TOYOTA ENGINEERING STANDARD
NO.:
TSA2650G
TITLE: chassis
CLASS: C1
Established/Revised:
Test method for static load-deflection characteristics of vibration isolating rubber of
Rev. 4 (May 2009 )
This standard has been revised as a result of the modification of terms and explanations in part.
Engineering Data Planning Dept. Prepared and Written by:
Engineering Data Control and Reliability Dept. 2
Management Div. Vehicle Evaluation & Engineering Div. 2
ⒸTOYOTA MOTOR CORPORATION
CONFIDENTIAL DO NOT REPRODUCE
TOYOTA ENGINEERING STANDARD TSA2650G CLASS C1Test method for static load-deflection characteristics of vibration isolating rubber of chassis 1. Scope This standard covers the measuring method for static load-deflection characteristics, and the calculation method for static spring constant, of vibration-isolating rubbers(1) of a vehicle chassis. Note (1): This standard does not apply to vibration-isolating rubbers other than those provided in Section 3. 2. Definitions Major terms used in this standard are defined in Table 1. Table 1 Term Description Also called static spring characteristics. A chart of characteristics curves drawn Static load-deflection with displacement (or angle) along X-axis and load (or torque) along Y-axis is characteristics called static load-deflection characteristics chart or static spring characteristics chart. Static spring constant (Ks)(2) refers to the mean gradient of static load-deflection characteristics curves in a specified range, obtained when deformation is given at Static spring constant the rate specified in this standard. Dynamic spring constant (Kd) is opposed to this term. The state in which a vehicle of the largest weight in a given vehicle family has a constant volume is called constant volume state of the vehicle. Static load Constant volume load received by a particular part of a vehicle in the constant load state is called constant volume load, and is expressed as Wp. This value shall comply with the specified value. Note (2): Static spring constant is, as a rule, expressed by the following symbol. Symbol of static spring constant (Ex.) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 1 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 3. Types of Vibration-Isolating Rubbers and Measuring Direction for Static Spring Characteristics (1) Rubber bush for suspension arm Measuring direction: vertical to axis, axial, torsional, and prising directions (2) Strut bar cushion rubber Measuring direction: axial, and prising directions (3) Strut cushion rubber Measuring direction: axial, vertical to axis, and prising direction (4) Suspension support rubber Measuring direction: axial, vertical to axis, and prising directions (5) Leaf spring eye bush (eye bush) Measuring direction: vertical to axis, axial, and torsional directions (6) Bumper spring Measuring direction: principal loading direction (7) Hollow spring Measuring direction: principal loading direction 4. General Test Conditions 4.1 Standard Laboratory Conditions Laboratory temperature shall be 23 specified in the test record. 2 unless otherwise specified. Test temperature shall be 4.2 Standard Specimen State (1) Specimens shall be sampled at least 16 h after vulcanization, and shall be left for at least 2 h at standard room temperature (20 10) before testing. (2) For a vibration-isolating rubber to be directly press-fitted into an arm, each specimen shall be left for at least 24 h at standard room temperature 2010 after it is press-fitted into an arm using press-fit liquid specified in the design drawing. 4.3 Preliminary Deformation and Recording With vibration-isolating rubber set on a jig, specified load or load for specified displacement shall be applied to the rubber two or more times at a specified rate. Data for the third time of loading in both increasing and decreasing directions shall be recorded by X-Y recorder unless otherwise specified. Data, which is not recorded by X-Y recorder, shall be recorded by the method specified in this standard. The recording scale shall be such that recorded result fits in a graph paper of A4 size. The graph shall be graduated for load and displacement so that data can be read easily. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 2 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 4.4 Determination Method for Static Spring Constant Unless otherwise specified, mean gradient of static load-deflection characteristics curves in increasing and decreasing directions in the specified range as shown in Fig. 1 shall be calculated and used for static spring constant. Fig. 1 4.5 Number of Specimens and Rubber Hardness For each measurement item, at least three specimens (or three sets) shall be tested. After testing, rubber hardness shall be measured with a hardness tester on the surface with no or little distortion. The measured result shall be recorded as data. 4.6 Test Equipment (1) Testing machine shall have such a measuring capacity that the largest test load is within 20 to 100% of the maximum measurable load of the machine. (2) Tolerance of graduation or indication for load of the testing machine shall be within 2% of the indication when the indication is 20 to 100% of the maximum measurable load of the machine. (3) Tolerance for deflection measurement shall be within 2% of the maximum deflection (deflection under the largest test load) of vibration-isolating rubber. (4) The crosshead of the testing machine shall be controllable to move at a constant speed in both ways. (5) Both testing machine and jigs shall be 100 times or more as rigid as specimens. If a specimen provides high static spring constant so that jig rigidity is less than 100 times that of the specimen, the rigidity of the testing machine and jigs shall be measured and specified in the test record. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 3 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 4.7 Recorder Characteristics data shall be recorded with a recorder capable of drawing curves on a chart with load or torque along Y-axis and deflection or angle along X-axis (e.g. X-Y recorder). 4.8 Verification of Test Equipment and Instruments Test equipment (excluding load cell) shall be verified at least once a year with an appropriate proving device (such as a loop load cell). Load cell, displacement meter and recorder shall be verified every 4 to 6 months with specified proving devices. 5. Measurement of Static Load-Deflection Characteristics and Calculation of Static Spring Constant An example of the test method is described below. This test method may be changed for each development vehicle. 5.1 Rubber Bush for Suspension Arm 5.1.1 Definitions Major terms used in this standard are defined as follows: (1) Suspension arm I-shaped arm supported by a cylindrical rubber bush secured to the arm by press-fitting or other appropriate method, as shown in Fig. 2, is called I-arm. I-shaped front lower arm, dual link rear suspension arm, lateral rod etc. are I-arms. Besides I-arm, suspension arms are classified by arm shape into A-arm and L-arm. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 4 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 2 Arm Assembly (Example) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 5 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD (2) Rubber bush Fig. 3 shows typical rubber bushes subject to this test. TSA2650G Fig. 3 Example of Rubber Bush (3) Maximum on-vehicle operating angle Refers to the torsional angle with larger absolute value of rubber bush twisted when tire is fully bound or rebound from the standard vehicle height, and is expressed as θmax. (4) Load per wheel on front/rear tire Refers to a vertical load applied to one front/rear tire in the constant volume state. This load is considered to include sprung and unsprung masses, and is expressed as 1W. (5) Constant volume load on rubber bush and loading direction Constant volume load on rubber bush refers to the static load received by the rubber bush in the constant volume state, and is expressed as Wp. It is necessary to specify the direction of constant volume load (axial or vertical to axis). 5.1.2 Items to Be Specified The test requesting department shall specify the following items to the testing department. (1) Maximum on-vehicle operating angle θmax = () (2) Load per wheel on front/rear tire 1W = (N) (only when required) (3) Constant volume load and loading direction Wp = (N) (only when required) (4) Rubber bush tightening torque T = (Nm) (5) Shape, dimensions and tolerances of outer tube (arm) (6) Measuring load range (7) Spring constant calculation range Preferably the above items should be specified in the design drawings of rubber bush. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 6 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.1.3 Test Items (1) Measurement of vertical-to-axis static load-deflection characteristics (2) Measurement of axial static load-deflection characteristics (3) Measurement of torsional static load-deflection characteristics (4) Measurement of prising static load-deflection characteristics 5.1.4 Test Method and Conditions (1) Measurement of vertical-to-axis static load-deflection characteristics (a) Assembling method Secure bush to jig by press-fitting or other appropriate method as shown in Fig. 4. Fig. 4 Measuring Method for Vertical-to-Axis Static Load-Deflection Characteristics Set an iron plate on each end of bush. The iron plate shall be thicker than the arm-mounting bracket of an actual vehicle. Tighten bolts and nuts to the specified torque. (b) Deformation rate shall be specified separately. (c) Make measurement under the specified load range. (d) Calculate static load-deflection constant for the specified range. (e) For a bush whose static load-deflection characteristics are different according to loading directions, measure static load-deflection characteristics for each direction. Remark: In the case of a bush whose spring reaction force or constant volume load (WP) is specified, calculation range for static spring constant shall be specified separately. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 7 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (2) Measurement of axial static load-deflection characteristics (a) Assembling method Set a specimen as shown in Fig. 5. (b) Supporting the jig, apply load to the bolt head. (c) Deformation rate shall be 2 to 4 mm/min. (d) Make measurement under the specified load range. However, if the outer tube can have metal contact with iron plates, stop increasing the load immediately before they make metal contact with each other. (e) Calculate static spring constant for the specified range. Remark: If rubber bush has a different shape on each end, static load-deflection characteristics must be measured in both directions. In that case, make measurement on the flanged side first. Fig. 5 Measuring Method for Axial Static Load-Deflection Characteristics (3) Measurement of torsional static load-deflection characteristics (a) Assembling method Set a specimen as shown in Fig. 6. (b) Use a torsional tester for measurement. Record data on X-Y recorder chart with angle along X-axis and torque along Y-axis. (c) Torsional angle measurement range shall be specified separately. (d) Torsional angular velocity shall be specified separately. (e) Calculation range for static spring constant shall be specified separately. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 8 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 6 Measuring Method for Torsional Static Load-Deflection Characteristics (4) Measurement of prising static load-deflection characteristics (only when requested) An example of measuring methods and of conditions is shown below: (a) Fig. 7 shows the measuring method. (b) Apply preliminary load for about 4 prising by hand or other appropriate means about 3 times. (c) While applying load to the specimen up to a prising angle of 4, measure loads for prising angles of 1, 2, 3 and 4 from the horizontal. (d) Deformation rate shall take 5 to 10 s to move 1 °. Read load within 5 s after stopping prising. Calculate prising torque from the load value(3) thus read and lever length. Note (3): Use the load value for the horizontal state to make correction for the lever weight. (e) Calculation range for static spring constant shall be specified separately. Remark: If the rubber bush has a different shape on each end, static load-deflection characteristics must be measured in both directions. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 9 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 7 Measuring Method for Prising Static Load-Deflection Characteristics 5.1.5 Static Load-Deflection Data Compilation Compile static load-deflection characteristics data in the following method. (1) Record shape and dimensions of specimen. Specify the shape and dimensions of rubber bush after vulcanization and those of completed rubber bush in drawings. (2) Make static load-deflection characteristics charts. Make vertical-to-axis, axial, torsional and prising(4) static load-deflection characteristics charts. For each of the charts, draw static load-deflection characteristics curves for the first and third times of loading in both increasing and decreasing directions. Figs. 8 through 11 show examples of static load-deflection characteristics charts. Note (4): For prising static load-deflection characteristic chart, draw static load-deflection characteristics curves for the third time of loading in increasing and decreasing directions. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 10 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 8 Vertical-to-Axis Static Load-Deflection Characteristics (Example) Fig. 9 Axial Static Load-Deflection Characteristics (Example) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 11 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 10 Torsional Static Load-Deflection Characteristics (Example) Fig. 11 Prising Static Load-Deflection Characteristics (Example) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 12 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (3) Summarize the specifications and initial static spring constants of specimens as shown in Table 2. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 13 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.2 Strut Bar Cushion Rubber 5.2.1 Definitions Major terms used in this standard are as follows: (1) Strut bar cushion rubber Fig. 12 shows typical strut bar cushion rubbers subject to this test. Fig. 12 Example of Strut Bar Cushion Rubber (2) Maximum on-vehicle operating angle Refers to the angle with larger absolute value between strut bar and bracket of an actual vehicle when the tire is fully bound or rebound from the constant volume state position, and is expressed as θmax. Maximum on-vehicle operating angle under prising load is called maximum on-vehicle prising angle, and that under torsional load called maximum on-vehicle torsional angle. (3) Load per wheel on front/rear tire Refers to a vertical load applied to one front/rear tire in the constant volume state. This load is considered to include sprung and unsprung masses, and is expressed as 1W. (4) Constant volume load on strut bar cushion rubber and loading direction Same as in Section 5.1.1 (5) 5.2.2 Items to Be Specified The test requesting department shall specify the following items to the testing department. (1) Load per wheel on front/rear tire in the constant volume state 1W = (N) (2) Maximum on-vehicle prising angle θmax = () (3) Nut tightening torque T = (Nm) (4) Shape and dimensions of bracket (for necessary parts only) (5) Constant volume load (Wp) and loading direction (only when required) Wp = (N) (6) Measuring load range (7) Static spring constant calculation range Preferably the above items should be specified in the design drawings of strut bar cushion rubber. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 14 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.2.3 Test Items (1) Measurement of axial static load-deflection characteristics I (2) Measurement of axial static load-deflection characteristics II (3) Measurement of prising static load-deflection characteristics 5.2.4 Test Method and Conditions (1) Measurement of axial static load-deflection characteristics I (a) Assembling method (i) Use bracket manufactured by cutting rigid iron sheet to the same dimensions as that of an actual vehicle. (ii) Use collar and retainer taken from an actual vehicle if possible. If they are not available, they may be manufactured by machining. (iii) Degrease bracket, collar and retainer. (iv) Tighten nuts to the specified torque. (b) Deformation rate shall be specified separately. (c) Make measurement under the specified load range. (d) Calculate static spring constant for the specified range. (For stopper type or other types of strut bar cushion rubber with completely nonlinear characteristics, determine the static spring constant calculation range upon consultation among the parties concerned.) (2) Measurement of axial static load-deflection characteristics II (a) Assembling method is the same as for (1) in Section 5.2.4. (b) Deformation rate shall be specified separately. (c) Make measurement under the specified load range. (d) Record measured data for all of the first through third times of loading by an X-Y recorder, and read permanent set value S (mm) before third time loading, from the recorded data. Make static load-deflection characteristics chart, on the basis of the data recorded for the third time loading by the X-Y recorder. (e) It is not necessary to calculate static spring constant. (3) Measurement of prising static load-deflection characteristics (a) Assembling method is the same as for (1) in Section 5.2.4. (b) Fig. 13 illustrates the measuring method. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 15 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 13 (i) Mount a strut bar taken from an actual vehicle, or a highly rigid, light lever. The lever length ℓ shall be almost the same as that of the strut bar of an actual vehicle. (ii) Prior to measurement, apply load for a prising angle of θmax or more in all directions. When θmax is not larger than 3, apply load for a prising angle of 3. (iii) Pull up the end of strut bar (lever), using a spring balancer etc. (iv) Measure the angle of inclination θ from the horizontal, the initial state of the bar (lever), using an inclinometer (goniometer). Displacement meter may be used to measure the angle θ. The inclinometer (goniometer) must be set as close to the strut bar cushion rubber as possible. (v) Torsional angle measurement range shall be specified separately. (vi) Deformation rate shall be specified separately. (c) Static load-deflection characteristic chart making Make static load-deflection characteristics chart with angle along X-axis and torque along Y-axis. (d) Calculation range for static spring constant shall be specified separately. 5.2.5 Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to Section 5.1.5. 5.3 Strut Cushion Rubber 5.3.1 Definitions Major terms used in this standard are as follows: (1) Strut cushion rubber Fig. 14 shows a typical strut cushion rubber subject to this test. The static load-deflection characteristics of outer/inner tube adhesion type or press-fit type strut cushion rubber shall be measured according to Section 5.1. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 16 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 14 Example of Strut Cushion Rubber (2) Maximum on-vehicle operating angle Refers to the angle with larger absolute value between piston rod and bracket of an actual vehicle when the tire is fully bound or rebound from the constant volume state position, and is expressed as θmax. Maximum on-vehicle operating angle under prising load is called maximum on-vehicle prising angle, and that under torsional load called maximum on-vehicle torsional angle. (3) Constant volume load on strut cushion rubber and loading direction Same as in Section 5.1.1 (5) 5.3.2 Items to Be Specified The test requesting department shall specify the following items to the testing department. (1) Maximum on-vehicle prising (torsional) angle θmax = () (2) Distance between upper and lower strut cushion rubber under the standard vehicle height condition (mm) ℓ = (3) Bolt/nut tightening torque T = (Nm) (4) Shape and dimensions of bracket (for only necessary parts) (5) Constant volume load (Wp) and loading direction (only when required) Wp = (N) (6) Measuring load range and static spring constant calculation range Preferably the above items should be specified in the design drawings of strut cushion rubber. 5.3.3 Test Items (1) Measurement of static load-deflection characteristics in axial direction of piston rod (2) Measurement of torsional static load-deflection characteristics NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 17 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.3.4 Test Method and Conditions (1) Measurement of static load-deflection characteristics in axial direction of piston rod (a) Assembling method (i) Manufacture jigs with the same dimensions and same lightening allowances as those of an actual vehicle, and mount them on the testing machine. (ii) Use retainer, bush-mounting eye etc. taken from an actual vehicle if possible. (iii) Degrease all parts. (iv) Tighten bolts and nuts to the specified torque. (b) Deformation rate shall be specified separately. (c) Make measurement under the specified measuring load P. (d) Calculate static spring constant for the specified range. An example is shown in Fig. 15. Fig. 15 Remarks: 1. When it is anticipated that absorber bush has different static load-deflection characteristics on pulling side and compression side, make measurement in both directions. 2. For absorber bush with completely nonlinear characteristics (like stopper or slit type bush), it may be necessary to calculate static spring constant separately for lower load range and higher load range. In that case, if turning point is in the specified static spring constant calculation range in the static load-deflection characteristics chart in the design drawing, set spring constant calculation range separately, based on careful study of the static load-deflection characteristic chart and consultation among the parties concerned. The static spring constant calculation range must also be set separately for specimen with constant volume load Wp. (2) Measurement of prising (torsional) static load-deflection characteristics (a) Assembling method Same as in Section 5.3.4 (1)(a) (b) Measuring method (i) Attach a highly rigid, light lever as absorber substitute, as shown in Fig. 16. The lever length ℓ shall be almost equal to the distance between the upper and lower bushes of an absorber under the standard vehicle height condition. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 18 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 16 (ii) To prepare for measurement, move the end of the lever manually up and down several times for the maximum operating angle (θmax) or larger range, to set the rubber in place. Then pull up the lever end, using a spring balancer. (iii) Measure the angle of inclination θ from the horizontal, the initial state of the lever, using an inclinometer (goniometer). The inclinometer (goniometer) must be set as close to the bush as possible. (iv) Measuring angle range shall be from 0 to the maximum on-vehicle operating angle θmax. Dividing this range into equal five portions, stop prising (twisting) at the end of each of the five divisions of the range, and read load F and angle θ under that load. Read these values within 5 s after stopping prising (twisting). Make measurement in both angle increasing and decreasing directions. (v) Deformation rate shall be such that deformation takes about 5 to 10 s for each division of the measuring angle range. Measure deformation rate only for the first time of loading. (c) Static load-deflection characteristics chart making Make static load-deflection characteristics chart with angle along X-axis and torque along Y-axis. Calculate torque using equation (1). T = F ℓ cosθ------ (1) where, T: torque (Nm) F: load (N) ℓ: length of lever (mm) θ: inclination of lever () Calculation range for static spring constant shall be specified separately. Remark: Measurement method for torsional static load-deflection characteristics shall conform to Section 5.1.4 (3). NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 19 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.3.5 Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to Section 5.1.5. 5.4 Suspension Support Rubber 5.4.1 Definitions Major terms used in this standard are defined as follows: (1) Names of suspension support rubber components Suspension support rubber (hereinafter referred to as \"support rubber\") comprises a rubber member adhered to or press-fit into outer and inner tubes, as shown in Fig. 17. The name of each support rubber component used in this standard conforms to Fig. 17. Fig. 17 Example of Suspension Support Rubber (2) Maximum on-vehicle operating angle Refers to the prising angle with larger absolute value of support rubber when tire is fully bound or rebound from the standard vehicle height, and is expressed as θmax. (3) Load per wheel on front/rear tire Refers to a vertical load applied to one front/rear tire in the constant volume state. This load is considered to include sprung and unsprung masses, and is expressed as 1W. (4) Constant volume load on support rubber and loading direction Constant volume load on support rubber refers to the static load received by the support rubber in the constant volume state, and is expressed as Wp. It is necessary to specify the direction of constant volume load (axial or vertical to axis). NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 20 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.4.2 Items to Be Specified (1) Constant volume load on support rubber in the constant volume state and loading direction Wp = (N) (2) Load per wheel on front/rear tire 1W = (N) (3) Configuration of support rubber mounting surface Inside diameter = mm R = mm (4) Bolt/nut tightening torque T = (Nm) (5) Maximum on-vehicle operating (prising) angle θmax = () (6) Measuring load range (7) Static spring constant calculation range Preferably the above items should be specified in the design drawings of support rubber. 5.4.3 Test Items (1) Measurement of axial static load-deflection characteristics I (for suspension support rubber receiving load per wheel) (2) Measurement of axial static load-deflection characteristics II (for suspension support rubber not receiving load per wheel) (3) Measurement of vertical-to-axis (transverse) static load-deflection characteristics (4) Measurement of prising static load-deflection characteristics 5.4.4 Test Method and Conditions (1) Measurement of axial static load-deflection characteristics I (a) Assembling method (i) For a jig corresponding to vehicle body, to be used to set support rubber for measurement of the static load-deflection characteristics, select highly rigid one (the jig need not have the same thickness but shall have the same inside diameter and radius as the support rubber mounting portion of a vehicle). Tighten bolts and nuts to the specified torque. (ii) For support rubber equipped with a separate stopper, mount a stopper as well. (b) Deformation rate shall be specified separately. (c) Make measurement under the specified measuring load range. (d) Calculate static spring constant for the specified range. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 21 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 18 Static Load-Deflection Characteristics Chart (Example) (2) Measurement of axial static load-deflection characteristics II (a) Assembling method Same as for measurement of axial static load-deflection characteristics I (b) Deformation rate shall be specified separately. (c) Make measurement under the specified measuring load range. (d) Calculate static spring constant for the specified range. An example is shown in Fig. 19. Fig. 19 NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 22 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (3) Measurement of vertical-to-axis (transverse) static load-deflection characteristics Fig. 20 shows the measuring method. (a) Secure a specimen to the fixing jig, and adjust the dimension H to the value given below using vertical load adjusting nuts. Dimension H: amount of deflection under a vertical load applied to the support rubber of a vehicle in the standard state (b) Make measurement under the specified measuring load range. (If the range is not specified, kN.) make measurement under a load of 0 1.96 Fig. 20 Measuring Method (c) Data compilation (i) Make a static load-deflection characteristics chart. (ii) Calculate static spring constant for the specified range. (4) Measurement of prising static load-deflection characteristics (only when requested) Same as in Section 5.2.4 (3) 5.4.5 Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to Section 5.1.5. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 23 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.5 Leaf Spring Eye Bush (Hereinafter Referred to as \"Eye Bush\") 5.5.1 Definitions Major terms used in this Section are as follows: (1) Constant volume load on eye bush Refers to a vertical load applied to the eye bush in the constant volume state, and is expressed as Wp. (2) Eye bush with outer and inner tubes Refers to an eye bush comprising a rubber member adhered by vulcanization to outer and inner tubes as shown in Fig. 21. Fig. 21 Eye Bush with Outer and Inner Tubes (3) Split-type eye bush Refers to an eye bush comprising two eye bushes mounted in a set on a leaf spring eye as shown in Fig. 22. Fig. 22 Split-Type Eye Bush NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 24 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (4) Stopper-type eye bush Refers to an eye bush comprising two eye bushes and one stopper bush mounted in a set on a leaf spring eye as shown in Fig. 23. Fig. 23 Stopper-Type Eye Bush (5) Maximum on-vehicle operating angle Refers to the torsional angle with larger absolute value of eye bush twisted when tire of an actual vehicle is fully bound or rebound from the standard vehicle height, and is expressed as θmax. 5.5.2 Items to Be Specified The test requesting department shall specify the following items to the testing department. (1) Nut tightening torque T = (Nm) (2) Constant volume load on eye bush, and loading direction Wp = (N) (3) Shape and dimensions of leaf eye (4) Shape and dimensions of body side bracket to be in contact with eye bush (5) Maximum on-vehicle operating angle θmax = () Preferably the above items should be specified in the design drawings of eye bush. 5.5.3 Test Items (1) Measurement of vertical-to-axis static load-deflection characteristics I (2) Measurement of vertical-to-axis static load-deflection characteristics II (3) Measurement of axial static load-deflection characteristics (4) Measurement of torsional static load-deflection characteristics NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 25 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.5.4 Test Method and Conditions (1) Measurement of vertical-to-axis static load-deflection characteristics I (a) Assembling method (i) Mount an eye bush on the leaf spring eye or a corresponding jig, and tighten the nut to the specified torque, using a hanger pin from an actual vehicle, or a corresponding jig. (ii) Prior to assembling, remove grease and rubber chips from the eye, brackets, hanger pin etc. using solvent, sandpaper, and the like. (b) Deformation rate shall be specified separately. (c) Measuring load range shall be specified separately. (d) Calculation range for static spring constant shall be specified separately. (e) For stopper-type bush and the like bushes, for which it is necessary to determine static spring constant for lower load range, turning points etc., set static spring constant calculation range, based on study of the static load-deflection characteristics chart in the design drawing and consultation among the parties concerned. (2) Measurement of vertical-to-axis static load-deflection characteristics II (only when requested) (a) Assembling method (i) Insert an eye bush into the jig corresponding to the leaf spring eye as shown in Fig. 24, and tighten the nut to the specified torque using a hanger pin from an actual vehicle. Fig. 24 (ii) Prior to assembling, remove grease and rubber chips from the eye, brackets, hanger pin etc. using solvent, sandpaper, and the like. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 26 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (b) Measuring method (i) Use a testing machine capable of applying both positive and negative loads (e.g. electro-hydraulic vibrator). (ii) Deformation rate shall be specified separately. (iii) Measuring load range shall be specified separately. Fig. 25 shows a typical static load-deflection characteristics chart. Fig. 25 Static load-Deflection Characteristics of Eye Bush (c) Calculation of static spring constant (i) Calculation of static spring constant K1 for low load range Focusing attention only on static load-deflection characteristics curves for the load range between -1Wp and +1Wp, connect the peak point E (F) and the median I (J) of the hysteresis AB (CD) at 0.25Wp, and calculate the mean gradient K1 of the lines thus obtained. The value K1 is also called static spring constant before turning. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 27 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (ii) Calculation of static spring constant K2 for high load range Connect the peak point K (M) of the curves for the load range between -3Wp and +3Wp and the peak point L (N) of the curves for the load range between -4Wp and +4Wp, and calculate the mean gradient K2 of the lines thus obtained. The value K2 is also called static spring constant after turning. (iii) Calculation of turning width δ Extend the lines used for calculating the values K1 and K2 to make them intersect with each other, and read deflection value at each intersection. The mean of positive and negative deflections is a turning width δ. This turning of static load-deflection characteristics curves generally occurs for stopper-type eye bushes. (3) Measurement of axial static load-deflection characteristics (a) Assembling method Same as in Section 5.5.4 (1)(a) (b) Supporting the jig corresponding to leaf spring eye, apply load on the hanger pin head. (c) Deformation rate shall be specified separately. (d) Measuring load range shall be specified separately. (e) Calculation range for static spring constant shall be specified separately. (4) Measurement of torsional static load-deflection characteristics (a) Assembling method Same as in Section 5.5.4 (1)(a) (b) Apply torsion to either the jig corresponding to leaf spring eye or the hanger pin. (c) Use a torsional tester for measurement. Record data on X-Y recorder chart with angle along X-axis and torque along Y-axis. (d) Torsional angle measurement range shall be specified separately. (e) Torsional angular velocity shall be specified separately. (f) Calculation range for static spring constant shall be specified separately. (Fig. 26.) Remark: If there is an evidence of slippage between bush and eye or pin, make a note of this the test record. Fig. 26 Torsional Static Load-Deflection Characteristics (Example) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 28 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.5.5 Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to Section 5.1.5. 5.6 Bumper Spring 5.6.1 Definitions Major terms used in this Section are defined as follows: (1) Free height of bumper spring: h For bumper spring with rubber member secured by bonding or other method to an iron plate, free height of bumper spring refers to the height \"h\" of the rubber portion with free surface (Fig. 27). Fig. 27 Free Height of Bumper Spring: h (2) Specified load: W Refers to a load applied to bumper spring, taking into consideration of load per wheel on spring operating with a vertical acceleration of 24.5 m/s2 in the constant volume state. Specified load (W) is determined by engineering designers. 5.6.2 Items to Be Specified The test requesting department shall specify the following items to the testing department. (1) Measuring method: Method = A or B (2) Specified load: W = (N) (3) Shape and dimensions of the surface to be in contact with bumper spring (Specify these items in drawing.) (4) Dimensions of each part (For only the measuring method B. The symbols are in accordance with Fig. 32.) ℓ1 = mm, ℓ2 = mm θ1 = , θ2 = Bumper spring mounting position = (e.g. arm side) Preferably the above items should be specified in the design drawings of bumper spring. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 29 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.6.3 Measuring Method A for Static Load-Deflection Characteristics (1) Objective The objective of this measurement is to determine relation between load and deflection of independent bumper spring in the static state and check that the relation meets the required characteristics. The measuring method A is applicable to bumper spring(5) in which load on bumper spring is almost directly applied to tire. Note (5): Bumper spring in Macpherson type absorber of front suspension, and bumper spring of rigid axle in rear suspension (2) Jigs For the portion with which bumper spring is to be in contact, use a jig manufactured to the same shape and dimensions as that of an actual vehicle, or use a part from an actual vehicle. (3) Measuring Conditions (a) The bumper spring surface and the surfaces with which bumper spring is to be in contact shall be degreased (with solvent). (b) Deformation rate shall be specified separately. (c) Measurement shall be made under the load range between 0 and specified load W. Fig. 28 Measuring Method A for Static Load-Deflection Characteristics NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 30 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G (4) Measuring Method (Procedure) (a) Measure the surface rubber hardness of a bumper spring at several points, and calculate mean hardness. (b) Mount the bumper spring and a jig on a testing machine (e.g. Amslar universal tester). (c) Move the crosshead of the testing machine, and stop it immediately (1 to 2 mm) before the bumper spring comes in contact with the opposite surface. (d) Adjust the balance between load cell and displacement meter, and position the X-Y recorder pen approximately at origin. (e) Apply load to the bumper spring at the specified deformation rate (crosshead speed) while recording data with the X-Y recorder. (f) When load on the bumper spring reaches the specified load, decrease load at the same rate as for increasing the load (deformation rate). Making sure that the load becomes zero, repeat the steps (e) and (f). Before repeating these steps, check that the bumper spring is free from abnormal deformation, such as buckling. If there is any abnormal deformation, specify the position in the test record. (g) Repeat steps (e) and (f) three times in total, as shown in Fig. 29. Fig. 29 Static Spring Characteristics Curves by X-Y Recorder (Example) (5) Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to the following methods. (a) Read permanent set value S (mm) before loading for the third time, from the static load-deflection characteristics curves (example shown in Fig. 29) recorded by the X-Y recorder. (b) Make a static load-deflection characteristics chart for the third time of loading, with reference to the curves recorded by the X-Y recorder. Fig. 30 shows an example of static load-deflection characteristics chart. Specify the measuring method used (method A) in the chart as shown in Fig. 30. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 31 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 30 Static Load-Deflection Characteristics of Bumper Spring (Measuring Method A) NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 32 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G 5.6.4 Measuring Method B for Static Load-Deflection Characteristics (1) Objective This measuring method is applied to bumper spring to be positioned in the center of arm as shown in Fig. 31. The objective is to measure the static load-deflection characteristics of bumper spring in a ball joint (or spindle) position, rather than determining the true static load-deflection characteristics of bumper spring. Fig. 31 Example of Bumper Spring to Be Measured by Method B (2) Jigs (a) For the portion with which bumper spring is to be in contact, use a jig manufactured to the same shape and dimensions as that of an actual vehicle, or use a part from an actual vehicle. (b) Use an arm from an actual vehicle, or manufacture a corresponding jig. Measurement is easier with a jig. However, note the following points in making a choice. (i) When an arm from an actual vehicle is used If rubber bush is provided at the pivot of arm as shown in Fig. 31, replace it with a bearing or screw bush; deflection of rubber bush will significantly affect the measurement. (ii) When a jig is manufactured for an arm Install a bearing at the pivot. Manufacture the arm-corresponding portion to such shape and dimensions that it does not have severe elastic deformation. (Design the jig so that it has higher flexural rigidity than the arm of an actual vehicle.) Also install a bearing at the portion corresponding to the ball joint of an actual vehicle. Design the jig so that the outer ring of the bearing projects above the upper surface of the arm-corresponding portion as shown in Fig. 32, preventing lateral movement of the arm-corresponding portion in pivotal motion. Design the jig so that bumper spring can be installed on the arm-corresponding portion at the same angle (θ1) as that in an actual vehicle. (c) Manufacture a rigid base on which to secure the arm and jig to be in contact with bumper spring at specified positions and angles. Set test assembly on this base, and mount them on a universal tester (Fig. 32). NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 33 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 32 Measuring Method B for Static Load-Deflection Characteristics (3) Measuring Conditions Same as in Section 5.6.3 (3) (4) Measuring Method The measuring method is basically the same as that specified in Section 5.6.3 (4). Observe the following points. (a) Measure load and deflection at the ball joint (or spindle) position of the arm. (b) Make sure that the crosshead does not interfere with the arm (jig) under a large deflection load. (5) Static Load-Deflection Data Compilation Compile static load-deflection characteristics data according to Section 5.6.3 (5). When making a chart shown in Fig. 30, specify the measuring method used (method B) in the chart. It is recommended to enter the dimensions of various parts (ℓ1, ℓ2, θ1, and θ2 of Fig. 32) in the chart. 5.7 Hollow Spring 5.7.1 Measurement of Spring Characteristics in Principal Loading Direction (1) Assembling method (a) Secure a hollow spring to an installation plate with sufficiently high rigidity, as shown in Fig. 33, and tighten the nut to the specified torque. NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 34 / 35
CONFIDENTIAL DO NOT REPRODUCE TOYOTA ENGINEERING STANDARD TSA2650G Fig. 33 (b) Place #80 sand paper on the support plate to secure constant friction with the hollow spring. (c) The installation and support plates shall be three or more times larger in size than the outside diameter of the hollow spring in free state. Degrease these plates in advance. (2) Deformation rate shall be specified separately. (3) Measuring load range shall be specified separately. (4) For the hollow spring, it is important to make a static load-deflection characteristic chart; it is not necessary to calculate static spring constant. If values equivalent to the static spring constant are necessary, indicate load values for deflection of 10, 20, 30, 40, 50 and 60% of the initial free height H of the hollow spring. (5) To consider possible interference of other parts with a hollow spring in an actual vehicle, measure the maximum outside diameter of the hollow spring using outside calipers. (6) Draw static load-deflection characteristics curves and outside dimension curve in a chart as shown in Fig. 34. Enter permanent set value S (mm) in the chart as for bumper spring. (Determine permanent set value S (mm) according to Section 5.6.3 (5).) Fig. 34 NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard. - The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they are no longer necessary due to the termination of the work concerned or the revision of current version of this standard, - This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation.. Rev. 4 May 2009 35 / 35
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