JB/T 5135.2-2001 Reliability and durability of general-purpose small gasoline engines
Some standard content:
ICS27.020
Machinery Industry Standard of the People's Republic of China
JB/T5135.2-2001
General utility small gasoline engineTest and evaluate method of reliability and durability durability2001-06-22Release
China Machinery Industry Federation
2001-10-01Implementation
JB/T5135.2-2001
This standard is a revision of JB/T5135.2-1999 "General Small Gasoline Engine Durability Test Method" and "Small Gasoline Engine Bench Reliability Test Assessment and Evaluation Method (Provisional Draft). In addition to the editorial changes made to the original standards, the main revisions and additions are: Adjustment of reliability and durability test conditions: Adjustment of reliability and durability test time; - Further clarification of fault classification and fault mode; Proposed new evaluation indicators and calculation methods: - Proposed a new comprehensive evaluation method.
Appendix A of this standard is the appendix of the standard.
This standard replaces JB/T5135.2-1999 from the date of implementation. This standard is proposed and managed by Tianjin Internal Combustion Engine Research Institute. The responsible drafting unit of this standard: Tianjin Internal Combustion Engine Research Institute. The main drafters of this standard: Wang Haiming, Guo Ping, Liu Yuange, Gong Yuying, and Wang Weisheng. This standard was first issued as ZBJ90003-87 in June 1987, and the standard number was adjusted to JB/T5135.2-1999 in 1998. This is the first revision.
1 Scope
Mechanical Industry Standard of the People's Republic of China
General small gasoline engine
Reliability, durability test and evaluation methodGeneral utilitysmall gasoline engineTest and evaluate method of reliability and durabilityJB/T $I35.2—2001
Replaces JB/T5135.21999
This standard specifies the reliability, durability test and evaluation methods of reciprocating piston general-purpose small gasoline engines (referred to as general-purpose small gasoline engines, generally referring to general-purpose gasoline engines not exceeding 30kW). This standard is applicable to the assessment of reliability and durability of general-purpose small gasoline engines. This standard is not applicable to gasoline engines for special purposes such as motorcycle gasoline engines and outdoor engines. 2 Cited standards
The provisions contained in the following standards constitute the provisions of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards are subject to revision, and parties using this standard should explore the possibility of using the latest versions of the following standards. GB/T 11051987
Internal combustion engine bench performance test method
General purpose small gasoline engine bench performance test method JB/T5135.1—2001
General purpose small gasoline engine technical conditions
JB/T5135.3—2001
3 Test sample and sampling regulations
3.1 Test sample
General purpose small gasoline engine for product finalization inspection or finished general purpose small gasoline engine produced within this evaluation period and accepted by the enterprise quality inspection department.
3.2 Sampling method
Random sampling.
3.3 Sampling cycle and sampling number
For regular inspection by enterprises, the sampling cycle and sampling number shall be determined by the enterprises according to the output of general purpose small gasoline engines and the actual situation of the enterprises. For inspections organized by the superior competent department, industry or quality supervision department, the sampling number shall be determined by the organizing unit. 3.4 Sampling location and sampling base
3.4.1 When sampling in the finished product warehouse of the manufacturer, the sampling base should be no less than 30 units; when sampling at the production assembly site or user unit, the sampling base is not limited.
3.4.2 When sampling by cross-cutting, the sampling location and sampling base are not limited. 3.5 The number of general small gasoline engine reliability and durability test samples is generally 2 units. 3.6 Reliability and durability tests can be conducted by separate sampling, or by using samples that have completed the main performance test during the same period. Approved by China Machinery Industry Federation on June 22, 2001, implemented on October 1, 2001
4 Test conditions
JB/T5135.2—2001
4.1 The environmental conditions, equipment accuracy and installation of the test sample during the test shall comply with the provisions of relevant standards such as JB/T5135.3 and JB/T5135.1.
4.2 The correction of standard atmospheric conditions, power and torque shall comply with the provisions of GB 1105. 4.3 The fuel and lubricating oil used in the test shall comply with the requirements of the instruction manual of the product being tested. 4.4 The cooling water temperature, lubricating oil pressure and temperature of general small gasoline engines shall comply with the regulations of the manufacturer. 5 Reliability and durability test steps, methods and inspection contents 5.1 Inspection of test prototypes
5.1.1 Before the prototype is tested, it is allowed to inspect the prototype and make one-time adjustments to each adjustment part in accordance with the instructions for use of the product being tested and the relevant technical documents.
5.1.2 Inspection and adding lubricating oil.
5.2 Running-in
5.2.1 Before the prototype is formally tested, it is allowed to carry out necessary running-in. The running-in specifications shall be in accordance with the technical documents of the manufacturer. If the manufacturer has no running-in specifications, refer to the relevant contents in JB/T5135.1. 5.2.2 The running-in time shall not exceed 10 hours.
5.2.3 After the running-in of the general-purpose small gasoline engine, it is allowed to carry out the following maintenance on the general-purpose small gasoline engine: a) Routine maintenance in accordance with the product instructions and relevant technical documents. b) Replace the lubricating oil.
c) Remove carbon deposits from the spark plug, combustion chamber, etc. d) Clean the filter elements of the air filter, fuel filter and lubricating oil filter. 5.3 Main performance test
When sampling separately for reliability and durability test assessment, the main performance test should be carried out in accordance with the requirements of JB/T5135.1 and JB/T5135.3 before the test. The reliability and durability test can be carried out only after the requirements are met. For the prototypes that have completed the running-in and main performance tests during the same period of inspection, the main performance test can be repeated when the reliability and durability tests are carried out, as long as the test results meet the requirements. 5.4 Reliability and durability test conditions
5.4.1 The reliability test is carried out continuously on the test bench according to the conditions specified in Table 1. Including running-in, the cumulative operating time is 120h (single prototype). For prototypes with a running-in of less than 10h, the insufficient time is not included in the reliability test. The calibrated power inspection time before the reliability test is included in the reliability test time.
The durability test is carried out continuously on the test bench according to the working conditions specified in Table 1. Including running-in, the cumulative operating time is 200 hours (single prototype). For prototypes with running-in of less than 10 hours, the insufficient time is incorporated into the durability test. The time for checking the rated power before the durability test is counted as the durability test time. The durability test can be carried out on a single prototype or on a prototype that has completed the reliability test (the reliability test time is included). 2
When the rated power is micro-high power
When the rated power is 15min power
When the rated power is 1h power
When the rated power is 12h power
When the rated power is continuous power
JB/T 5135.2—2001
Table 1 Reliability and durability test cycle speed
(Percentage of rated speed)
(Percentage of rated power)
5.4.2 For general-purpose small gasoline engines with more than two power ratings, the test conditions shall be carried out according to the power used by the main supporting equipment. Once selected, it shall not be changed during the test.
5.5 Maintenance and care
5.5.1 The reliability and durability test is one cycle every 10 hours. During the test, it is allowed to stop once for routine maintenance every 10 hours of operation. Maintenance content is in accordance with the product manual or relevant technical documents, and it is allowed to add lubricating oil and tighten external fasteners: 5.5.2 During the test, it is allowed to stop for maintenance every 20 hours of operation. In addition to completing the maintenance content specified in 5.5.1, it is allowed to remove carbon deposits in the combustion chamber, piston, piston ring, exhaust port and muffler; it is allowed to adjust the relevant gaps; it is allowed to clean the filter elements of the air filter, fuel filter and lubricating oil filter; it is allowed to replace the spark plug. 5.6 Measurement and Recording
During the test, it should be in accordance with JB/T5135.1. Measure and record relevant parameters as required by 1. During the test, various situations that occur and are found during the operation and shutdown maintenance of the general-purpose small gasoline engine should be recorded in detail: the number of shutdown failures, failure phenomena and causes, parts damage, names and quantities of replaced parts, etc. During the test, the speed, torque, fuel consumption and spark plug gasket temperature and other parameters should be measured at least once every 1 hour, and the atmospheric pressure, ambient temperature and relative humidity should be recorded once in each cycle. 5.7 Main performance retest
After the reliability and durability tests are completed and maintained, the calibrated speed load characteristic test or external characteristic test should be carried out to measure the calibrated power and fuel consumption rate. This value should be compared with the calibrated value of the manufacturer, and the fault should be determined according to the fault mode and included in the final assessment. 6 Principles of description of fault mode
6.1 In the reliability and durability tests of general-purpose small gasoline engines, in principle, the faults of general-purpose small gasoline engines are described by the failure mode of components.
6.2 When it is difficult to describe with the failure mode of components, or it is impossible to confirm that a certain component has failed, the failure mode of the whole machine can be used to describe it.
7 Fault classification and record
7.1 According to the degree of harm caused by the fault and the difficulty of eliminating the fault, the fault is divided into four categories. The classification principles are shown in Table 2. 2
Fault category
Fatal fault
Serious fault
General fault
Minor fault
JB/T5135.2—2001
Table 2 Fault classification principles
Classification principles
Endangering operation safety, causing the main components to be scrapped, or causing serious harm to the surrounding environment affecting normal operation, the main components are damaged or the performance is significantly reduced, and the main components need to be replaced to repair the shutdown or performance reduction, which can be repaired in a short time (30 minutes) by using the random tools and replacing non-major parts. No replacement of seasonal parts is required, and it can be repaired in a short time (30 minutes) with the random tools. Note: Major parts refer to the parts that have a direct and obvious impact on the main performance of the product, such as races, piston rings, etc. 7.2 During the reliability, durability test and performance retest, the obvious decline of the main performance of general small gasoline engines shall be converted into failures and included in the failure statistics, and participate in the calculation of reliability and durability scores. 7.3 During the reliability and durability test, the failures that occur shall be classified according to Appendix A (Appendix to the standard). Failures not included in the failure mode classification table can be determined by referring to the same type of failure mode in Appendix A. If there is no failure mode of the same type, they can be classified according to the principles specified in Table 2. After the test, all failure classifications are included in the statistical score calculation. 7.4 If a certain failure causes a related failure, the category is divided according to the most serious one in the series of related failures. 7.5 If a certain failure causes three or more serious failures at the same time, it is judged as a fatal failure. 7.6 For serious faults and general faults that occur during regular maintenance, the fault category should be reduced by one level when recording the fault category, that is, recorded as general faults and minor faults respectively
7.7 If a fatal fault occurs during the test or the entire test process cannot be completed, the comprehensive evaluation score (2 value) of the reliability and durability of the prototype will be zero. 8 Evaluation indicators and calculation methods
The calculation and evaluation of the evaluation indicators are based on the test conditions of two prototypes. 8.1 Average first failure time T,
Where: \
Number of sub-samples;
n—Number of sub-samples with failures;
1,—First failure time of the i-th sub-sample, h;—Test deadline, h.
8.2 Average failure interval time T
Where: r-
Total number of failures of the tested prototypes. When r=0, count as r=1. 8.3 Equivalent failure rate D
Wherein: the number of type I failures occurring in the inspected sample; s—the equivalent failure rate of type I failure;
Fatal failure e,=100;
General failure 6,\4;
Serious failure 6;*20;
Minor failure 6,-1
Comprehensive evaluation score 9
9 Comprehensive evaluation of reliability and durability tests
JB/T5135.22001
g=100g-0.0
After the reliability and durability tests, the following three conditions are met at the same time to be evaluated as qualified: a) average time to first failure T,≥50b; b) average time between failures T,≥35 h; c) comprehensive evaluation score 0≥60.
10For fixed small gasoline engines, as long as the user permits, they can be tested and evaluated together with the matching equipment according to the reliability and durability requirements of the matching equipment.
Parts Name
Cylinder Seat
Cylinder Gasket
Cylinder Bolt
Cylinder Head Bolt Hole
Cylinder Head Bolt
Cylinder Head Spark
Spike Plug Scale
Failure Mode
JB/T5135.2-2001
Appendix AbZxz.net
(Standard Appendix)||t t||Classification table of fault modes of general small gasoline engines
1. General small gasoline engine complete machine
Obvious abnormal noise
Cannot start
Difficulty in starting
Power reduction
Power reduction
Fuel consumption
Increase
Fuel consumption
Rate 1 liter||tt| |Fuel consumption
Speed is not good
Unsteady speed
Speed is out of control and the engine is running away, causing the gasoline engine to be scrapped. There is obvious cylinder noise and it cannot work normally
Caused by improper assembly or adjustment, it can work normally after adjustment
Caused by oil circuit, circuit or mechanical reasons, it is necessary to replace the main parts before repairing. It cannot start within 30 days, which can be eliminated in a short time. The reason for stopping and not working normally
The power value after reliability test does not reach 95% of the calibration value. The power value after durability test does not reach 90% of the calibration value. The power value after durability test does not reach 95% of the calibration value. The fuel consumption rate after reliability test exceeds 105% of the calibration value. The fuel consumption rate after durability test exceeds 110% of the calibration value. The fuel consumption rate after durability test exceeds 105% of the calibration value. It still cannot reach the standard after adjustment
After adjustment, it can meet the standard
Cannot be repaired with the supplied spare parts
Repairable with the supplied spare parts
Repairable without replacing parts
Air cover and cylinder block
Serious air stagnation
The method of tightening nuts or replacing gaskets cannot eliminate the obvious decrease in power and needs to be replaced
Air leakage on the joint surface can be removed by dripping
Bolt hole damage||tt| |Bolt damage
Need to replace cylinder head
Fault category
Part name
Cylinder liner
Cylinder head
Cylinder liner
Cylinder liner
Exhaust pipe fixing
Fixing screw hole
Crankcase
Crankcase
Crankshaft gasket
Crankcase cover
Crankcase Cover
Timing gear
Crankcase
Crankcase
Crankcase
Crankcase
Crankcase
Crankcase
Crankcase
Crankcase
Piston pin
Failure mode
Falling
Severely strained
Cracks
Combined but not
Flat or damaged
Bearing shell
Flow bolt or screw hole
Crankcase
Connecting screw hole
Fuel filler cap
Breathing device
Oil pan
Oil pan gasket
Sensitive oil plug
Non-important butterfly bolt
(nail), nut
Need to be replaced
JB/T 5135.2—2001
Table (continued)
Severe cracks need to be replaced
Obvious scratches need to be replaced
Piston melted at high temperature, partly adhered to cylinder liner, need to be replaced. Visible scratches can be repaired and can continue to be used
Cannot be repaired, need to be replaced
3. Crankcase
Obvious oil leakage and air slippage, affecting the use of the positive belt
Minor oil leakage, can be repaired with simple methods, does not affect the use of the joint surface, needs to be replaced
Minor oil leakage, does not affect the use
Oil leakage, can be repaired||tt ||Broken teeth, severe grinding or peeling of broken teeth, damaged tooth tips, need to be replaced
Damaged, need to be replaced
Cracked, deformation causes oil leakage, need to be replaced
Damaged oil stagnation, storage replacement
Loose oil leakage, purple solid can eliminate
Detachment, looseness
Fourth, piston
Need to be replaced
Serious ablation of the joint, need to be replaced
Slight pitting can still be used
Serious strain, need to be replaced
Repair can be used
No serious consequences caused
Fault category
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