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27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Table of Contents
目录

1Introduction4
1引言4

2Roles and Contacts5
2角色和联系人5

2.1Roles and Definitions5
2.1角色和定义5

2.2Contacts5
2.2联系人5

3Program Description6
3程序说明6

3.1Part Complexity and model list6
3.1零件复杂性和型号列表6

3.2Timing6
3.2计时6

3.3Progress Reporting6
3.3进度报告6

3.4Start-up Support7
3.4启动支持7

3.5Service Manuals & Training7
3.5服务手册和培训7

3.6Equipment Warranty8
3.6设备保修8

4General Equipment Description9
4一般设备说明9

4.1General Information9
4.1一般信息9

4.2Electrical and Controls9
4.2电气和控制9

4.3Test Control Software10
4.3测试控制软件10

4.3.1Test Machine Runoff10
4.3.1试机径流10

4.3.2Hardware Requirements10
4.3.2硬件要求10

4.3.3Software Requirements11
4.3.3软件要求11

4.4Hydraulic and Pneumatic11
4.4液压和气动11

4.5Instrumentation and Calibration12
4.5仪器和校准12

4.6Spare Parts and Equipment12
4.6备件和设备12

4.7Complexity and automation12
4.7复杂性和自动化12

4.7.1Product Complexity12
4.7.1产品复杂度12

4.7.2Semi-Automatic Connections13
4.7.2半自动连接13

4.8Safety13
4.8治理13

4.9Quality14
4.9质量14

4.9.1Machine Acceptance Checklist14
4.9.1机器验收清单14

4.9.2GR&R and Statistical Capability14
4.9.2GR&R 和统计能力14

4.9.327 Hour Dry Cycle14
4.9.327 小时干循环14

4.9.4Vendor Runoff Requirements14
4.9.4供应商径流要求14

4.10Touchpoints15
4.10接触点15

4.10.1Battery Header Touchpoints and Nomenclature15
4.10.1电池接头接触点和命名法15

4.10.2Battery Header Electrical Connector Details15
4.10.2电池接头电气连接器详细信息15

5Pack Leak Test19
5件装泄漏测试19

5.1General Information19
5.1一般资料19

5.2Test Sequence19
5.2测试序列19

5.2.1Pack Leak Test19
5.2.1电池组泄漏测试19

5.3Hardware Requirements19
5.3硬件要求19

5.3.1Test Circuit19
5.3.1测试电路19

5.3.2Environmental20
5.3.2环境20

5.4Electrical Requirements20
5.4电气要求20

5.5Pneumatic, Hydraulic, or Coolant Requirements20
5.5气动、液压或冷却液要求20

5.6Alignment, Mastering, and Calibration20
5.6对齐、母带处理和校准20

6Challenge Parts20
6挑战部分20

6.1.1Calibration20
6.1.1校准20

7Electrical Test21
7电气测试21

7.1General Information21
7.1一般资料21

7.2Test Sequence21
7.2测试序列21

7.2.1BECM Flash and ENS21
7.2.1BECM Flash 和 ENS21

7.2.1.1Write Values to BECM21
7.2.1.1将值写入 BECM21

7.2.1.2Current and Pressure Sensor Test22
7.2.1.2电流和压力传感器测试22

7.2.1.3HVIL and Leakage Resistance Test22
7.2.1.3HVIL 和耐泄漏测试22

7.2.1.4Polarity Voltage Check22
7.2.1.4极性电压检查22

7.3Hardware Requirements22
7.3硬件要求22

7.3.1BECM Flash22

7.3.2Voltage and Current Measurement23
7.3.2电压和电流测量23

7.3.3Test Circuit23
7.3.3测试电路23

7.3.4High Power Connector Tests23
7.3.4高功率连接器测试23

7.3.5Low Power Connector Tests23
7.3.5低功率连接器测试23

7.3.6Controlled Shutdown23
7.3.6受控关机23

7.3.7Cycler Requirements24
7.3.7Cycler 要求24

7.3.8Cable Sizing24
7.3.8电缆尺寸24

7.3.9BECM and Power Supply Hardware24
7.3.9BECM 和电源硬件24

7.3.10Additional Hardware24
7.3.10其他硬件24

7.4Electrical Requirements25
7.4电气要求25

7.5Pneumatic, Hydraulic, or Coolant Requirements25
7.5气动、液压或冷却液要求25

7.6Alignment, Challenge, and Calibration25
7.6对齐、挑战和校准25

8Challenge Part25
8挑战 第25 部分

8.1.1Calibration25
8.1.1校准25

9Test Regress Stations26
9测试回归站26

9.1Minimum Hardware Requirements26
9.1最低硬件要求26

9.1.1Integrator Supplied Hardware26
9.1.1集成商提供的硬件26

9.1.2Test Control Software Hardware26
9.1.2测试控制软件硬件26

9.2Minimum Software Requirements26
9.2最低软件要求26

10Document Editing Tips27
10个文档编辑技巧27

11Change Log28
11更新日志28

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Introduction
介绍

The supplier is invited to submit a quotation to supply equipment and services to Ford Motor Company as detailed in this Statement of Work for the 27MY FHEV product going to the RCP Battery Assembly Plant.
邀请供应商提交报价,以便向福特汽车公司供应设备和服务,如本工作说明书中所述用于将 27MY FHEV产品送往 RCP 电池组装厂。

In addition to cost, suppliers will be evaluated on their compliance with these quotation instructions, as well as prior experience in delivering similar equipment. The supplier is required to complete the SQF document along with their proposal.
除了成本之外,还将评估供应商是否遵守这些报价说明,以及之前交付类似设备的经验。供应商需要完成 SQF 文档及其提案。

If any clarifications are required, please contact the lead test engineer listed in the Roles and Contacts Section.
如果需要任何说明,请联系 Roles and Contacts部分中列出的首席测试工程师。

Specification discrepancies or recommendations indicated by the supplier shall be reviewed prior to awarding the order, at which time any pricing changes may be made. Any cost items indicated after placing the order, will not be negotiated.
供应商指出的规格差异或建议应在授予订单之前进行审查,此时可能会进行任何定价更改。下单后指示的任何成本项目,将不予协商。

The supplier is required to allow Ford to runoff the equipment at their facility, this means supplying the required power and air to properly test the functionality of the test stands. This runoff will be repeated on the plant floor as well.
供应商需要允许福特在其设施中对设备进行运行,这意味着提供所需的电力和空气以正确测试测试台的功能。这种径流也将在工厂车间重复。

This document details the requirements for the Test Equipment only and will be supplied in addition to the Assembly SOW/RFQ. Please note all requirements and specifications listed in the Assembly SOW/RFQ must also be met for test equipment, as these are Ford Requirements.
本文件仅详细说明了测试设备的要求,并将与组装 SOW/RFQ 一起提供。请注意,测试设备也必须满足装配 SOW/RFQ 中列出的所有要求和规格,因为这些是福特要求。

This document contains confidential information and is not allowed to be shared with any other suppliers besides what is absolutely necessary for quotation purposes.
本文档包含机密信息,除报价绝对必要的信息外,不得与任何其他供应商共享。

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Roles and Contacts
角色和联系人

This section defines the Roles, Responsibilities, and Contacts for this program.
本节定义此程序的 Roles、Responsibilities 和 Contacts。

Roles and Definitions
角色和定义

“Vendor, integrator, or Supplier” refers to the Test Stand Supplier and integrator, they will deliver AND integrate the stands with the other suppliers. This includes integrating the CAD drawings and electrical, mechanical, and pneumatic drawings and prints. The main role of the Equipment supplier will be part handling and station design, including the base test stand and guarding.
“供应商、集成商或供应商”是指测试台供应商和集成商,他们将交付测试台并将其与其他供应商集成。这包括集成 CAD 图纸以及电气、机械和气动图纸和打印件。 设备供应商的主要职责是零件处理和工位设计,包括基础测试台和防护装置。

“Test control software supplier” refers to the supplier delivering the software to control the test stands, as well as a portion of the hardware defined later in this document.
“测试控制软件供应商”是指交付软件以控制测试台的供应商,以及本文档后面定义的部分硬件。

“Test circuit supplier” Refers to the vendor that will supply the leak test hardware and software. This will include hardware such as: flow meters, pressure transducers, etc. and will be defined later in this document.
“测试电路供应商” 是指将提供泄漏测试硬件和软件的供应商。这将包括硬件,例如:流量计、压力传感器等,并将在本文档的后面定义。

Contacts
接触

The lead test engineer will be responsible for approving all changes, as well as signing off on all designs from the equipment supplier.
首席测试工程师将负责批准所有更改,并签署设备供应商的所有设计。

Role
角色

Name
名字

Email
电子邮件

Test Lead Engineer
测试首席工程师

Test Engineer
测试工程师

Michael Bednarz
迈克尔·贝德纳兹

mbednarz@ford.com

Test Engineer
测试工程师

Amir Tazi
阿米尔·塔齐

atazi@ford.com

Test Supervisor
测试主管

Hamid Tabti
哈米德·塔布蒂

htabti@ford.com

Test Technical Specialist
测试技术专家

Rob Keeton
罗伯·基顿

rkeeton@ford.com

Assembly Lead Engineer
装配首席工程师

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Program Description
计划描述

This SOW/RFQ is to be used for Test Equipment for the 27MY FHEV product that will be delivered to the RCP Battery Assembly Plant.
该 SOW/RFQ 将用于 27MY FHEVp 产品的测试设备,该产品将交付给RCP 电池组装厂。

Part Complexity and model list
零件复杂性和型号列表

Part Number:
零件编号:

Details:
详:

NZ68-10B759-**

258V, 175A (FHEV B)
258V,175A (FHEV B)

PZ18-10B759-**

258V, 175A (FHEV B)
258V,175A (FHEV B)

Timing
定时

TT (LR, Single Path):
TT (LR, 单通道):

5/31/2027

Unit Job 1 (Need Full Capability):
单元作业 1(需要完整功能):

07/15/2026
202 年 7 月 15日 6

The Initial timing plan will be finalized within 14 days of receiving a purchase order. During the course of the contract, the timing plan shall be regularly addressed and, if necessary, updated. No timing changes shall be made without agreement from the Ford Test Engineer.
Initial timing plan 将在收到采购订单后的 14 天内最终确定。在合同过程中,应定期处理时间计划,并在必要时进行更新。未经 Ford 测试工程师同意,不得更改正时。

The supplier shall confirm the date by which a Purchase Order needs to be placed by in order to comply with the provided program timing plan.
供应商应确认需要下采购订单的截止日期,以便遵守所提供的计划时间安排。

Progress Reporting
进度报告

The supplier shall report their project timing status on a regular basis and in an agreed format acceptable to the Requisitioning Engineer. The timing status shall include such activities as those listed below:
供应商应定期以申请工程师可接受的商定格式报告其项目时间状态。计时状态应包括下列活动:

PO Received from Ford
从福特收到的 PO

Designs/Drawings Approved
设计/图纸批准

Procurement
采购

Build

Commissioning/Debug at the Supplier
供应商的调试

Try-out parts required.
需要试用零件

Supplier runoff
供应商流失

Pack & ship
打包和运输

Delivery
交货

Installation
安装

Commissioning/Capability at the Plant
工厂调试/能力

The supplier shall be responsible to designate a representative contact person (e.g., project engineer) for promptly replying to progress report requests from Ford during the period of engineering and machine build. These requests shall typically be on a monthly basis with notifications sent to the supplier via email. The supplier shall be responsible for supplying pictorial evidence of machine/equipment build progress in a specified format and posting the progress photos in the supplier specific SharePoint detailed in the notification email.
供应商应负责指定一名代表联系人(例如项目工程师),以便在工程和机器制造期间及时回复 Ford 的进度报告请求。这些请求通常应每月一次,并通过电子邮件向供应商发送通知。供应商应负责以指定格式提供机器/设备制造进度的图片证据,并在通知电子邮件中详细说明的供应商特定 SharePoint 中发布进度照片。

Start-up Support
启动支持

The Test Systems will be installed and launched at Ford’s RCP plant. Installation support must include vendor personnel on-site at the Ford Motor Company manufacturing facility until the system has met all expectations of this specification, including R&M projections. It is imperative to maintain an on-site staff sufficient to support all Ford timing requirements including installation, commissioning, capability, pilot line, burst runs, Job #1 and production build schedules. At a minimum, the vendor must provide project management and installation support throughout the course of the project as follows:
该测试系统将在福特的 RCP 工厂安装和启动。安装支持必须包括福特汽车公司制造工厂现场的供应商人员,直到系统满足此规范的所有期望,包括R&M预测。必须保持足够的现场工作人员来支持所有福特计时要求,包括安装、调试、能力、试产线、突发运行、工作 #1 和生产构建计划。供应商至少必须在整个项目过程中提供项目管理和安装支持,如下所示:

Pre-Delivery of Equipment
设备交付前

The vendor will control a single-issue log.
供应商将控制单个问题日志。

Weekly meetings will be conducted between the vendor's project management team and the Ford Test Team to discuss, gain concurrence, assign responsibility, and track all issues through resolution.
供应商的项目管理团队和福特测试团队将每周举行一次会议,以讨论、获得同意、分配责任并跟踪所有问题直至解决。

The meetings will be held at the vendor's facility, or by way of a teleconference link. The vendor's project management team must be able to support WebEx meetings as required.
会议将在供应商的设施中举行,或通过电话会议链接举行。供应商的项目管理团队必须能够根据需要支持 WebEx 会议。

A review of the retool kits and/or test stands will be reviewed and approved by Ford Personnel before shipping.
发货前,福特工作人员将审查和批准对重新工具包和/或测试台的审查。

Post-Delivery of Equipment
设备交付后

The vendor will control a single-issue log (carried over from pre-delivery).
供应商将控制单个问题日志(从交货前结转)。

Weekly meetings will be conducted between the vendor's project management team and the Ford Test Team to discuss, gain concurrence, assign responsibility, and track all issues through resolution.
供应商的项目管理团队和福特测试团队将每周举行一次会议,以讨论、获得同意、分配责任并跟踪所有问题直至解决。

The meetings will be held at the Ford Motor Company manufacturing facility, or by way of a teleconference link. The vendor's project management team must be able to support WebEx meetings as required.
会议将在福特汽车公司的制造工厂举行,或通过电话会议链接举行。供应商的项目管理团队必须能够根据需要支持 WebEx 会议。

The vendor must provide supervision for the installation of the machines at the Ford Motor Company manufacturing facility.
供应商必须监督 Ford Motor Company 制造工厂的机器安装。

All vendor personnel working within a Ford Motor Company manufacturing facility must comply with all local safety regulations, including their attendance at, and completion of all required safety training.
在 Ford Motor Company 制造工厂内工作的所有供应商人员必须遵守所有当地安全法规,包括参加和完成所有必要的安全培训。

Post Job #1
发布工作 #1

The issue log will continue to be reviewed in meetings between the vendor's project management team and the Ford Test Team until all issues have been resolved.
在供应商的项目管理团队和 Ford 测试团队之间的会议上,将继续审查问题日志,直到所有问题都得到解决。

The vendor must provide continuing on-site support until all vendor-responsible issues have been resolved.
供应商必须提供持续的现场支持,直到所有供应商负责的问题都得到解决。

Service Manuals & Training
服务手册和培训

All supplier literature that is associated with purchased components must be collected, organized, and provided to the Ford Test Team at the time of machine delivery.
在机器交付时,必须收集、整理和提供给福特测试团队与采购组件相关的所有供应商资料

Electronic service manuals, in accordance with the specifications that are included in the documentation referenced in the Ford Production System (FPS), Reliability and Maintainability(R&M), & Training section of the Enquiry Specification.
电子服务手册,根据在福特生产系统(FPS)、可靠性和可维护性(R&M)和查询规格的培训部分引用的文档中包含的规格。

Formal operator training related to Test Stands must be included as an option.
必须与测试台相关的正式操作员培训作为一个选项。

Equipment Warranty
设备保修

A warranty must be provided in accordance with the Ford Motor Company Global Terms and Conditions. The warranty period will be agreed upon at the Program Level and shall be applied to the Test System in a manner that is consistent with the entire Assembly & Test Systems
必须根据福特汽车公司全球条款和条件提供保修。保修期将在程序级别商定,并应以与整个组装和测试系统一致的方式应用于测试系统
.

The test control hardware should have a minimum warranty of 2 years (starting from Job 1 + 90 days) and shall at a minimum include manufacturing defects of the supplied hardware. This same 2 year warranty should be supplied for the test control software.
测试控制硬件应具有至少 2 年的保修期(从作业 1 + 90 天开始),并且至少应包括所提供硬件的制造缺陷。测试控制软件应提供相同的 2 年保修。

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

General Equipment Description
通用设备描述

General Information
一般信息

There will be 3 types of Test stations that will test the 27MY FHEV Product:
将有 3 种类型的测试站将测试 27MY FHEV产品:

OP 8100: Pack Leak Test (2 Stands): Leak test the entire battery assembly.
OP 8100:电池组泄漏测试(2 个支架):对整个电池组件进行泄漏测试。

OP 8200: Electrical Test (6 Stands): Electrical checks and charging (if applicable)
OP 8200: 电气测试(6 个支架):电气检查和充电(如适用)

Machine Integrators are requested to submit a base quote including ATEQ cost
机器集成商需要提交包括 ATEQ 成本在内的基本报价
.

Test Cyclers and Test Control Software will be quoted separately by Ford.
Test Cyclers 和 Test Control Software 将由 Ford 单独报价。

Approved Software Supplier:Approved Software Supplier:Approved Test Circuit Supplier
认可软件供应商:认可软件供应商:认可测试电路供应商

W.M. Associates, Inc.National InstrumentsAteq USA
W.M. Associates, Inc. 美国国家仪器公司

13796 Spring StreetJason CallBrandon Pilon

Burton, Ohio 44021ORTelephone (269) 303-626335980 Industrial Rd
俄亥俄州 伯顿 44021电话 (269) 303-626335980 Industrial Rd

Telephone (440) 834-8522E-Mail Jason.call@ni.comLivonia, MI 48150
电话 (440) 834-8522电子邮件 Jason.call@ni.com Livonia, MI 48150

E-Mail sales@wmainc.comE-Mail bpilon@atequsa.com
电子邮件 sales@wmainc.com电子邮件 bpilon@atequsa.com

Approved Cycler Suppliers:
经批准的 Cycler 供应商:

Motion Control Corporation (Unico)Morrell
运动控制公司 (Unico) Morrell

35796 Veronica St.3333 Bald Mountain Rd
35796 维罗妮卡街 秃头山路 3333

Livonia, Michigan 48150ORAuburn Hills, Michigan 48326
利沃尼亚, 密歇根州 48150 OR奥本山, 密歇根州 48326

Telephone (586) 292-3937Telephone (616) 822-5121
电话 (586) 292-3937电话 (616) 822-5121

E-Mail jhorton@motioncontrolcorp.com E-Mail alittle@morrellinc.com
电子邮件 jhorton@motioncontrolcorp.com 电子邮件 alittle@morrellinc.com

Suppliers are welcome to provide an alternate option using their preferred suppliers by way of an “alternative” quote in addition to the base quote.
欢迎供应商使用其首选供应商提供替代选项,除了基本报价外,还使用“替代”报价。

Electrical and Controls
电气和控制

The Controls specification PTS02-083ME needs to be followed and will detail the electrical and controls related requirements
需要遵循控制规范 PTS02-083ME,并将详细说明电气和控制相关要求
.

The Operator Console and PLC must provide discrete, detailed messages for a wide range of machine faults, including machine motion, communications feedback, and drive faults. Conditions for each fault state indicated on the operator console should be documented. Blank or ‘Spare’ are not acceptable fault messages.
操作员控制台和 PLC 必须为各种机器故障提供离散、详细的消息,包括机器运动、通信反馈和驱动故障。应记录操作员控制台上指示的每种故障状态的条件。空白或“备用”是不可接受的错误消息。

Un-interruptible power supplies (UPS) must be included for each test stand computer/monitor. All systems that require power to do a safe shutdown need to be on the UPS (ie: BECM power supply).
每台测试台计算机/显示器必须包含不间断电源 (UPS)。 所有需要电源才能进行安全关机的系统都需要在 UPS 上(即:BECM 电源)。

Communication cables cannot be run alongside power cables, this is to reduce the noise through the communication cables.
通信电缆不能与电源线并排运行,这是为了减少通过通信电缆的噪音。

Power regulation Required on all DC Power supply circuits.
电源调节 所有直流电源电路都需要

Special attention needs to be given to panel and component grounds as well as communication cable shielding and/or twisted cables as specified by the ES
需要特别注意 ES 规定的面板和组件接地以及通信电缆屏蔽和/或双绞电缆
.

Additional time is required when powering down the BECM of 7-10 seconds to ensure the software does not get corrupted, this is required when powering it down at the end of the test and if any BECM restarts are required. This will allow the BECM current to drop to the quiescent current.
关闭 BECM 电源时需要 7-10 秒的额外时间以确保软件不会损坏,在测试结束时关闭它并且需要重新启动任何 BECM 时需要这样做。 这将允许 BECM 电流下降到 静态电流。

Every test stand must have Ambient Environmental Monitoring sensors, this includes:
每个测试台都必须配备环境监测传感器,其中包括:

Ambient Temperature
环境温度

Ambient Dew Point
环境露点

Ambient Pressure
环境压力

Test Control Software
测试控制软件

There are two approved vendors for Test Control Software: WMA and NI. The machine integrator can supply a separate quote for their test control software that may be considered as a third option for the Ford Test Team.
测试控制软件有两家获得批准的供应商:WMA 和 NI。 机器集成商可以为其测试控制软件提供单独的报价,该报价可被视为福特测试团队的第三个选项。

This test control software will be used to control the test sequence on the test station as well as store models, limits, parameters, challenge sequences, and route challenge/master parts to the stands at user-defined intervals. This software needs to be able to be modified by Ford Test Engineers without help or cost from the test control software supplier.
该测试控制软件将用于控制测试站上的测试序列,以及存储模型、限值、参数、挑战序列,并按用户定义的间隔将挑战/标准件路由到机架。此软件需要能够由 Ford Test Engineers 进行修改,而无需测试控制软件供应商的帮助或费用。

The test control software will interface with the Test Stand PLC, electrical test cyclers, and Leak test equipment directly. It is not permitted for the test stand PLC to be a ‘middle-man’ between the test stand and the cycler or leak test hardware, with the exception of the safety circuits, as this adds cycle time and could cause additional problems.
测试控制软件将直接与测试台 PLC、电气测试循环仪和泄漏测试设备连接。除安全电路外,不允许测试台 PLC 成为测试台和循环仪或泄漏测试硬件之间的“中间人”因为这会增加循环时间并可能导致其他问题。

If the test station loses access to the host database, it needs to be able to continue functioning, then when access is restored, it needs to be able to check for updates to parameters and publish the locally saved data.
如果测试站无法访问主机数据库,它需要能够继续运行,然后当访问恢复时它需要能够检查参数的更新并发布本地保存的数据。

The test control software supplier should write the initial test sequence based on Ford BME test engineering input and should include every required test inside the ES at a bare minimum. Ford will also request some additional information to be recorded on top of ES requirements for troubleshooting and data retention and commonization of test sequences across Ford.
测试控制软件供应商应根据 Ford BME 测试工程输入编写初始测试序列,并应至少包括 ES 中每个必需的测试。除了 ES 对故障排除和数据保留的要求以及整个 Ford 测试序列的通用化之外,Ford 还将要求记录一些其他信息。

Test Machine Runoff
测试机器径流

The test control software supplier will be responsible for supporting the vendor runoff at the integrators’ facility. This includes a temporary host setup (if required) so the Ford Test Engineering team can develop or view the host server, databases, models, limits, and test sequences remotely.
测试控制软件供应商将负责支持集成商设施的供应商流失。这包括临时主机设置如果需要),以便 Ford Test Engineering 团队可以远程开发或查看主机服务器、数据库、模型、限制和测试序列。

The cost to ship any hardware to the Vendor Runoff location should be included as well. The integrator will be responsible for shipping the test control software hardware with the equipment to the final Ford plant location.
还应包括将任何硬件运送到供应商 Runoff 位置的费用。集成商将负责将测试控制软件硬件与设备一起运送到福特的最终工厂位置。

The test control software supplier will also be responsible for supporting the runoff at RCP .
测试控制软件供应商还将负责支持 RCP 的径流

Hardware Requirements
硬件要求

The Test control software supplier is responsible for supplying the Siemens PC to control the test stand, and all associated data acquisition, and CAN communication Hardware.
测试控制软件供应商负责提供西门子 PC 来控制测试台、所有相关数据采集和 CAN 通信硬件。

Data Acquisition
数据采集

A minimum of 8 Analog channels must be supplied at a data rate of 1 KHz, if any external power supplies are required to support this data acquisition it will be supplied by the machine integrator in the electrical panel.
必须至少以 1 KHz 的数据速率提供 8 个模拟通道,如果需要任何外部电源来支持此数据采集,则将由电气面板中的机器集成商提供。

A minimum of 16 Analog channels must be supplied that can support 100Hz sampling rate.
必须至少提供 16 个可支持 100Hz 采样率的模拟通道。

Communication
通信

CAN-FD cards will come installed in the PC to communicate with the BECM in the battery. 6 channels should be supplied as a minimum, 4 will be needed for the battery, and 2 spares minimum
CAN-FD 卡将安装在 PC 中,以便与电池中的 BECM 通信。至少应提供 6 个通道,电池需要 4 个通道,最少 2 个备件
.

PC Requirements
PC 要求

The test control software supplier will supply a Siemens PC that is capable of holding all the hardware required for CAN-FD communication and all data acquisition that the test stand requires.
测试控制软件供应商将提供一台西门子 PC,该 PC 能够容纳 CAN-FD 通信所需的所有硬件和测试台所需的所有数据采集。

Software Requirements
软件要求

This section defines how the test control software supplier will handle the software and test sequences.
本节定义了测试控制软件供应商将如何处理软件和测试序列。

Initial Sequence and Deliverables
初始序列和可交付成果

The test control software supplier will be responsible for writing and delivering the initial test sequence, database, models, and limits for the assumed models of the battery program. This sequence shall have the capability to run multiple ‘strings’ or tests in parallel.
测试控制软件供应商将负责为电池程序的假设模型编写和交付初始测试序列、数据库、模型和限制。 此序列应具有并行运行多个 'strings' 或测试的能力。

This supplied test sequence should be capable of running all models, and all challenge/master parts, in a fully automatic manner.
此提供的测试序列应能够以全自动方式运行所有模型和所有挑战/主零件

Global Limits and Monitoring
全局限制和监控

Certain parameters need to be constantly monitored on the test stands during all operation, and there must be limits on these that will automatically take down these test stands if these conditions are met.
在所有操作期间,需要在测试台上持续监控某些参数,并且必须对这些参数进行限制,如果满足这些条件,这些参数将自动关闭这些测试台。

Model Parameters and Limits
模型参数和限制

Model parameters must be able to be loaded specifically for separate models with separate limits. This process should be streamlined to allow for easy limit changes when new models are added.
模型参数必须能够专门为具有不同限制的单独模型加载。应简化此过程,以便在添加新模型时轻松更改限制。

Challenge/Master Part Handling
挑战/主零件处理

Challenge/Master parts must be able to be automatically routed to each test stand at set intervals by the Ford Test Engineer. Delay times must also be easily implemented to allow the Challenge part to return to standard parameters before being tested again.
Challenge / Master 零件必须能够由 Ford 测试工程师以设定的时间间隔自动路由到每个测试台。 延迟时间也必须易于实现,以允许 Challenge 部分在再次测试之前返回标准参数。

Common Data Model
通用数据模型

Ford has a new specification to be used for ALL data handling, this requirement does apply to test equipment. The CDM specification is GMS02-700AM.
福特有一个用于所有数据处理的新规范,此要求适用于测试设备。CDM 规格为 GMS02-700AM。

Hydraulic and Pneumatic
液压和气动

No hydraulics are to be used on any Ford Equipment.
任何福特设备都不得使用液压系统。

Shop air will be supplied to the Test Stands (where required) and must be handled in accordance with the Control specifications. A pressure switch must be provided to monitor the supply circuit and signal the test system controls (PLC) if the air pressure falls below the limit in psi.
车间空气将供应到测试台(如果需要),并且必须按照控制规范进行处理。必须提供压力开关来监控供应电路,并在气压低于 psi 限值时向测试系统控制 (PLC) 发出信号。

All stands will use shop air unless otherwise specified.
除非另有说明,否则所有展位都将使用 Shop Air

Instrumentation and Calibration
仪器和校准

General Specifications – All Transducers
一般规格 – 所有传感器
:

All transducers used must include NIST traceable calibration documentation.
使用的所有传感器必须包括 NIST 可追溯校准文档。

Calibration documents for transducers will need to be updated and provided at the beginning of plant runoff.
传感器的校准文件需要在工厂径流开始时更新并提供。

Calibration
校准

Certification documentation must be provided for all precision orifices and process-controlling transducers that are included in the test circuit.
必须为测试电路中包含的所有精密孔口和过程控制传感器提供认证文件。

Calibration procedures and setup guides must be provided for all the items listed in this section.
必须为本节中列出的所有项目提供校准程序和设置指南。

The Test Stand design must include provisions to support a "Setup Mode" similar to the existing Ford machines to allow for possible ECSPMT related to troubleshooting and setup of test stand.
测试台设计必须包括支持类似于现有福特机器的“设置模式”的规定,以允许与测试台的故障排除和设置相关的可能的 ECSPMT。

Spare Parts and Equipment
备件和设备

A complete list of suggested spare parts will be developed during SE and must be provided 90 days prior to machine delivery. The vendor should Reference the Machine Spares section of the Enquiry Specification.
在 SE 期间将制定建议备件的完整清单,并且必须在机器交付前 90 天提供。供应商应参考查询规范的机器备件部分。

Three sets of spare perishable details, to be provided with the machine at the time of delivery, must be included with any proposal. “Perishable details” are loosely defined as part-touching details, with certain exceptions like faceplates and pallets. A complete “set” of perishable details includes all of the details required to outfit one Test Station.
任何提案都必须包括三套备用的易腐烂细节,在交付时随机器一起提供。“易腐烂细节”被宽泛地定义为部分接触细节,但面板和托盘等例外情况除外。一整套易腐烂的细节包括装备一个测试站所需的所有细节。

Complexity and automation
复杂性和自动化

This section reviews all the product complexity and automatic connection requirements.
本节回顾所有产品复杂性和自动连接要求。

It is very important to Ford Motor Company that the designs of these test stands are futureproofed in every way possible, ideally this would be of modular design so that portions of the test stands can be retooled to fit new battery architectures in the future. This includes but is not limited to modular cyclers with the opportunity to upgrade the transformer, fusing, and minimal components to achieve the rated 250A output. The same is true for equipment bases, support, overhead structures, tool changers, auto connections, electrical panels, and any other components responsible for the future proofing of these stands.
对于福特汽车公司来说,这些测试台的设计必须以各种可能的方式面向未来,这一点非常重要,理想情况下,这将是模块化设计,以便测试台的某些部分可以重新调整以适应未来的新电池架构。这包括但不限于模块化循环仪,他们有机会升级变压器、熔断器和最少的组件,以实现额定 250A 的输出。设备底座、支架、架空结构、换刀装置、自动连接、配电盘以及负责这些支架未来验证的任何其他组件也是如此。

Product Complexity
产品复杂性

There are 2 major factors for complexity that can exist on battery packs, all complexity MUST be handled automatically by the test stands without any interaction from operators.
电池组可能存在两个主要复杂性因素,所有复杂性都必须由测试台自动处理,无需操作员的任何干预。

Pack Length will have complexity on most batteries and will require servo driven slides to handle longer and shorter packs and will affect where the touchpoints are located to connect to the battery. If any additional brackets or hardware can be present on the batteries, it is essential to ensure that these added parts will not cause a crash when moving through the test stands. Additional sensors may be required to detect parts that may not always be present such as fixtures on the AGV, etc.
电池组长度在大多数电池上都很复杂,并且需要伺服驱动的滑块来处理更长和更短的电池组,并且会影响接触点连接到电池的位置。如果电池上可能存在任何其他支架或硬件,则必须确保这些添加的部件在穿过测试台时不会导致碰撞。可能需要额外的传感器来检测可能并不总是存在的部件,例如 AGV 上的固定装置等。

Automatic Connections
自动连接

All test stands are fully automatic and will not have any operator interaction during normal production besides resetting faults and troubleshooting. Provisions must be implemented to ensure connectors are placed (such as by proxy sensors or camera)
所有测试台都是全自动的,除了重置故障和故障排除外,在正常生产期间不会有任何操作员干预必须实施规定以确保放置连接器(例如通过代理传感器或摄像头)
.

Stack-up tolerances between the battery, header, and connectors can vary greatly between programs, and these stack-up tolerances may not be available until later in the program timing. It is crucial that the auto connection systems are robust and are designed to handle a large amount of variation from part-to-part. Headers can have varying stack-up tolerances ranging from ±0.5mm (positional tolerance of connectors on headers) all the way to ±6mm (positional tolerance of headers on the battery pack tray).
电池、接头和连接器之间的叠加公差可能因程序而异,并且这些叠加公差可能要到程序时序的后期才能获得。至关重要的是,自动连接系统必须坚固耐用,并且其设计能够处理不同零件之间的大量变化。接头可以具有不同的堆叠公差,范围从 ±0.5 mm(接头上连接器的位置公差)一直到 ±6mm(电池组托盘上接头的位置公差)。

Electrical Connections
电气连接

All electrical connections should be connected using automated tooling from the test stand.
所有电气连接都应使用测试台上的自动化工具进行连接。

If a connector carries more than 100A during the test, it is required to have a temperature monitoring inside the connector to monitor for temperature spikes in case of a bad connection, this feedback shall go back to the test control software so global limits can be placed on these signals.
如果连接器在测试期间承载的电流超过 100A则需要在连接器内部进行温度监控,以便在连接不良的情况下监控温度峰值,此反馈应返回测试控制软件,以便对这些信号设置全局限制。

The electrical connections SHALL always be sized for the max capacity of the cycler for that circuit and not to the battery individually. This is to allow the test stand to be future proofed for newer batteries that may have additional power requirements.
电气连接的大小应始终适合该电路的 Cycler 的最大容量,而不是单独连接到电池。这是为了让测试台能够适应可能具有额外电源要求的新型电池。

Other Connections
其他连接

For all other connections such as the seals in Pack Leak Test, it is important to design for a robust solution that can handle parts variations coming into the test stand.
对于所有其他连接,例如包装泄漏测试中的密封件,设计一个强大的解决方案非常重要,该解决方案可以处理进入测试台的零件变化

Also, for these connections that need to be sealed such as those on Pack Leak Test should be sealed in a manner that is consistent with where we seal in the vehicle. If this vehicle-style method is not a robust solution, then this issue can be discussed during SE to come up with a viable solution that balances performance and reliability.
此外,对于这些需要密封的连接,例如包装泄漏测试中的连接,应以与我们在车辆中密封位置一致的方式进行密封 。如果这种车辆式方法不是一个稳健的解决方案,那么可以在 SE 期间讨论这个问题,以提出一个平衡性能和可靠性的可行解决方案。

Sealing design should be fail safe, such that if the seal tooling fails, it will cause the leak test to fail as well. A failed seal/tool shall not generate negative leak or mask leaky test parts.
密封设计应具有故障安全性,如果密封工具出现故障,也会导致泄漏测试失败。 失败的密封件/工具不应产生负泄漏或掩盖泄漏的测试部件

Safety
安全

Guarding shall enclose all test stands with light screens for the entrance and exit of the test stands to protect any operators or personnel working on or near the stands. These safety circuits will be tied into the PLC and HMI for each stand in order to view and clear faults as well as E-stop the stand.
防护装置应在测试台的入口和出口用遮光屏封闭所有测试台以保护在测试台上或附近工作的任何操作员或人员这些安全电路将连接到每个测试台的 PLC 和 HMI 中,以便查看和清除故障以及紧急停止测试台。

All manual ball valves should be protected with proximity switches as well as home, work, and any other motions with feedback to the PLC/HMI and test control software supplier.
所有手动球阀都应使用接近开关以及家庭、工作和任何其他运动进行保护,并将反馈给 PLC/HMI 和测试控制软件供应商。

If a chain is required to hold the weight under the servo motor, there needs to be a method to fully inspect the chain during PM.
如果需要链条来承受伺服电机下的重量,则需要有一种在 PM 期间全面检查链条的方法。

The Ford BME Safety Engineer should be contacted for any questions or clarification regarding safety.
如有任何有关安全的问题或澄清,应联系福特 BME 安全工程师。

Quality
质量

The Equipment Verification Plan for each machine (to be performed during the Vendor Runoff and In-Plant Runoff events) will be developed during SE, but will include the following:
每台机器的设备验证计划(在供应商径流和厂内径流事件期间执行)将在 SE 期间制定,但将包括以下内容:

Machine Acceptance Checklist
机器验收清单

All specifications that are included in the documentation referenced in the General Machine Specifications section must be verified, with special consideration given to the following documents:
必须验证“通用机器规格”部分中引用的文档中包含的所有规格,并特别考虑以下文档:

PTP02-094MEMachine Acceptance
PTP02-094ME 机器验收

PTF02-186MEMachine Acceptance Checklist
PTF02-186ME 机器验收清单

All related references or procedures identified in Section 4 of PTP02-094ME.
PTP02-094ME 第 4 节中确定的所有相关参考资料或程序

GR&R and Statistical Capability
GR&R 和统计能力

A 3x10 (three parts, ten times each or when parts are available, ten parts three times each) statistical run will be performed to verify the cohesion of each Test Stand with the production test sequence. This study will include verification of stand-to-stand correlation. A plan will be developed during SE to test different battery models repeatedly during the run. The capability of all analog test point signals must adhere to the Six Sigma Academy's “Best Practice for Gage R&R and Stand Correlation” to the discretion of the Ford Test Engineer.
将执行 3x10(三个部件,每个部件 10 次,或者当部件可用时,每个部件 10 个部件 3 次)统计运行,以验证每个测试台与生产测试序列的内聚力。本研究将包括对林间相关性的验证。在 SE 期间将制定一个计划,在运行期间重复测试不同的电池型号。所有模拟测试点信号的能力必须符合六西格玛学院的“测量和恢复和支架相关性最佳实践”的规定,由福特测试工程师自行决定。

The number of runs will be chosen by Ford Test Engineers depending on the number of MTO parts available.
Ford Test Engineers 将根据可用的 MTO 零件数量选择运行次数

27 Hour Dry Cycle
27 小时干循环

A 27-hour, non-stop run using a "dry" test sequence and a 27MY FHEV Battery must be completed. A written log of the run must be kept, to provide for the identification and correction of machine failure modes. The dry cycle run of the machine is required before the capability run and must be repeated if approval is not granted. The Ford Test Team will have the final say regarding the success of this run. The vendor is to supply all labor required for this run.
必须完成 2次 7 小时的不间断运行,使用“干”测试序列和27 款 FHEV电池必须保留运行的书面日志,以便识别和纠正机器故障模式。在功能运行之前,需要机器的空循环运行,如果未获得批准,则必须重复运行。福特测试团队将对这次运行的成功拥有最终决定权。供应商将提供此运行所需的所有人工。

Note: the “dry cycle” will be similar to the production sequence and will be developed by a Ford PTME Test Engineer. This sequence will be developed to verify the functionality and reliability of all drives, motions, controls, and components of the Test Stand.
注意:“干循环”将类似于生产顺序,并将由福特 PTME 测试工程师开发。开发此序列是为了验证测试台的所有驱动器、运动、控件和组件的功能和可靠性。

Vendor Runoff Requirements
供应商径流要求

8 Weeks’ time (per test stand type) will need to be allocated for runoff on the completed and fully functional test stands and Ford test sequence development for the first test stand, plus 2 weeks for each additional test stand, both on the vendors floor and on the plant floor.
需要分配 8 周的时间(每种测试台类型)用于已完成且功能齐全的测试台的径流和第一个测试台的福特测试序列开发以及供应商车间和工厂车间每个额外测试台的 2 周时间。

The Vendor will also be responsible for supplying power to all test stands including the electrical test stands which will at least 50% of full test current. Full runoff is required for Electrical test stands at the equipment integrator.
供应商还将负责为所有测试台供电,包括电气测试台,该电源至少为 满测试电流的 50%。设备集成商的电气测试台需要完全径流。

The Vendor is also responsible for allowing remote access via a VPN connection so that multiple test engineers can connect to the test control software databases to develop the database and test sequences remotely. Also, the vendor will need to supply power and an internet connection for the temporary host to store these databases.
供应商还负责允许通过 VPN 连接进行远程访问,以便多个测试工程师可以连接到测试控制软件数据库,以远程开发数据库和测试序列。此外,供应商还需要为临时主机提供电源和 Internet 连接来存储这些数据库。

Touchpoints
接触点

Battery Header Touchpoints and Nomenclature
电池接头接触点和命名法

Figure : Top Touchpoints
主要接触点

Figure : Battey Vent Port
Battey 通气口

Battery Header Electrical Connector Details
电池接头电连接器详细信息

Below are the Electrical touchpoints for the 27MY FHEV Product:
以下是 27MY FHEV 产品的电气接触点

HV Connector:
高压连接器

BECM LV/VO (BECM Low Voltage):
BECM LV/VO(BECM 低电压):

HS_CAN Interface:
HS_CAN 接口:

Test Equipment Instrumentation must provide twisted pair wiring on pins 15 & 16 (120 ohm) termination resistance (118-132 ohms with tolerance) on test equipment side of the CAN-FD backbone (i.e. between pins 15 and 16). The test equipment must record a log of all CAN traffic following the initial flash of M-code on the BECM. For reference, CAN Data Link and Physical Layer requirements are detailed in 000603.001, attached to RQT-000600-009571.
测试设备仪器必须在CAN-FD主干的测试设备侧(即在引脚15和16之间)的引脚15和16(120欧姆120欧姆)(118-132欧姆,带公差)上提供双绞线布线。在 BECM 上首次闪烁 M 代码后,测试设备必须记录所有 CAN 流量的日志。作为参考,CAN 数据链路和物理层要求在 RQT-000600-009571 随附的 000603.001 中进行了详细说明。

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Pack Leak Test
包装泄漏测试

General Information
一般信息

The purpose of the pack leak test is to leak check the entire Battery Pack Assembly, specifically the header/connectors, tray, cover, and pressure valves.
电池组泄漏测试的目的是对整个电池组组件进行泄漏检查,特别是接头/连接器、托盘、盖子和压力阀。

The part will enter the test stand on an AGV or Conveyor, the test stand operator will connect to all electrical connectors that are not sealed from the supplier, and all Pressure Equalization Devices (A.K.A. PED/PEV).
零件将进入 AGV 或传送带上的测试台,测试台操作员将连接到所有未从供应商处密封的电气连接器,以及所有压力平衡装置(又名 PED/PEV)。

The Machine Integrator will ensure that the test stand can clamp/unclamp, and the AGV/Conveyor can go into and out of the test stand fully automatically. Actual test sequence time will vary and will be controlled solely by the Ford BME Test Engineer and the test circuit supplier (ATEQ). The current estimate for test cycle time is 43 seconds
系统集成商将确保测试台可以夹紧/松开,并且 AGV/输送机可以全自动进出测试台。实际测试序列时间会有所不同,并且将完全由福特 BME 测试工程师和测试电路供应商 (ATEQ) 控制测试周期时间的当前估计值为 43 秒
.

Test Sequence
测试序列

The test sequence needs to set global limits based on the stand type to protect the stand, battery, and operator. These global limits will need to be easily edited by the Ford Test Engineer and will have the ability to have small offsets added to each stand specifically. These global limits will need to be monitored continually throughout the entire test and the test should stop if these limits are reached. Global Limits will monitor things like temperature and pressure for this test stand to ensure safe and normal operation.
测试序列需要根据支架类型设置全局限制,以保护支架、电池和操作员。这些全局限制需要由 Ford 测试工程师轻松编辑并且能够专门为每个支架添加小偏移。需要在整个测试过程中持续监控这些全局限制,如果达到这些限制,测试应停止。 Global Limits 将监控该测试台的温度和压力等信息,以确保安全和正常运行。

Pack Leak Test
包装泄漏测试

Pack leak test should be done using a Pressure Differential Decay method to compare the test part to a reference volume to rule out temperature and environmental changes during testing.
填料泄漏测试应使用压差衰减法进行,将测试部件与参考体积进行比较,以排除测试过程中的温度和环境变化。

The Leak Test consists of Pressuring the ‘pre-fill tank’ to a slightly higher test pressure, then opening the tank up to the test part. The pressure is then stabilized before supply pressure is turned off in reference to the part. The pressure decay delta is then monitored and measured between the test part and the reference volume. These values are then converted into a flow value and sent to the test control software to test against the limits.
泄漏测试包括将“预填充罐”加压至略高的测试压力,然后将罐打开至测试部件。然后,在根据零件关闭供气压力之前,压力会稳定下来。然后监测和测量测试部件和参考体积之间的压力衰减增量。然后将这些值转换为流量值并发送到测试控制软件以根据限值进行测试。

The current leak specification is: 5 sccm @ 1psi (subject to change when ES is published).
目前的泄漏规格为:5 sccm @ 1psi(在 ES 发布时可能会发生变化)。

Hardware Requirements
硬件要求

The following sections detail the hardware requirements of the test stands above and beyond the standard Ford auto stations requirements such as: safety, PLC, stack lights, HMI, etc.
以下部分详细介绍了测试台的硬件要求,这些要求超出了标准的福特汽车站要求,例如:安全、PLC、堆栈灯、HMI 等。

Test Circuit
测试电路

The following circuitry and components are what BME Test Engineers consider the test circuit for this test stand.
以下电路和组件是 BME 测试工程师认为该测试台的测试电路。

This is not an exhaustive list of all components, but a list of the main components required to complete all testing and which supplier is responsible for what components. It is the sole responsibility of the equipment integrator to ensure that all required components to do all testing is included.
这不是所有组件的详尽列表,而是完成所有测试所需的主要组件以及哪个供应商负责哪些组件的列表。设备集成商全权负责确保包含执行所有测试所需的所有组件。

The test circuit will be supplied by ATEQ and will consist of:
测试电路将由 ATEQ 提供,包括

20L tank in line with the plant air supply that is used to supply pilot air
20L 油箱与用于供应先导空气的工厂空气供应一致

ATEQ Controller that contains:
ATEQ 控制器,其中包含:

All electronics and sensors
所有电子元件和传感器

Valving to route air and vent
阀门以路由空气和通风

2 Certified leak orifices will be supplied to handle all self-diagnosis and challenge routines.
2 将提供经过认证的泄漏孔口,以处理所有自我诊断和质询程序。

10L Challenge Tank/Coil.
10L 挑战罐/线圈。

The Machine Integrator will supply the electrical cabinet to house the Test Control PC and any other hardware required for the stand to operate.
机器集成商将提供电气柜,以容纳测试控制 PC 和支架运行所需的任何其他硬件。

*Environmental
*环境

An environmental chamber around the part that automatically comes down over the part to protect from wind is required, this should be a clear chamber so the equipment and part can be viewed easily.
需要在零件周围安装一个环境室,该环境室会自动落在零件上以防止风吹,这应该是一个透明的房间,以便于查看设备和零件。

Electrical Requirements
电气要求

There are no additional requirements above what is already listed in section 4.2
除了第 4.2 节中已列出的要求之外,没有其他要求
.

Pneumatic, Hydraulic, or Coolant Requirements
气动、液压或冷却液要求

There are no additional requirements above what is already listed in section 4.4
除了第 4.4 节中已经列出的要求之外,没有其他要求
.

Alignment, Mastering, and Calibration
对齐、母带处理和校准

The following sections will review the Alignment, Challenge, and Calibration requirements of the test stands.
以下部分将回顾测试台的对准、质询和校准要求。

Challenge Parts
挑战零件

Two Challenge parts (one for each model) will be required for this test station. These Challenge parts need the ability to automatically go into each stand at set intervals determined by the Ford Test Engineer.
此测试站需要两个 Challenge 部件(每个型号一个)。这些 Challenge 零件需要能够按照 Ford 测试工程师确定的设定间隔自动进入每个支架。

‘Blanking chambers’ will also need to be supplied to allow the test stand to easily connect to in order to verify that the test stand and all pneumatic hoses are not leaking.
还需要提供“盲室”,以便轻松连接测试台,以验证测试台和所有气动软管没有泄漏。

Calibration
校准

All transducers used for measurement should be checked and certified annually using devices with sufficient accuracy (minimum 10x that of the sensor) should be supplied by the equipment integrator.
所有用于测量的传感器应每年使用设备 集成商提供的具有足够精度(至少是传感器的 10 倍)的设备进行检查和认证。

The ATEQ controller and all transducers inside will also need to be calibrated Annually by ATEQ.
ATEQ 控制器和内部的所有传感器也需要每年由 ATEQ 校准。

Will need to develop a method to leak test the blanking chamber during SE.
开发一种 在 SE 期间冲裁室进行泄漏测试的方法

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Electrical Test
电气测试

General Information
一般信息

The purpose of this stand is to perform electrical tests and interact with the BECM to test it and modify the BECM software. The test stand will be fully automatic, a part will enter on a pallet or AGV and the test stand will connect to the part without aid from an operator and will leave automatically once the tests are complete.
该支架的目的是执行电气测试并与 BECM 交互以测试它并修改 BECM 软件。测试台将是全自动的,零件将进入托盘或 AGV,测试台将连接到零件上,无需操作员的帮助,并在测试完成后自动离开。

The design of the electrical test stands shall use a single high-power cycler to test the battery.
电气测试台的设计应使用单个大功率循环器来测试电池。

Lots of thought should be put into the design of all test circuits to maximize the flexibility and control of all connections and components. The batteries will have many different electrical connectors with many separate functions, so pathways to each of these need to be fully programmable. This will be fully controllable by the test sequence written by the Ford BME Test Engineering team, as requirements may change over time.
所有测试电路的设计都应该投入大量思考,以最大限度地提高所有连接和组件的灵活性和控制。电池将具有许多不同的电气连接器,具有许多独立的功能,因此通往每个连接器的路径都需要完全可编程。这将完全由福特 BME 测试工程团队编写的测试序列控制,因为要求可能会随着时间的推移而变化。

The Machine Integrator will ensure that the test stand can clamp/unclamp, and the part can go into and out of the test stand fully automatically. Actual test sequence time will vary and will be controlled solely by the Ford BME Test Engineering team. The current estimate for test cycle time is 175 seconds.
机器集成商将确保测试台可以夹紧/松开,并且零件可以全自动进出测试台。实际测试序列时间会有所不同,并且将完全由福特 BME 测试工程师团队控制 测试周期时间的当前估计值为 175秒。

Test Sequence
测试序列

Global Limits will be monitored continuously by the test control software to ensure the safety of the battery, test stand, and personnel. These parameters are Temperature, Voltage, Current, and Pressure, and will be monitored via CAN from the BECM, as well as each voltage and Current sensor on the test stand.
测试控制软件将持续监控 Global Limits,以确保电池、测试台和人员的安全。这些参数是温度、电压、电流和压力,将通过 CAN 从 BECM 以及测试台上的每个电压和电流传感器进行监控。

Due to the high current rating of the connectors, they will also need continuous temperature monitoring with global limits to shut the stand down if the limits are exceeded on all connectors that go above 100A.
由于连接器的额定电流很高,它们还需要连续的温度监测和全局限制,以便在所有连接器超过 100A 的电流超过限制时关闭支架。

The test sequence will begin by locating the part on the conveyor then confirming all necessary touchpoints on the Battery is made by the operator touching a palm switch. The PLC will read all data from the RFID or Virtual Tag and transferring it to the test control software.
测试序列将从在传送带上找到零件开始, 然后确认操作员触摸掌形开关即可电池上完成所有必要的接触点。PLC 将从 RFID 或虚拟标签中读取所有数据,并将其传输到测试控制软件。

BECM Flash and ENS
BECM Flash 和 ENS

BECM flash is handled by the test control software via a CAN-FD connection to the BECM and should take approximately 80 seconds to complete.
BECM 闪存由测试控制软件通过与 BECM 的 CAN-FD 连接进行处理,大约需要 80 秒才能完成。

A 10Hz 50% duty cycle ENS signal will need to be applied to the BECM, as well as 13.5Vdc voltage to the LV BECM Connector.
需要将 10Hz 50% 占空比 ENS 信号施加到 BECM,并将 13.5Vdc 电压施加到 LV BECM 连接器。

Write Values to BECM
将值写入 BECM

Write S/N to BECM and Shunt Sensor Calibration
将 S/N 写入 BECM 和分流传感器校准
:

The S/N will be written to the BECM via DID write and requires a level 3 BECM security key.
S/N 将通过 DID 写入写入 BECM,并且需要 3 级 BECM 安全密钥。

Format: GSDB Code + 5 Digit Julian Date + 6 Digit S/N + Part number
格式:GSDB 代码 + 5 位儒略日期 + 6 位 S/N + 零件编号

Example: [DSB0G19170000001T3R8 10B759 AA]
示例:[DSB0G19170000001T3R8 10B759 AA]

Shunt Resistance Format: XXXXXX
分流电阻格式:XXXXXX

Example: XXXXXX
示例:XXXXXX

Shunt Thermal Calibration Format: XXXXX
分流热校准格式:XXXXX

Example: XXXXXX
示例:XXXXXX

A specific shutdown method is required (remove power from HEV_Wakeup, monitor current to drop below 100mA, then remove power from B+)
需要特定的关断方法(断开 HEV_Wakeup 的电源,监控电流降至 100mA 以下,然后断开 B+ 的电源)

Current and Pressure Sensor Test
电流和压力传感器测试

Current and pressure sensors inside the Battery will need to be checked against the sensors on the test stand to confirm they are working. These may require a checksum since they are inverted delta parameters. Measurements will need to be recorded by the Test Control PC.
需要对照测试台上的传感器检查电池内部的电流和压力传感器,以确认它们是否正常工作。这些参数可能需要校验和,因为它们是反转的 delta 参数。测量结果需要由 Test Control PC 进行记录。

HVIL and Leakage Resistance Test
HVIL 和耐泄漏测试

The High Voltage Interlocks will need to be tested:
高压联锁装置需要测试:

Open the interlock loop on the PDU, SDU, and DCFC.
打开 PDU、SDU 和 DCFC 上的联锁回路。

Record the Battery System HVIL state (closed or open).
记录电池系统 HVIL 状态(已关闭或打开)。

Activate relay to close PDU interlock loop, then record HVIL state.
激活继电器以关闭 PDU 联锁回路,然后记录 HVIL 状态。

Activate relay to close SDU interlock loop, then record HVIL state.
激活继电器以关闭 SDU 联锁回路,然后记录 HVIL 状态。

Activate relay to close DCFC interlock loop, then record HVIL state.
激活继电器以关闭 DCFC 联锁回路,然后记录 HVIL 状态。

Clear DTC’s.
清除 DTC。

Apply 13.5V ± 1V to CONT_PWR, send message 0x25b, confirm no DTC.
将 13.5V ± 1V 施加CONT_PWR,0x25b发送消息,确认无 DTC。

Record contactor voltage and wait 6 seconds for isolation resistance measurement to complete.
记录接触器电压并等待 6 秒以完成隔离电阻测量。

Disconnect CONT_PWR then HEV_WAKEUP and wait for B+ current to drop below 100mA
断开 CONT_PWR 然后HEV_WAKEUP并等待 B+ 电流降至 100mA 以下

Apply CONT-PWR and then HEV_WAKEUP then record Leakage Resistance DID and DTC’s.
应用 CONT-PWR,然后HEV_WAKEUP然后记录漏电阻 DID 和 DTC。

Polarity Voltage Check
极性电压检查

Polarity checks will be completed on all electrical connectors to ensure they are working and not hooked up backwards (negative voltage), this will be done using the same voltage sensors as the Electrical Test Stands to ensure correlation. This step could potentially be combined with the HVIL and leakage resistance testing to save cycle time.
将对所有电气连接器进行极性检查,以确保它们正常工作且未向后连接(负电压),这将使用与电气测试台相同的电压传感器完成,以确保相关性。此步骤可以与 HVIL 和耐泄漏性测试相结合,以节省循环时间。

Hardware Requirements
硬件要求

The following sections detail the hardware requirements of the test stands above and beyond the standard Ford auto stations requirements such as: safety, PLC, stack lights, HMI, etc.
以下部分详细介绍了测试台的硬件要求,这些要求超出了标准的福特汽车站要求,例如:安全、PLC、堆栈灯、HMI 等。

BECM Flash
BECM 闪存

A power supplies capable of generating 13.5Vdc @ 10A continuously to power the BECM and Contactors through the LV BECM connector (Tolerance of ± 1 Vdc) is required. This power supply must be able to handle 50A (100ms) inrush current.
需要一个能够连续产生 13.5Vdc @ 10A 的电源,以通过 LV BECM 连接器为 BECM 和接触器供电(容差± 1 Vdc)。 此电源必须能够处理 50A (100ms) 浪涌电流。

A waveform generator capable of producing the heartbeat and ENS Signal of 13.5Vpp at 10Hz with a 50% Duty cycle (Tolerance of ± 1 Vdc, and ± 10% Frequency).
波形发生器能够在 10Hz 下产生 13.5Vpp 的心跳和 ENS 信号,占空比为 50%(容差为 ± 1 Vdc,频率± 10%)。

Electrical relays or similar devices will be required for all powered connections that go from the power supply and waveform generator to the BECM/LV connector to turn the power on/off based on the test sequence.
从电源和波形发生器到 BECM/LV 连接器的所有通电连接都需要继电器或类似设备,以根据测试序列打开/关闭电源。

Every electrical path that supplies power must have current and voltage measurement devices that can be recorded by the test control software with reasonable accuracy (±1V, ±100mA). These circuits are BECM Power, and Contactor Power.
每个供电的电气路径都必须具有电流和电压测量设备,这些设备可以由测试控制软件以合理的精度(±1V、±100mA)记录。这些电路是 BECM Power 和 Contactor Power。

Voltage and Current Measurement
电压和电流测量

The same level of voltage measurement devices should be used as we are using for Electrical Test.
应使用与我们用于电气测试相同级别的电压测量设备。

Test Circuit
测试电路

The following circuitry and components are what BME Test Engineers consider the test circuit for this test stand.
以下电路和组件是 BME 测试工程师认为该测试台的测试电路。

This is not an exhaustive list of all components, but a list of the main components required to complete all testing and which supplier is responsible for what components. It is the sole responsibility of the equipment integrator to ensure that all required components to do all testing is included.
这不是所有组件的详尽列表,而是完成所有测试所需的主要组件以及哪个供应商负责哪些组件的列表。设备集成商全权负责确保包含执行所有测试所需的所有组件。

Electrical panel containing:
电气面板包含:

Test control PC and UPS.
测试控制 PC 和 UPS。

BECM Power Supply and ENS Waveform Generator.
BECM 电源和 ENS 波形发生器。

High Power Connector Tests
高功率连接器测试

Before ramping the voltage and current of the battery we will need to setup the BECM and battery contactors to their proper settings before the battery can input/output voltage and current.
在提高电池的电压和电流之前,我们需要将 BECM 和电池接触器设置为适当的设置,然后电池才能输入/输出电压和电流。

Low Power Connector Tests
低功率连接器测试

The BECM/LV connector will be used to communicate with and power the BECM which controls a lot of functions within the battery. See section 4.10.2.4 for more details on this connector. This connector will deliver power, and the wakeup signal necessary to turn on the BECM.
BECM/LV 连接器将用于与 BECM 通信并为 BECM 供电,BECM 控制电池内的许多功能。有关此连接器的更多详细信息,请参阅 Section 4.10.2.4 。此连接器将提供电源和打开 BECM 所需的唤醒信号。

Many calculations will be done using the data recording during these ramp sequences to ensure the battery is operating properly. All requirements are listed in the most recent Engineering Specification for each program which is published by the Product Development Team at regular intervals throughout the process.
在这些斜坡序列中,将使用数据记录进行许多计算,以确保电池正常运行。所有要求都列在每个程序的最新工程规范中,该规范由产品开发团队在整个过程中定期发布。

Controlled Shutdown
受控关断

The controlled shutdown process of the BECM takes some time to complete, anywhere from 5-10 seconds. There is a certain order that power must be removed from certain pins on the BECM/LV connector, then the power supply current must be monitored until it goes below 100mA before disconnecting any connectors. Failure to do so could result in a damaged Battery and/or BECM.
BECM 的受控关闭过程需要一些时间才能完成,大约需要 5-10 秒。有一定的顺序,必须从 BECM/LV 连接器上的某些引脚断开电源,然后必须监控电源电流,直到它低于 100mA,然后再断开任何连接器。否则可能会导致电池和/或 BECM 损坏。

All necessary information will be passed from the test control software to the PLC to write to the RF tag or Virtual tag at the end of the test.
所有必要的信息将从测试控制软件传递到 PLC,以便在测试结束时写入 RF 标签或虚拟标签。

Cycler Requirements
Cycler 要求

The electrical Test stands will require 1 High-Powered cycler which will deliver power to the battery to test and charge the battery with the following specifications:
电气测试台需要 1 个高功率循环仪,它将为电池供电,以测试和充电电池,规格如下:

Environmental Range: Temperature: 15°C to 40°C, Humidity: <95%.
环境范围:温度:15°C 至 40°C,湿度:<95%。

The following requirements apply for the entire environmental operating range:
以下要求适用于整个环境操作范围:

Typical Power: 70kW (100 kW peak for 10 seconds).
典型功率:70kW100 kW 峰值持续 10 秒)。

Typical Voltage: 350V
典型电压:350V
.

Sustained Current: 175A (Peak Cycler Output Current: 250A for 10 seconds Maximum).
持续电流:175A(峰值循环器输出电流:最大 250A 持续 10 秒)。

Minimum electrical isolation of 2.0 giga-ohms between HV+/ground and HV-/ground.
HV+/接地和 HV-/接地之间的最小电气隔离为 2.0 GHz。

Current and Voltage Accuracy of ± 1% or better.
电流和电压精度为 ±1% 或更高。

Current and Voltage Ripple of 0.75% or lower.
电流和电压纹波为 0.75% 或更低。

Command latency of 10ms.
命令延迟 10ms。

Current and Voltage rise time of 10ms.
电流和电压上升时间为 10ms。

Output data sampling 10ms.
输出数据采样 10ms。

Input voltage of 480 VAC (3-phase).
输入电压为 480 VAC(三相)。

Cyclers must be max 50 feet (cable run) from the test stands.
Cyclers 必须距离测试台最大 50 英尺(电缆)。

Each electrical pathway shall have dedicated voltage and current instrumentation in the electrical panel. All current will be measured using LEM fluxgate style ammeters with an accuracy of 1.0% full scale or better. Also, these 3 circuits should be properly protected with fuses, and any other required electrical protections.
每个电气路径应在电气面板中有专用的电压和电流仪表。所有电流都将使用 LEM 磁通门式电流表测量,精度为 1.0% 满量程或更高。此外,这 3 个电路应使用保险丝和任何其他所需的电气保护进行适当保护。

Cable Sizing
电缆尺寸

Cabling and component designs inside the cycler and test stand should be sized to the MAX CYCLER SPECIFICATION to allow us to easily retool this stand for future products that may require more power.
循环仪和测试台内部的 C abling 和组件设计应根据 MAX CYCLER 规格调整尺寸,以便我们可以轻松地为未来可能需要更多功率的产品重新调整该支架。

BECM and Power Supply Hardware
BECM 和电源硬件

A power supply capable of generating 13.5Vdc @ 10A continuously to power the BECM and Contactors through the LV BECM connector (Tolerance of ± 1 Vdc) is required.
需要一个能够连续产生 13.5Vdc @ 10A 的电源以通过 LV BECM 连接器为 BECM 和接触器供电(容差± 1 Vdc)。

A waveform generator capable of producing the heartbeat and ENS Signal of 13.5Vpp at 10Hz with a 50% Duty cycle (Tolerance of ± 1 Vdc, and ± 10% Frequency).
波形发生器能够在 10Hz 下产生 13.5Vpp 的心跳和 ENS 信号,占空比为 50%(容差为 ± 1 Vdc,频率± 10%)。

Electrical relays or similar devices will be required for all powered connections that go from the power supply and waveform generator to the BECM/LV connector to turn the power on/off based on the test sequence.
从电源和波形发生器到 BECM/LV 连接器的所有通电连接都需要继电器或类似设备,以根据测试序列打开/关闭电源。

Every electrical path that supplies power must have current and voltage measurement devices that can be recorded by the test control software with reasonable accuracy (±1V, ±100mA). These circuits are BECM Power and Contactor Power
每个供电的电气路径都必须具有电流和电压测量设备,这些设备可以由测试控制软件以合理的精度(±1V、±100mA)记录。这些电路是 BECM Power 和 Contactor Power
.

Additional Hardware
其他硬件

Depending on which test control software supplier was chosen, the hardware required for the electrical cabinet may vary depending on the type of data acquisition being used.
根据所选的测试控制软件供应商,电气柜所需的硬件可能会有所不同,具体取决于所使用的数据采集类型。

Electrical Requirements
电气要求

This station has some additional requirements above those listed in section 4.2
该电台在第 4.2 节中列出的要求之外还有一些额外的要求
.

Every electrical path must have its own dedicated voltage and current measurement instrumentation and will need high voltage contactors or low voltage relays (depending on the nature of the circuit) to control their functionality.
每个电气路径都必须有自己专用的电压和电流测量仪器,并且需要高压接触器或低压继电器(取决于电路的性质)来控制其功能。

It is very important to consider arc-flash ratings and ECPL when designing the system and cyclers. This design will need to be reviewed by the Ford Safety team during SE.
在设计系统和循环仪时,考虑弧闪等级和 ECPL 非常重要。此设计需要在 SE 期间由 Ford Safety 团队进行审查。

Pneumatic, Hydraulic, or Coolant Requirements
气动、液压或冷却液要求

This test stand has some additional requirements above and beyond those listed in 4.4
除了 4.4 中列出的要求之外,该测试台还有一些额外的要求
.

Manual ball valves for the cycler coolant circuit should be located outside the panel to troubleshoot.
用于 Cycler 冷却液回路的手动球阀应位于面板外部以进行故障排除。

Alignment, Challenge, and Calibration
对齐、挑战和校准

The following sections will review the Alignment, Challenge, and Calibration requirements of the test stands.
以下部分将回顾测试台的对准、质询和校准要求。

Challenge Part
挑战部分

No Challenge Parts are required for these Electrical Test Stations.
这些电气测试站不需要 Challenge Parts。

Calibration
校准

All transducers used for measurement should be checked and certified annually using devices with sufficient accuracy (minimum 10x that of the sensor being checked)
所有用于测量的传感器都应每年使用具有足够精度的设备(至少是被检查传感器的 10 倍)进行检查和认证
.

The cycler supplier should supply all required equipment and documentation to complete the yearly calibration verifications on all sensors contained inside the Cycler. ECPL and Arc-flash requirements should be considered when designing the panel so that the annual calibration checks and troubleshooting can be completed without danger to the personnel (IP2X)
Cycler 供应商应提供所有必需的设备和文档,以完成 Cycler 内所有传感器的年度校准验证。在设计面板时,应考虑 ECPL 和弧闪要求,以便在不对人员造成危险的情况下完成年度校准检查和故障排除 (IP2X)
.

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Test Regress Stations
测试回归站

The test regress stations will be the responsibility of the Ford BME Assembly Lead Engineer, but the test team would like to add some input into the capability and process of these regress stations to ensure their success
测试回归站将由 Ford BME 装配首席工程师负责,但测试团队希望为这些回归站的能力和过程添加一些输入,以确保它们的成功
.

Minimum Hardware Requirements
最低硬件要求

At a minimum the following hardware should be supplied for every test regress station.
至少应为每个测试回归站提供以下硬件。

Integrator Supplied Hardware
Integrator S提供的硬件

The test stand integrator should supply all the necessary hardware to support a basic regress station such as:
测试台集成商应提供所有必要的硬件来支持基本的回归站,例如:

All necessary PC and Hardware to read the RFID or Virtual Tag information and pass it to the test control software to present to the operator and
读取 RFID 或虚拟标签信息并将其传递给测试控制软件以呈现给操作员的所有 必要 PC 和硬件

Palm button and HMI to control the tag and AGV/Pallet
掌控按钮和 HMI 控制标签和 AGV/托盘

Test Control Software Hardware
测试控制软件硬件

Both Test Control Software Manufacturers should be quoted for these regress stations to provide the necessary functionality mentioned in this section. At a minimum this shall include a PC, monitor, keyboard, and mouse. If less is required, then it can be added as an optional quote on the SQF document.
应为这些回归站引用两个测试控制软件制造商以提供本节中提到的必要功能。这至少应包括 PC、显示器、键盘和鼠标。如果要求较少,则可以将其添加为 SQF 文档中的可选引文。

Minimum Software Requirements
最低软件要求

At a minimum, each test-specific regress station should be capable of automatically reading all tag information including the S/N from the Battery RFID or Virtual Tag and displaying it on a monitor to the regress operator. This Software should be supplied and quoted from the test control software supplier.
至少,每个特定于测试的回归站都应该能够自动读取所有标签信息,包括来自电池 RFID 或虚拟标签的 S/N并将其显示在监视器上给回归操作员。本软件应由测试软件供应商提供和引用

The regress software should be capable of tracking all test results from the test stands and displaying them to the operator so they can determine the best method of repair. This software also needs to be able to limit retests of a battery to a Ford test engineer defined value (standard is 3 tests maximum). Also, the software should allow the operator to send the part to a certain test stand for re-test.
回归 software 应该能够跟踪来自测试台的所有测试结果并将其显示给操作员,以便他们确定最佳修复方法。该软件还需要能够将电池的重新测试限制为福特测试工程师定义的值(标准为最多 3 次测试)。 此外,该软件应允许操作员将零件发送到某个测试台进行重新测试。

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Document Editing Tips
文档编辑技巧

*This section is instructions for the editor, suppliers can disregard this section.
*本节是给编辑的说明,供应商可以忽略本节。

This document uses Quick Parts to make editing the document easy.
此文档使用 Quick Parts 来简化文档的编辑。

They can be found in: Insert > Quick Parts
它们可以在插入 > 快速零件中找到

Quick Part Name:
快速部件名称:

Subject:
主题:

Subject
主题

Battery Name (BEV-X)
电池名称 (BEV-X)

Company Address
公司地址

Plant Name
工厂名称

27MY FHEV
27MY FHEV (全能)

TEST EQUIPMENT STATEMENT OF WORK (SOW)
测试设备工作说明书 (SOW)

Change Log
更改日志

5/12/23

Created original document and layout
创建原始文档和布局

6/12/23

Added note about power regulation in electrical section
在电气部分添加了有关电源调节的说明

3/12/24

Started working on this document again, added test stand specifics
再次开始编写本文档,添加了测试台的具体信息

3/13/24

Added a lot of information including test regress stations
添加了很多信息,包括测试回归站

4/18/24

Completed the first Draft for PHEV-T3H
完成 PHEV-T3H 的初稿

6/27/24

First Draft for FHEV
FHEV 初稿