QC/T 1035-2016Electronic throttle bodies for automotive engines (English PDF)

3.1 Electronic throttle body

An electronic device, that receives control commands from the engine management system, controls the throttle's opening by driving the DC motor, finally realizes the control of the engine's air intake; meanwhile can feedback the throttle's opening position information to the engine management system, in real time through sensors.

It is usually composed of a mechanical housing, a valve plate, a DC motor, a sensor.

3.2 Upper mechanical stop (UMS)

In the case of power failure, the maximum opening position of the valve plate of the throttle body, when pushed manually (see Figure 1).

4.3 Air flow characteristics

4.3.1 Air flow at the lower mechanical stop

The air flow of the electronic throttle body, at the lower mechanical stop, shall comply with the provisions of the product technical documents.

4.3.2 Air flow at the limb home position

The air flow of the electronic throttle body, at the limb home position, shall comply with the provisions of the product technical documents.

4.3.3 Air leakage from bearing

The air leakage of the electronic throttle body, at the bearing, shall not exceed 20 cm³/min.

4.4 Insulation resistance

The insulation resistance of the electronic throttle body shall be greater than 10 Mohm.

4.5 Withstanding voltage performance

After the electronic throttle body is subjected to the withstanding voltage test, the performance of the product meets the requirements of 4.2.

4.6 High-temperature storage performance

After the electronic throttle body is subjected to the high-temperature storage test, the appearance of the product shall not be deformed or damaged; the performance of the product shall meet the requirements of 4.2.

4.7 Low-temperature storage performance

After the electronic throttle body subject to the low-temperature storage test, the appearance of the product shall not be deformed or damaged; the product shall be able to drive normally.

4.8 Resistance to temperature cycle

After the electronic throttle body is subject to the temperature resistance cycle test, the appearance of the product shall not be deformed or damaged; the performance of the product shall meet the requirements of 4.2.

4.9 Resistance to cyclic damp heat

After the electronic throttle body is subjected to the wet heat cycle test, the appearance of the product shall not be deformed or damaged; the performance of the product shall meet the requirements of 4.2.

4.10 Salt spray resistance

After the electronic throttle body is subjected to the salt spray resistance test, the appearance of the product shall not have abnormal corrosive damage; the performance of the product shall meet the requirements of 4.2.

4.11 Resistance to high-concentration of sulfur dioxide

After the electronic throttle body is subjected to the high-concentration sulfur dioxide resistance test, the appearance of the product shall not have abnormal corrosive damage; the performance of the product shall meet the requirements of 4.2.

4.12 Chemical resistance

After the electronic throttle body is subjected to the test of resistance to chemical reagents, the performance of the product shall meet the requirements of 4.2.

4.13 Anti-free fall performance

After the electronic throttle body is subjected to the drop test, the product shall not have hidden damage.

4.14 Vibration resistance

After the electronic throttle body is subjected to the sinusoidal vibration test, the appearance of the product is not deformed or damaged; the performance of the product shall meet the requirements of 4.2.

4.15 Durability

After the electronic throttle body is subjected to the durability test, the appearance of the product is not deformed or damaged; the performance of the product shall meet the requirements of 4.2.

4.16 Protection performance

The degree of protection of the electronic throttle body is IP6K9K.

4.17 Electromagnetic compatibility

4.17.1 Radiated immunity

The electronic throttle body shall be tested for radiation immunity, according to Table 1. During the test, the product can be driven normally; the performance of the product […]

5.1.2 Test voltage

The test voltage of the electronic throttle body is (13.5 ± 0.2) V.

5.1.3 Tolerance

Unless otherwise specified, it shall meet the following tolerance requirements: Test current error: ±2%; Test resistance error: ±10%; Test frequency and time error: ±5%; Test temperature (steady state) error: ±3 °C; Test relative humidity error: ±5%RH.

5.2 Visual inspection

Visual inspection.

5.3 Test of working voltage range

The electronic throttle body's sensor is tested, under the supply voltage of 4.5 V and 5.5 V, respectively, to test the signal output of the position sensor.

The electronic throttle body is driven by the engine electronic controller. It is tested under the power supply voltages of 6 V, 9 V, 16 V, respectively, to observe the position, to which the electronic throttle body reaches.

5.4 Basic performance test

5.4.1 Response time

Power the controller, according to the test voltage, to drive the electronic throttle body.

Measure the time, which is required for the electronic throttle body's valve plate to reach 90% of the full stroke, which uses the upper electronic stop as the end, from the start of the trigging of the control signal, which uses the lower electronic stop as the start point.

Power the controller, according to the test voltage, to drive the electronic throttle body.

Measure the time, which is required for the electronic throttle body's valve plate to reach 90% of the full stroke, which uses the lower electronic stop as the end, from the start of the trigging of the control signal, which uses the upper electronic stop as the start point.

5.4.2 Return time

Supply power to the controller, according to the test voltage, to drive the electronic throttle body. Measure the time, which is required for the electronic throttle body's valve plate to reach the limb home position, for the first time, from the start of the trigging of the control signal, which uses the upper electronic stop as the start point.

5.4.3 Sensor signal output

Supply power to the controller, according to the test voltage, to drive the electronic throttle body. Measure the percentage, -- of the output voltage value of the position sensor, at the opening position defined in the product technical file, TO the working input voltage of the position sensor.

5.5 Air flow characteristic test

5.5.1 Air flow at lower mechanical stop

On the test bench for the air flow of electronic throttle body, under the condition that there is no pressure difference between the two sides of the valve plate, drive the throttle valve plate, at a given current and voltage value, until the valve plate reaches the lower mechanical stop. Then apply a certain pressure difference, on both sides of the valve plate. Record the air flow value, which passes through the throttle body's air passage, at this valve plate position.

5.5.2 Air flow at the limb home position

On the test bench for the air flow of electronic throttle body, disconnect the power supply of the throttle body motor. Use the spring return force, to return the throttle valve plate to the limb home position. Then apply a certain pressure difference, on both sides of the valve plate. Record the air flow, which passes through the valve plate, at this position.

5.5.3 Air leakage from bearing

On the test bench for the air flow of electronic throttle body, seal the inlet and outlet ends of the throttle body. Then apply an absolute atmospheric pressure of 2.5 KPa, from one end, to test its air leakage from bearing, by the pressure drop method.

5.6 Insulation resistance test

It is carried out, in accordance with the provisions of 4.12 of GB/T 28046.2-2011.

5.7 Withstanding voltage test

It is carried out, in accordance with the provisions of 4.11 of GB/T 28046.2-2011.

5.8 High-temperature storage test

Put the electronic throttle body into the temperature control test box. Carry out the test, […]

5.14 Chemical resistance test

Carry out test according to GB/T 28046.5. During the test, it must block the air passages on both sides. The test conditions are as follows:

- Test medium: Throttle body cleaner, gasoline, coolant, engine oil, alcohol, transmission oil;

- Wetting time: 5 s;

- Storage time: 48 h;

- Test temperature: 85 °C.

5.15 Anti-free fall test

It is carried out, according to the requirements of 4.3 of GB/T 28046.3-2011. The test conditions are as follows:

- Drop height: 1 m;

- Drop contact surface: Cement floor;

- Number of drops: Space axis X axis, Y axis, Z axis, 2 drops in each axis direction, 6 drops in total.

5.16 Vibration resistance test

It is carried out, according to the requirements of 4.1.2.1.2.1 in GB/T 28046.3-2011.

The difference is that the frequency sweep rate in GB/T 28046.3 is 1 oct/min. After the test, test the product performance, according to 5.4 of this standard.

5.17 Durability test

Fix the throttle body, on the durability test bench. Under the working mode 3.2, which is defined in GB/T 28046.1, carry out 10 x 10^6 cycle test of load changes. The test conditions are as follows:

- Drive curve: See Figure 2;

- Temperature curve: See Figure 3;

- Number of cycles: Each cycle shall contain 20 load changes; it shall perform 5 x 10^5 cycles.

6.2.3 Judgment principle

After the sampling inspection of the exit-factory products is completed, all qualified products that have been inspected batch by batch are qualified batches, which can be provided to the user; the batches, which are judged to be unqualified, during the exit-factory inspection, shall be rejected.

6.3 Type inspection

6.3.1 Inspection conditions

In one of the following cases, type inspection is carried out on the electronic throttle body:

- Trial-type identification of new products or ex-situ production of old products;

- After the formal production, such as when the structure, material, process are greatly changed, which may affect the performance of the product;

- For batch or mass-produced products, it is not less than once every 2 years;

- When the production is restored, after suspension for more than 1 year;

- When there is a big difference, between the exit-factory inspection results and the last type inspection results;

- When the national quality supervision agency requests type inspection.

6.3.2 Inspection items

Unless otherwise agreed, the inspection items are in accordance with Table 5.