is MINOR during forced excitation on >>>SCORE = 40 points

>> If issue is MAJOR during forced excitation on: >>>SCORE = 80 points

MINOR = noise audible at ear 25 cm removed

MAJOR = noise audible at ear 60 cm removed


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15. Concern handling

Current model PV testing :

The following issue types needs to be treated as real issues and require

an immediate and adequate issue resolution (ICA/PCA) approach.

1. all issues, caused by SDS in-compliance;

2. all issues, caused by Health Chart in-compliance;

3. all assembly issues (eg loose components & bonus parts);

4. all quality related issues (eg component spec. incompliance);

For issues, caused by components that meet specification, the issue needs to

be verified per Ford’s vehicle and system level S&R tests (see next page)

IF issue can be reproduced, then issue to be considered as REAL issue;

IF issue can NOT be reproduced, then issue to be further monitored during shaker

evaluation, action plan to be prepared, but NO implementation required.

Tracking system : S&R shaker issue list, Real IP/SEAT S&R list

Forum : weekly IP/SEAT VRT/VFG Ford/supplier MEETING


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15. Concern handling - continued

Forward Model DV/PV testing :

ALL issues, found during DV- and PV-launch Shaker testing, need to be

considered and treated as REAL issues, for which immediate action

( Interim Containment Action/ Permanent Corrective Action) is required

Tracking system : Ford AIMS

Forum : Weekly PMST meeting (or dedicated weekly S&R meeting)

Responsibility : Ford’s IP/SEAT S&R engineer

Supplier’s IP/SEAT S&R engineer


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16. Other IP / SEAT related S&R Test procedures

CETP 01.10-L-413 SEAT shaker testing

CETP 01.12-L-423 IP shaker testing

CETP 00.00-L-301 Vehicle level key life test/ Environmental Four Poster Durability

CETP 00.00-L-603 Plant Four poster Evaluation

CETP 01.05-L-400 Squeak and Rattle Evaluation of Material Pairs (Ziegler System)

CETP 01.10-L-413 Squeak and Rattle Evaluation Testing of Seats (ST009)

CETP 01.12-L-300 Instrument Panel & Console System Key Life Test (KLT)

CETP 15.01-E-405 Center Stack Laboratory Key Life Test (KLT) Squeak and Rattle

Durability with Environmental Cycling

18-0001 Durability Vehicle Life

ARL 08-0352 S&R : Environmental Four Poster and Proving Grounds

ARL 08-0357 VEHICLE MATERIAL COMPATIBILITY FOR S&R AVOIDANCE

ARL 08-0358 VEHICLE CLEARANCE & ISOLATION FOR S&R AVOIDANCE

VOPFAG202 Final Assembly Engineering Squeak and Rattle Program

And finally S&R Global Health Chart


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17.1. IP/SEAT S&R ISSUE TRACKING LIST (1) – the principle


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17.2. Issue Tracking Matrix – continued (2)

SECTION 1


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17.3. Issue Tracking Matrix - continued (3)

FOR STATIC IP BSR EVALUATION (PART I)

>> If issue is NOK operational noise (eg cheap sound)

>>> SCORE = 20 points

>> If issue is squeak/rattle during operational noise

>>> SCORE = 60 points

FOR DYNAMIC IP BSR EVALUATION (PART II)

>> If issue is MINOR during forced excitation on

>>>SCORE = 40 points

>> If issue is MAJOR during forced excitation on:

>>>SCORE = 80 points

MINOR = noise audible at ear 25 cm removed

MAJOR = noise audible at ear 60 cm removed


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18. Records

The JIT-plant Squeak and Rattle Reports, painter charts and G8Ds are retained in the plant database system until superseded, plus 2 year, and must be available for engineering review;

The preventative maintenance and calibration data for the 4-Poster are retained in the JIT plant database system until tool superseded, plus 2 year;

The S&R Evaluator certification data is retained in the plant database system until superseded,plus 3 year.

The Evaluator certification data includes Training and the pending Audiometric Test qualification results;

The S&R 4-Poster training data is retained in the plant database system until superseded, plus 3 year.


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19. S&R evaluator hearing test

The following hearing test requirements are mandatory for the 4-Poster

and S&R Test Track Evaluators/drivers.

A hearing test to ensure adequate hearing must be performed annually to

insure that the employees assigned to these jobs can hear squeaks and rattles.

All current and new operators for the position of 4-poster and S&R test track

evaluators and/or drivers to pass the audiometric surveillance exam that

includes testing frequencies @ 500, 1000, 2000, 3000, 4000, 6000, and 8000 Hz;

The hearing test results for the right ear and left ear must be less than or

equal to 40dB;

This Hearing test is to be performed annually;

An operator is not to be placed in the S&R evaluator position until the audiometric

surveillance exam is taken again, with results less than or equal to 40dB;

All S&R evaluators/investigators require at least a full week a on the job training;


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APPENDIX


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A. Track surface Nr 1 – Harsh Road ( 25 mph / 40 kmph)


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B. Track surface Nr 2 – Belgian Blocks ( 25 mph / 40 kmph)


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C. Track surface Nr 3 – Tar patch ( 45 mph / 72 kmp)


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D. Track surface Nr 4 – Cobble Stones ( 5 mph / 8 kmph)


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E. Track surface Nr 5 – Rough Brick ( 25 mph / 40 kmph)

Rough Bric

k

Rough B

rick

Automotive

Bsr shaker process description 03012012