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AK-LV 02 Englisch
AK-LV 02 Englisch
8F M5 1 July 2005
Norm vor Anwendung auf Aktualität prüfen / Check standard for current issue prior to usage.
Airbag System
Airbag Cushions (Mounting Location: Steering Wheel, TL
Numerical notation according to ISO practice (see VW 01000).
Dashboard) 825 12
In case of discrepancies the German version shall govern.
Descriptors: airbag, airbag system, airbag module, steering wheel, airbag cushions
dashboard D
Preface
The contents of Team Supply Specification AK-LV 02 (May 2005) have been adopted without
changes by Technical Supply Specification TL 825 12.
AK-LV 02 was drafted by the "Supply Specifications" team of the automobile companies Audi AG,
Bayerische Motoren Werke AG, Daimler Chrysler AG, Porsche AG and the Volkswagen AG.
Changes
The following changes have been made as compared to TL 825 12, 1999-09:
─ see change documentation for AK-LV 02
Previous issues
1997-11; 1999-09
─ Approval of first supply and changes according to Volkswagen standard VW 011 55.
─ Sections marked with a documentation bar " " are subject to mandatory documentation.
The documents shall be kept on file for 15 years.
Referenced standards
VW 011 55 Vehicle Supply Parts; Approval of First Supply and Changes
VW 911 01 Environmental Standard for Vehicles; Vehicle Parts, Materials, Operating Fluids;
Avoidance of Hazardous Substances
as well as all documents referred to in AK-LV 02.
QUELLE: NOLIS
Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the B2B supplier platform “www.vwgroupsupply.com”.
.
VOLKSWAGEN AG
Team Supply Specification
May 2005
Airbag System
Airbag Cushions
(Mounting Location: Steering Wheel, Dashboard)
AK - LV 02
Requirements and Test Conditions
airbag system; airbag cushions (installation location: steering wheel, dashboard); requirements and test procedures
Contents
2 Definitions
3 General
4 General requirements and their test conditions for the airbag cushion
4.1 Marking
4.2 Volume
4.3 High pressure air permeability
4.4 Visual requirements
8 Previous issues
9 Changes
Continued on pages 2 to 22
This specification is intended to ensure the product quality and function of the airbag cushion
within the overall system to which it belongs by providing precise, clear and uniform guidelines for
its properties. The specification also describes the test methods used to document airbag cushion
requirements and their implementation. The specification is a part of the drawing. The
specification applies to all airbag cushions that have a note in the drawing indicating this.
2 Definitions
The airbag cushion is part of a restraint system. It is filled with gas when the gas generator
detonates, thus ensuring increased occupant safety in the event of a collision.
3 General
The manufacturer shall ensure that the provisions in this specification and the drawing
are observed. This is documented along with the process reliability and must be demonstrated
with suitable methods and a sufficient test scope.
Alternative test methods are permissible, as long as they facilitate equally suitable verification.
The examining body must provide documentation that its tests correlate with the test methods
described in this specification.
Unless otherwise indicated, these requirements apply to parts in as-received condition (with
no prior load). Deviations must be noted in the test report.
If a requirement bears only the note "see drawing", the applicable value shall be taken from the
drawing. If the drawing does not contain any related information, the requirement can be omitted.
In the case of a discrepancy between the drawing and the specification, the entry in the drawing
takes precedence.
In general, the airbag cushion must conform to all requirements listed in this specification. This
conformity must be documented in the release or first-sample test.
The sections of this specification marked with a documentation bar or a "D" are
subject to mandatory documentation.
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AK-LV 02 : 2005-05
4 General requirements and their test conditions for the airbag cushion
The proper department must be informed of any changes to the airbag cushion and/or
manufacturing methods and manufacturing locations before they are introduced in standard
production; these changes require a new release.
The airbag cushion undergoes an environmental simulation once installed in the module. After
testing it must meet the requirements after the module environmental simulation as well as the
airbag cushion requirements.
4.1 Marking
An easy-to-read and permanent marking must be applied to the airbag cushion. This marking
must show the manufacturer and the warp direction as well as permit retracing of the components
and manufacturer parameters.
4.2 Volume
The volume of the airbag cushion shall be determined using a suitable measuring method. The
measuring method shall be coordinated with the customer. Alternatively, calculation methods are
permitted. If possible, the method described below shall be used.
4.2.1 Preface
This test is used to determine the airbag cushion volume of a finished airbag.
4.2.2 Requirements
To perform the test, a base container is required with a volume corresponding to that of the
airbag cushion in order to hold the hollow balls (see Table 1 and Table 2, for example). When
dimensioning the container, the bulk volume of the hollow balls used must be taken into
consideration.
Table 1: Container 1, dimensions
Test temperature: RT
The airbag cushion openings must be closed such that no hollow balls can escape.
The mouth of the airbag cushion is clamped suspended freely on the funnel. The airbag cushion
is then filled with hollow balls from the store container until no more balls can be pressed into the
airbag cushion.
The hollow balls remaining in the store container are poured into the measurement container
and the remaining volume is measured.
hollow balls
Hohlkugeln
base container
Grundbehälter
funnel
Trichter
4.3.1 Preface
This test is used to determine the total flow rate of a finished airbag cushion.
This test is only conducted upon special request, because it can aid in the calculation.
4.3.2 Requirements
The flow rate of the airbag cushion must be determined and a tolerance zone established using
statistical methods (see Table 3).
Table 3: Tolerance zone value pairs using a sample airbag cushion design as an example
Airbag cushion 0,02 0,04 0,06 0,08 0,10 0,12 0,14 0,16 0,18 0,20 0,22 0,24 0,26 0,28 0,30
internal pressure
[bar]
Upper limit 83,9 121,5 159,1 196,7 234,3 271,9 309,5 347,1 384,7 422,3 459,9 497,5 539,1 572,7 610,3
[g/s]
Lower limit [g/s] 76,5 113,2 149,8 186,5 223,3 259,8 296,5 333,1 369,8 406,5 443,1 479,8 516,5 553,5 589,8
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AK-LV 02 : 2005-05
700
600
[g/s]
flow rate [g/s]
500
Massenstrom
400
300
Mass
200
100
0
0 0,05 0,1 0,15 0,2 0,25 0,3 0,35
Bag-Innendruck
Airbag cushion [bar] [bar]
internal pressure
Figure 2. Tolerance zone of the high pressure air permeability for a sample airbag cushion design
The visual requirements must be met before and after the high pressure air permeability test.
p pi
Beruhigungsstrecke
smoothing path
diffusor
Diffusor
5
100 50
Meßblendeorifice
measuring run-out path
Auslaufstrecke
Test temperature: RT
The airbag cushion shall be tested according to the drawing status. The airbag cushion to be
measured is secured to a system according to Figure 3. The system is supplied with compressed
air via a compressed air system. The over-pressure pi that builds up in the airbag cushion is
measured in comparison to the atmospheric pressure. At the same time, the mass flow rate Qm of
the air flowing through is measured using the metering orifice method according to DIN 1952.
During the test, the following measured variables are recorded using suitable registering
instruments:
A linear fitted line with a correlation coefficient > 0,995 must be plotted through the airbag
cushion internal pressure/mass flow rate value pairs determined. The fitted line must be within the
tolerance zone defined according to Table 3 (see Figure 2 for example).
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AK-LV 02 : 2005-05
4.4 Visual requirements
4.4.1 Preface
4.4.2 Requirements
The airbag cushion shall not have any breaks or tears in the fabric. During a normal visual
inspection, the fabric shall not exhibit any flaws that adversely affect the function.
The airbag cushion fabric must not have any manufacturing flaws of any kind that could adversely
affect the processing and functional characteristics.
Test temperature: RT
The test is a standard visual inspection. Fold points shall be examined for breaks and tears using
a magnifying glass with 6 times enlargement.
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AK-LV 02 : 2005-05
5 Fabric requirements and their test conditions
5.1 Preface
The tests serve to determine the characteristics of the fabrics used to make the airbag cushions.
5.2 Requirements
The fabric requirements listed in Table 4 shall be determined and tested by the supplier
and entered and documented with the occurring tolerances in the table. This sheet shall be
maintained by the supplier. The supplier guarantees through its component and system trials that
the integrity requirements are fulfilled with the documented fabric tolerances.
Suitable proofs of calibration shall be documented for the test equipment used.
If the tests cannot be conducted exactly according to DIN standards, the deviations must be
noted in the test report.
The test is conducted according to DIN 53 350, separately for warp and weft directions.
Depending on the fabric used, the test method according to ASTM D-4032 can also be used
if required.
The test is conducted according to DIN 54 301, but with 20 mm edge spacing and 50-mm-wide
specimens. Depending on the material used, tests according to DIN 53331 or ASTM D-6479
can also be used.
Temperature: 105 C°
Duration: 60 min
Apparatus: Forced ventilation drying cabinet
Specimen setup: Place on a grate without tension
Specimen dimensions: 600 mm x 600 mm
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AK-LV 02 : 2005-05
5.5.4 Fabric thickness
Evaluation according to ISO 6133, Method B, with F>10% N. The specimen size used must
be indicated.
Deviating from the standard, specimens with 100 cm² surface area shall be used.
The supplementary air outlet, which is suggested as optional in the standard, is obligatory here;
the value to be subtracted must be specified. Distribution of the measuring points: see Figure 4.
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AK-LV 02 : 2005-05
Figure 4. Distribution of the measuring points across the web width for the air permeability test.
Warp N ≥ 110
D 9.1 In as-received condition AK - LV 02
Weft N ≥ 110
Warp N
9.2 Environmental simulation AK - LV 02
Weft N
5.7.1 Airbag cushion requirements after aging and the module environmental simulation
After aging and the module environmental simulation (see Section 8.2 "Environmental simulation"
according to specification AK-LV 01), the following requirements according to this specification
must be met:
Fabric requirements
• Maximum tensile strength/elongation
• Tear propagation strength
• Air permeability
For values deviating from those of the unused condition, suitable documentation must be
provided that ensures the functional capability over the life of the airbag.
The tests are conducted on climate-aged specimens (24 h, 20 C ° , 65% rel. hum.).
A test program according to Table 5 must be performed with the airbag cushions.
Table 5 shows the minimum number of specimens (No. 1 to 2) that must undergo the complete
aging process to cover all test parameters and to be able to check all the requirements after the
environmental simulation (the required number of specimens for the following tests is decisive for
this).
The actual number of specimens for each test sequence is determined by the department
requesting the test (see Section 3).
Table 6 shows the distribution of the tests that are necessary to document the requirements set
for the airbag cushion after aging.
Table 7 shows the distribution of the tests that are necessary to document the requirements set
for the airbag cushion after the module environmental simulation.
• The fabric aging must first be conducted according to textile aging rather than within the
framework of the module environmental simulation due to the aging mechanisms for fabrics
and the reproducibility of the aging effects. The conditions are defined below.
Upon receipt of the products returned from the module environmental simulation, these shall
also be checked according to Section 5.7.1.
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Table 6. Test program to document the requirments for the airbag cushion after aging
Table 7. Test program to document the requirments for the airbag cushion after the module
environmental simulation
5.7.2.1.1 Preface
This test shall be performed in order to ensure that an airbag cushion will withstand high
temperatures without damage.
5.7.2.2.1 Preface
This test shall be performed in order to ensure that an airbag cushion will withstand high humidity
without damage.
6.1 Circumference seam/seam between the jacket portion and the side portion
To evaluate the circumference seams, or the seam between the jacket portion and the side
portion of the airbag cushion, with regard to safety and usability for the intended purpose, the
airbag cushion manufacturer must provide an expert opinion from a recognized institute for each
airbag cushion design.
Specimens that are removed or prepared must sufficiently represent all fabric directions
that occur.
The position of the sampling point must be documented in the test report.
Clamping:
Free length at beginning of pull: 100 mm; seam position in the middle of the free length,
right angle to the pull direction; see Figure 8.
80 mm
15 mm
SeamNaht
Einschnitt
Incision upbis
to auf 2 Restfäden
2 remaining parallel
threads zur Naht
parallel to the seam
The airbag function shall not be adversely affected by the inflation test.
To evaluate the airbag cushion tear seams with regard to safety and usability for the intended
purpose, the airbag cushion manufacturer must provide an expert opinion from a recognized
institute for each airbag cushion design.
The position of the sampling point must be documented in the test report.
Clamping:
Free length at beginning of pull: 100 mm; seam position in the middle of the free length,
right angle to the pull direction; see Figure 9.
Reißnaht
tear seam
Einspannvorrichtung
clamping device
airbag
Luftsack
The airbag function shall not be adversely affected by the inflation test.
The rebound strap fabric used must meet the respective requirements according to Section 5.7.
To evaluate the airbag cushion rebound strap attachment with regard to safety and usability for
the intended purpose, the airbag cushion manufacturer must provide an expert opinion from a
recognized institute for each airbag cushion design.
Test conducted according to DIN 53 857, Part 1. However, the specimen width equals the
rebound strap width.
Specimens must be taken or prepared depending on the rebound strap arrangement that
sufficiently represent all fabric directions that occur.
Clamping: Free length at beginning up pull 100 mm; the following applies to the test: seam
position at a right angle to the pull direction and in the middle of the clamped section (see Figure
10).
The airbag function shall not be adversely affected by the inflation test.
seam 2
rebound strap
seam 1
Naht
seam11 Naht 22
seam
Luftsack-
airbag cushion
Fangband
rebound strap upper side
Oberseite
airbag cush-
Luftsack- Fangband
rebound strap
ionMund
mouth
8 Previous issues
Airbag System, Airbags, Requirements and Test Conditions, AK-LV 02: 01.96
Airbag System, Airbags, Requirements and Test Conditions, AK-LV 02: 02.97
Airbag System, Airbags, Requirements and Test Conditions, AK-LV 02: 01.99
9 Changes
The following changes and additions have been made as compared to the January 1999 issue:
a) Section 3, "The airbag is a component whose functional characteristics must remain constant
for over 15 years driving operation."; sentence omitted completely
b) Section 4.2, "The volume of the airbag shall be determined …"; added
c) Section 4.4 revised, reference to list of flaws in ASTM D-5426 included, reference to
Supplement 2, list of flaws omitted, Supplement 2 omitted
d) Section 5, fabric requirements revised, alternative test methods permitted in certain cases,
Supplement 1 omitted, fabric requirements, related independent documentation and updating by
the supplier, updating of DIN standards
e) Section 7, airbag cushion aging incorporated as Section 5.7 in Section 5, Fabric requirements
added, Section 5.7.2 made more precise
1) In this section terminological inconsistencies may occur as the original titles are used.