HARMAN INTERNATIONALRELIABILITY TEST PLANforAUTOMOTIVE AUDIO SPEAKERharman consumer groupCentral Quality GroupRelease Date: 2/1/98 Revision Level: KRevision Level Date: 03/31/051.0 PurposeThe purpose of this test plan is to describe the environmental and functional performancerequirements to which the speaker will undergo in order to be validated. The intent of thevalidation program is to expose the speaker to an accelerated aging process.2.0 Test PlanThis test plan details the type of tests and the number of units required for each. The sample size outlined below may change depending on Reliability Target.2.1 Test ImplementationThe full qualification test program consists of the groups listed below. This is a parallel test sequence such that each group is run independently. This test plan must be performed on at least one member of a “Product Family”. The most complex or highest power model should be chosen.Full Qualification Test SequenceGroupQuantityDV PVTest Name Spec. Sect.No.Functional TestRequirementsA 2 6Life Cycle 5.1 4.4 and 4.5B 2 6Power Test 5.4 4.4 and 4.5UV Exposure Test 5.8Impact Test 5.5C 2 6Humidity Test 5.3 4.4 and 4.5Random Vibration Test 5.6 4.4 and 4.5D 2* 6 Packaging Test (ASTM) 5.7 4.4 and 4.5For Packages up to 150 lbs (ASTM4169)Handling (Drop), First Sequence 5.7.1 4.4 and 4.5Compression Test (Vehicle StackingAssurance Level II)5.7.2 4.4 and 4.5Loose Load Vibration 5.7.3 4.4 and 4.5Vehicle Vibration 5.7.4 4.4 and 4.5Handling (Drop), Second Sequence 5.7.5 4.4 and 4.5Temperature Test 5.2 4.4 and 4.5(1) For Master Pack Shipping Option (ifavailable)5.7.9Humidity Storage Test 5.7.9.1Loose Load Vibration 5.7.3VehicleVibration 5.7.4* If packaging is available.Note 1: Unless otherwise specified, all units shall be tested in the orientation that unit will be mounted in the car.Note 2: The performance limits of the units under test will be specified in the HCG approved Engineering Test Specification (ETS) [see Section 6].2.2 Abbreviated QualificationThe abbreviated test program consists of the groups listed below. This is a parallel test sequence such that each group is run independently. These tests must be performed on all members of a “Product Family” not subjected to the Full Qualification found in section 2.1.Abbreviated Qualification Test ScheduleGroupDV PV Test Name Spec. Sect.No.Functional TestRequirementsA 2 6Life Cycle 5.1 4.4 and 4.5B 2 6Power Test 5.4 4.4 and 4.5Handling Drop Test 5.5C 2* 6Packaging Test (ASTM) 5.7 4.4 and 4.5For Packages up to 150 lbs (ASTM4169)Handling (Drop), First Sequence 5.7.1 4.4 and 4.5Compression Test (Vehicle StackingAssurance Level II)5.7.2 4.4 and 4.5Loose Load Vibration 5.7.3 4.4 and 4.5Vehicle Vibration 5.7.4 4.4 and 4.5Handling (Drop), Second Sequence 5.7.5 4.4 and 4.5* If packaging is available.Note 1: Unless otherwise specified, all units shall be tested in the normal car mounting orientation.Note 2: The performance limits of the UUT will be specified in the Engineering Test Specification.3.0 Standard Test Conditions3.0.1 Signal SourceUnless otherwise specified, all tests shall be conducted with the Audio SignalGenerator/Amplifier output configured to be balanced, less than or equal to 50-ohm source impedance, and floating. The signal source GND shall be connected to the speaker PWRGND at the speaker.3.0.2 PositionUnless otherwise specified, the speaker shall meet all requirements in the “normal mounting position”. It is defined on the Product Specification as to the horizontal or vertical position of the mounting surface.3.0.3 Room TemperatureUnless otherwise specified, all measurements shall be made at room temperature. Roomtemperature is specified as 23o C +/-3o C.3.0.4 Frequency RangeThe frequency range is specified from the -3dB point at the upper and lower operating range of the driver. This range and the limits with in that range shall specified on the ProductSpecification.3.0.5 NoiseThe products are divided into three groups, full range (multi-element), mid-bass, and sub-woofer. The type of product shall be specified on the Product Specification.Full Range will use track 13 on the Car Audio Test Disc Version 2.0: IEC noise with acrest factor of 9dB.Mid-bass will use track 14 on the Car Audio Test Disc Version 2.0: a decade of pinknoise, 50 to 500Hz (-3dB points) 12dB slopes, with a crest factor of 9dB.Sub-woofer will use track 15 on the Car Audio Test Disc Version 2.0: a decade of pinknoise, 30 to 300Hz (-3dB points), 12dB slopes, with a crest factor of 9dB.3.0.6 Music SignalThe products are divided into two groups: 1) full range (multi-element) and mid-bass, 2) sub-woofer. The type of product shall be specified on the Product Specification.Full Range and Mid-bass – track 16 on the Car Audio Test Disc Version 2.0: “Beat It”by Michael JacksonSub-woofer – track 17 on the Car Audio Test Disc Version 2.0: “Crime Stories” by MCHammer4.0 Functional RequirementsFunctional requirements are to be tested in accordance with an HCG approved product engineering specification (ETS).4.0.1 PolarizationWith the driver face down and the terminal facing toward you the Product Specification shall identify the positive terminal, which shall be labeled Pin 1 or “+”. When a positive potential is applied to the positive terminal, the cone shall move outward from the basket producingpositive pressure.Ref. IEC 268-24.0.2 DC ResistanceEnsure that the test lead resistance is factored out of this measurement. Connect the test leads to the speaker and measure the resistance in ohms with an averaging ohmmeter to ensure that ambient noise levels do not produce an EMF at the meter yielding false resistance readings.The DCR shall be within the limits specified on the Product Specification.4.0.3 ImpedanceRigidly suspend the speaker from the motor structure in free air at least 50 cm from thenearest reflecting surface. Mounting means must be minimal in bulk such that the airmovement during testing is substantially unrestricted.Measure the deviation from the Reference Sample Speaker impedance at each of the definedfrequencies. The deviation at all frequencies shall be within the limits specified on the Product Specification.4.0.4 Frequency ResponseApply a stepped sine wave sweep or a Canetics signal over the specified frequency range,using the specified frequency spacing, with the specified bandwidth smoothing per theProduct Specification, and analyze the microphone output. Calibrate the measurement system to display the 1 Watt 1 Meter equivalent sensitivity based on Z nom as specified on the Product Specification. Display the SPL and the Frequency in ISO standard 25dB/decade aspect ratio.The resultant graph of amplitude vs. frequency is defined as the frequency response. Measure the deviation from the Reference Sample Speaker sound pressure level at each of the definedfrequency bands. The deviation at all frequencies shall be within the limits specified on theProduct Specification.To verify that no damage has occurred to the Reference Sample Speaker and that the testequipment is functioning properly, the first process shall be to test the Reference SampleSpeaker against the stored data from the previous production runs. If there is a change of more than one standard deviation at any frequency, both the Reference Sample Speaker and testequipment shall be re-calibrated.4.0.5 Extraneous NoiseThe speaker assembly shall not produce extraneous noise when a dynamic test is performed.The following types of deficiencies are some typical causes of extraneous noise:Buzz: Any noise produced by a looseness of components vibrating against othercomponents.Rub: Any noise produced by the voice coil sliding or rubbing against other components.Bottoming: The noise produced by the contact of the moving system with the speakerstructure.Rattle: The random noise produced by an object trapped within the speaker strikingmoving components or any intermittent noise caused by loose electrical connections orcontrols.Frozen Coil: Absence of free excursion caused by adhesive in the magnetic gap or anoffset (loose) component of magnetic circuit.Air Noise: The noise produced by high velocity airflow through a small leak.5.0 Qualification TestingThe reliability target for all car speaker products is zero defects at 50,000 miles operation.Successful completion of the test is intended to demonstrate 90% reliability with 90% confidence.5.1 Life CycleEach speaker shall withstand 5 cycles (totaling 215 hours) of the environmental conditionsoutlined below. The speakers should be checked once a day on a regular basis. A full functional test should be performed on all units at the end of the second and fifth cycles.5.1.1 Life Cycle CalibrationThe supplied Car Audio Test Disc Version 2.0 facilitates accurate test level calibration and testing consistency by incorporating sine wave test tones (first three tracks) that are calibrated to the music tracks specified for testing.Using the RMS number from the Product Specification under the “Life Cycle” column, the level will be calibrated with the appropriate test tone (track 1 for subwoofers, track 2 for mid-bass, and track 3 for multi-element full range). Then skip to track 16 “Beat It” for full range and mid-bass or track 17 “Crime Stories” for subwoofer and repeat for the specified duration.The level of the music signal is already calibrated to the test tone.A. Over a 30-minute period, raise the temperature to 40°C with a relative humidity of 95%.B. Stabilize the temperature at 40°C with a relative humidity of 95% for 16 hours. After 6 ½hours, apply the designated music signal at 1/8th the specified RMS voltage (section3.0.6). At the end of the 16-hour period, remove the signal.C. Over a 30-minute period, raise the temperature to 90°C with a relative humidity of <20%.D. Stabilize the temperature at 90°C with a relative humidity of 20% for 8 hours. After 3hours, apply the designated music signal at 1/8th the specified RMS voltage. At the end of the 8-hour period, remove the signal.E. Over a 30-minute period, lower the temperature to 25°C.F. Stabilize the temperature at 25°C for 2 hours.G. Over a 30-minute period, lower the temperature to -35°C.H. Stabilize the temperature at -35°C for 5 hours. After 2 hours, apply the designated musicsignal at 1/8th the specified RMS voltage. At the end of the 5-hour period, remove the signal.I. Over a 1-hour period, raise the temperature to 90°C.J. Stabilize the temperature at 90°C for 5 hours. After 2 hours, apply the designated music signal at 1/8th the specified RMS voltage. At the end of the 5-hour period, remove the signal.K. Over a 30-minute period, lower the temperature to 25°C.L. Stabilize the temperature at 25°C for 3.5 hours.M. This is the end of one cycle.(See graph on next page)5.2 Temperature (Non-Operational) TestEach speaker shall withstand 24 hours of exposure to -35o C and 24 hours to 90o C inside theenvironmental chamber. The test duration should be 24 hours at each temperature with aminimum of 4 hours between temperature conditions. Let the speakers cool down to a normal room temperature before any post-test evaluation is performed. The speaker should be tested at the end of each 24-hour period.Ref. Chrysler PF 9506 2.2.2.5 Temperature Test5.3 Humidity (Non-Operational) TestEach speaker shall withstand exposure to 40o C at 95% relative humidity for 16 hours, then 90o C at 20% relative humidity for 8 hours with 15 minutes ramp between the two temperature and humidity conditions. This is considered one cycle. The total test is 5 cycles long totaling 122 hours. Leave the speakers for a minimum of 4 hours at room temperature before any post-test evaluation is performed.Ref. Chrysler PF 9506 2.2.2.1 Damp/Dry Cycling5.4 Operating Power (Noise) TestEach speaker shall withstand 100 hours of application of noise signal specified in section 3.0.5.The noise signal should be calibrated to 100% of the RMS voltage rating as specified on the Product Specification. Leave the speakers for a minimum of 4 hours at room temperature before any post-test evaluation is performed.5.4.1 Power Test Calibration ProcedureThe supplied Car Audio Test Disc Version 2.0facilitates accurate test level calibration andtesting consistency by incorporating sine wave test tones (first three tracks) that are calibrated to the noise tracks specified for testing.Using the RMS number from the Product Specification under the “Power Test” column, the level will be calibrated as follows:Subwoofer – use track 1: 50 Hz 0 dBMid-bass – use track 2: 100 Hz 0 dBFull range (multi-element) – use track 3: 1 kHz 0 dBThen skip to the appropriate noise track (Subwoofer – track 15, Mid-bass – track 14, Fullrange – track 13) and repeat for the designated 100-hour duration of speaker testing. Thelevel of the test signal is already calibrated to the test tone.NOTE: The amplifier used in the test set-up must be capable of slightly higher PEAKvoltage than the level required for testing. An oscilloscope will be used to verify theabsence of a clipped output signal (which could cause damage to the transducer andpremature failure).5.5 Impact (Non-operational) TestEach speaker (without the packaging) shall withstand one (1) drop from a height of 1 meter onto a concrete base. Each speaker shall be dropped once for each side. A total of 6 units are needed to cover all six (6) sides.Each speaker shall be visually inspected for any loose or broken parts and components. Results of the test should be treated for information purposes only and not part of the acceptancecriteria.5.6 Random Vibration (Non-operational) TestEach unit shall withstand 2 hours per axis of the Random Vibration outlined below: Z – AxisBreakpoint (Hz) Magnitude (G2/Hz)0.005550.059100.035602000.00070.000041000Total Spectral Content = 1.8 GrmsY-AxisBreakpoint (Hz) Magnitude (G2/Hz)0.009250.07680.076120.00031000Total Spectral Content = 1.685 GrmsX-AxisBreakpoint (Hz) Magnitude (G2/Hz)0.00545100.05120.00271900.000233700.000231000Total Spectral Content = 1.4 GrmsPost TestTest units shall be visually inspected for any loose or broken parts and components, followed by functional testing.Ref. Chrysler PF 9825 2.3.2.1 Vibration5.7 Packaging Test (ASTM)5.7.1 Schedule A–Manual Handling, First SequenceFor purposes of this procedure, the bottom of a small parcel is the surface on which the parcel rests in its most stable orientation. Recommended drop heights, the number of drops, thesequence of drops, and the shipping unit orientation at impact are as follows:Shipping Weight, lb (kg) Drop Height, in. (mm)0 to 20 (0 to 9.1) 24 (610)20 to 40 (9.1 to 18.1) 21 (533)40 to 60 (18.1 to 27.2) 18 (457)60 to 80 (27.2 to 36.3) 15 (381)80 to 100 (36.3 to 45.4) 12 (305)100 to 200 (45.4 to 90.7) 10 (254)Number ofImpacts AtSpecified Height Impact Orientation –First Sequence of Distribution CycletopOneTwo adjacent bottom edgesTwo diagonally opposite bottom cornersbottomOneRef: ASTM D 4169 – 99Post TestThe units should be checked for functional performance and external appearance after the test.No impaired function or concealed damage is permitted. End pads may be cracked with no separation. Cartons should have no tearing or de-bonding of the seam edge.5.7.2Compression Test: Vehicle Stacking Assurance Level IISchedule B – Warehouse Stacking and Vehicle StackingThis test is intended to determine the ability of the shipping unit to withstand thecompressive loads that occur during warehouse storage or vehicle transport. Theformula calculates the compressive load over the largest footprint of the package usinga shipping density factor. A safety factor is used to take into effect time in storage,stacking pattern, variables in container strength and atmospheric conditions(temperature, humidity). The test is to be conducted by loading the shipping unit to thecomputed load value, as calculated below. The compressive load is to be uniformlydistributed about its largest footprint. Remove the load within 3 seconds after reachingthe specified value.Formula:L = Mf*J*((l*w*h)/K)*((H-h)/h)*FL = Minimum Required Test Load=lb or NMf = Shipping Cargo Density factor = 10.0 lb/ft3 or 160 kg/m3J = conversion factor = 1 lbf/lb or 9.8 N/kgl = length of shipping unit = in or mw = width of shipping unit = in or mh = height of shipping unit = in or mK = conversion factor = 1728 in3/ft3 or 1 m3/m3H = maximum stack height = 108.0 in or 2.7mF = factor to account for individual factors described above = 7Acceptance Criteria:1. No visible damage2. Product intact internally3. Packaging components able to provide further protection4. Compression test cannot cause the outer shipping container to crease, split or tear at the joint.Test Conditioning: 73.4o F (+/-2o F) [23o C (+/-1o C)] and 50% (+/-2%) relative humidity in accordance with practice D 4332.Ref: ASTM D 41695.7.3 Loose Load Vibration Method A1—Repetitive Shock TestPlace the test specimen on the test machine platform in its normal shipping orientation. Attach restraining devices to the platform to prevent the specimen from moving horizontally off the platform and to prevent excessive rocking without restricting the vertical movement. Adjust the restraining devices to permit free movement of the specimen of approximately 10 mm (0.4 in.) in any horizontal direction from its center position. Start the vibration of the platform at a frequency of about 2 Hz and steadily increase the frequency until some portion of the test specimen repeatedly leaves the test surface. To ensure that the test specimen receives acontinuing series of repetitive shocks, a shim with a 1.6 mm (1 /16 -in.) thickness and a width of 50 mm (2.0 in.) shall be used to determine when the test specimen is leaving the testplatform. The shim should be inserted under the package a minimum of 100 mm (4.0 in.) and moved intermittently along one entire length of the package.Continue the test at this frequency for a period of 1 hour. The test may be stoppedmomentarily to inspect for damage.If the container might possibly be transported in any other orientations, test at least onecontainer in each possible orientation for the full-specified test duration.Inspect the container and its contents and record any damage or deterioration resulting from the test.Ref: ASTM D 4169 – 99, ASTM D 999 – 965.7.4 Schedule E-Vehicle VibrationPerform the test for each possible shipping orientation. Recommended intensities anddurations for the random tests are given below.Random Test:The following power spectral densities (as defined by their mode of transport, frequency and amplitude breakpoints) and test durations are recommended:Air: Assurance Level IFrequency, Hz Power Spectral Density Level, g 2 /Hz0.000420.02120.021000.00002300Overall, g rms 1.49Duration, min B180B For vehicle vibration tests in multiple shipping unit orientations, the total duration should bedistributed evenly between the orientations tested.Ref: ASTM D 4169 - 995.7.5 Schedule A–Manual Handling, Second SequenceFor purposes of this procedure, the bottom of a small parcel is the surface on which the parcel rests in its most stable orientation. Recommended drop heights, the number of drops, the sequence of drops, and the shipping unit orientation at impact are as follows:Shipping Weight, lb. (kg) Drop Height, in. (mm)0 to 20 (0 to 9.1) 24 (610)20 to 40 (9.1 to 18.1) 21 (533)40 to 60 (18.1 to 27.2) 18 (457)60 to 80 (27.2 to 36.3) 15 (381)80 to 100 (36.3 to 45.4) 12 (305)100 to 200 (45.4 to 90.7) 10 (254)Number ofImpacts AtSpecified Height Impact Orientation –Second Sequence of Distribution CycleOne vertical edgeTwo adjacent side facesTwo one top corner and one adjacent top edgeOne the drop should be in the impact orientation most likely for adrop to occur, usually the largest face or the bottom. Fordistribution cycles where any drop orientation is possible (i.e.,small parcel environment), this drop should be in the mostcritical or damage–prone orientation.Ref: ASTM D 4169 – 99Post TestThe units should be checked for functional performance and external appearance after the test.No impaired function or concealed damage is permitted. End pads may be cracked with no separation. Cartons should have no tearing or de-bonding of the seam edge.5.7.9 Master Pack Shipping Option (if available)This test is intended to determine the ability of the individual beauty boxes in a mastershipping carton to withstand the potentially abrasive environment that could occur during vehicle transport following warehouse storage. A master pack is considered to be at least six units in a larger carton. If the product master pack is less than this number, then additional master packs will be tested until the six individual unit requirement is met.The test samples will be repacked in previously untested beauty boxes free of any visibledefects before being packed in the master pack for this test. Samples will complete theHumidity Storage test in the master carton.5.7.9.1 Humidity Storage TestThe units shall be exposed to the following conditions:ConditionTemperature 40° C (+/-2° C)-2%/+3%Humidity 93%Exposure Time 48 hoursStabilization Time AfterMinimum of 8 hoursTest*Unit Configuration With Packaging*Stabilization Time is referred to as the elapsed time the unit has been out of theenvironmental chamber and allowed to reach ambient temperature and humidityconditions before continuing into the next test.The master pack will complete the Loose Load Vibration test (5.7.3). This will be followed by the Vehicle Vibration test (5.7.4).Post TestAfter the test the individual unit beauty boxes must be checked for appearance. No visiblesurface abrasion or carton degradation is permitted.5.8 Ultraviolet (UV) Exposure TestEach speaker should be place inside the UV test chamber and withstand 20 cycles of UVexposure test outlined below. The type of UV lamp should be 40 watts UV-C lamp as shown: Test Set Up:Environmental conditions as follows:Temperature is 90° C constant.Over a 30-minute period, raise the humidity from ambient to 90%.Maintain at this level for 2 hours.At the end of 2 hours, discontinue the humidity (allow to return to ambient).Continue at 90° C constant for 5 hours 30 minutes.This is one cycle (eight hours). Total test duration is 20 cycles.UV Test Environmental Profile:Int 1Post TestTest units shall be visually inspected for any degradation in parts and components, followed by functional testing. Cone and surround material should not become brittle or crack and there should be no de-bonding cone-to-dust cap or cone-to-surround. Some discoloration or fading is expected.6.0 PRODUCT SPECIFICATIONTEST PARAMETER SECTIONPosition 3.2 Hor/VertFrequency Range 3.4 Range +dB -dBNoise 3.5 Product Type RMSLevelPolarization 4.1 Lt/RtDC Resistance 4.2 Min Max NomOhmsMaxMinImpedance 4.3RangeOhmsOhms Frequency Response 4.4 Range +dB -dB。
