2921 02 023 A0188 - Radiator Cooling Fan Motor - Technical Specification - Version1.4

TECHNICAL SPECIFICATION
RADIATOR FAN MOTOR
RADIATOR COOLING FAN MOTOR
Document Version: 1.4
Issue Date Author E-mail

1.4 31st August 2015 RAJESH KUMAR BALUSU Rajesh.Balusu@tatatechnologies.com
Document History
Issue Date Author Details
1.0 18th June 2010 Ramakrishna Koduru First release

1.1 12th October 2010 Ramakrishna Koduru Second release
1.2 20th January 2011 Ramakrishna Koduru Third release
1.3 08th March 2011 Ramakrishna Koduru Fourth release
1.4 31st August 2015 Rajesh Kumar Balusu Fifth release
First Release : 31st Aug 2015 TECHNICAL SPECIFICATION – RADIATOR COOLING FAN MOTOR Page 1 of 78
Version : 1.4 Specification No: 2921 02 023 A0188
Author : RAJESH KUMAR BALUSU, E-mail : Rajesh.Balusu@tatatechnologies.com
This specification is the exclusive property of Tata Motors Ltd. Without their consent it may not be reproduced or given to third
parties. The above specifications are subject to change and therefore suppliers are requested to refer to the latest version.
RADIATOR FAN MOTOR
Change History
Version Page Section Change Details
1.1 - - Revised after an internal review
1.2 - - Revised and reorganized the content
Environmental and EMI / EMC requirements streamlined
1.2 - -
to TST/TS/WI 233 and TST/TS/WI 257
1.3 2.3.14 Clause revised as per APQP feedback
1.3 - Annexure-2 Reliability targets added as per APQP feedback
Design and Development requirements are specified.
1.4 All All
Test specifications are completely revisited.
RADIATOR FAN MOTOR
TABLE OF CONTENTS
1. GENERAL ------------------------------------------------------------------------------------------------- 7
1.1 Scope ------------------------------------------------------------------------------------------------------------------------------------------ 7
1.2 General Conditions ------------------------------------------------------------------------------------------------------------------------ 7
1.3 VA/VE Proposals --------------------------------------------------------------------------------------------------------------------------- 7
1.4 Samples and Document retention requirements--------------------------------------------------------------------------------- 7
1.5 Product Identification requirements on Motor ----------------------------------------------------------------------------------- 8
1.6 Raw Material Specific requirements ------------------------------------------------------------------------------------------------- 8
1.7 Plastic Parts ---------------------------------------------------------------------------------------------------------------------------------- 8
1.8 Rubber Parts--------------------------------------------------------------------------------------------------------------------------------- 8
1.9 Warranty Specific requirements ------------------------------------------------------------------------------------------------------ 9
1.10 Warranty Part analysis ------------------------------------------------------------------------------------------------------------------- 9
1.11 Warranty response Specific requirements ----------------------------------------------------------------------------------------- 9
1.12 Product approval condition ------------------------------------------------------------------------------------------------------------- 9
1.13 Project Review OPL ------------------------------------------------------------------------------------------------------------------------ 9
1.14 Learnings integration ------------------------------------------------------------------------------------------------------------------- 10
1.15 Component Weight tracking---------------------------------------------------------------------------------------------------------- 10
1.16 Part Inspection Report and Material Verification Report requirements ------------------------------------------------ 10
1.17 Change Management requirements ----------------------------------------------------------------------------------------------- 10
1.18 Product Design and Development Cost ------------------------------------------------------------------------------------------- 10
2. RFQ RESPONSE ---------------------------------------------------------------------------------------- 11

3. PRODUCT DESIGN REQUIREMENTS ------------------------------------------------------------- 12
3.1 Product Development Cycle Overview -------------------------------------------------------------------------------------------- 12
3.2 DFMEA + PFMEA requirements ------------------------------------------------------------------------------------------------------ 14
3.3 2D + 3D requirements ------------------------------------------------------------------------------------------------------------------ 15
3.4 Technology roadmap requirements ------------------------------------------------------------------------------------------------ 15
3.5 Benchmarking requirements --------------------------------------------------------------------------------------------------------- 15
3.6 Design review requirements---------------------------------------------------------------------------------------------------------- 16
3.7 Samples support (Proto and Production Samples)----------------------------------------------------------------------------- 16
3.8 Design Simulation Requirements --------------------------------------------------------------------------------------------------- 17
3.9 Digital Validation Requirements ---------------------------------------------------------------------------------------------------- 17
3.10 Anti rotation requirements for motor assembly ------------------------------------------------------------------------------- 18
3.11 Mating Connectors information ----------------------------------------------------------------------------------------------------- 18
3.12 Water drain hole requirements & Colour of Motor --------------------------------------------------------------------------- 18
4. PRODUCT VALIDATION – TML SPECIFIC ------------------------------------------------------- 19

4.1 Validation test result report requirements -------------------------------------------------------------------------------------- 19
4.2 Product Definition Sign-off ------------------------------------------------------------------------------------------------------------ 19
4.3 Vehicle level Validation requirements--------------------------------------------------------------------------------------------- 19
4.4 Part Validation requirements (Design validation and Process validation) ---------------------------------------------- 19
4.5 Periodic Validation requirements (Design and Process) --------------------------------------------------------------------- 20
RADIATOR FAN MOTOR
5. REFERENCE DOCUMENTS / STANDARDS------------------------------------------------------- 21

5.1 TML Documents -------------------------------------------------------------------------------------------------------------------------- 21
5.2 National / International Standards ------------------------------------------------------------------------------------------------- 21
6. ENVIRONMENTAL CONCERNS --------------------------------------------------------------------- 22

6.1 Use of Green Materials ----------------------------------------------------------------------------------------------------------------- 22
6.2 Prohibited Materials -------------------------------------------------------------------------------------------------------------------- 22
6.3 Platting Specific requirements ------------------------------------------------------------------------------------------------------- 22
7. SUB-SUPPLIERS DEVELOPMENT REQUIREMENTS ------------------------------------------- 23
8. SERVICEABILITY REQUIREMENTS --------------------------------------------------------------- 24
8.1 Service Manual --------------------------------------------------------------------------------------------------------------------------- 24
8.2 Service Network to support serviceability --------------------------------------------------------------------------------------- 24
9. PRODUCT LOGISTICS PACKING REQUIREMENTS – REGULAR SUPPLY AND SPARE
PARTS -------------------------------------------------------------------------------------------------------- 24
10. ELECTRICAL REQUIREMENTS --------------------------------------------------------------------- 25
10.1 Voltage -------------------------------------------------------------------------------------------------------------------------------------- 25
10.2 Current -------------------------------------------------------------------------------------------------------------------------------------- 25
10.3 Input power ------------------------------------------------------------------------------------------------------------------------------- 25
10.4 Armature resistance -------------------------------------------------------------------------------------------------------------------- 26
10.5 Armature Inductance ------------------------------------------------------------------------------------------------------------------- 26
10.6 Electrical time constant ---------------------------------------------------------------------------------------------------------------- 26
10.7 Motor back emf constant ------------------------------------------------------------------------------------------------------------- 26
10.8 EMI / EMC requirements -------------------------------------------------------------------------------------------------------------- 26
10.9 Demagnetization ------------------------------------------------------------------------------------------------------------------------- 26
11. MECHANICAL REQUIREMENTS ------------------------------------------------------------------- 27
11.1 Output power ----------------------------------------------------------------------------------------------------------------------------- 27
11.2 Torque speed characteristics --------------------------------------------------------------------------------------------------------- 27
11.3 Axial play ----------------------------------------------------------------------------------------------------------------------------------- 27
11.4 Radial play --------------------------------------------------------------------------------------------------------------------------------- 28
11.5 Shaft run-out ------------------------------------------------------------------------------------------------------------------------------ 28
11.6 Rotor Inertia ------------------------------------------------------------------------------------------------------------------------------- 28
11.7 Frictional constant ----------------------------------------------------------------------------------------------------------------------- 28
11.8 Mechanical time constant ------------------------------------------------------------------------------------------------------------- 28
11.9 Motor time constant -------------------------------------------------------------------------------------------------------------------- 28
11.10 Speed torque gradient (Speed regulation) --------------------------------------------------------------------------------------- 28
11.11 Maximum axial load -------------------------------------------------------------------------------------------------------------------- 29
11.12 Maximum radial load ------------------------------------------------------------------------------------------------------------------- 29
11.13 Motor Mounting ------------------------------------------------------------------------------------------------------------------------- 29
11.14 Shaft coupling requirements --------------------------------------------------------------------------------------------------------- 29
11.15 Residual unbalance ---------------------------------------------------------------------------------------------------------------------- 29
11.16 Blade unit retention --------------------------------------------------------------------------------------------------------------------- 29
11.17 Motor terminals -------------------------------------------------------------------------------------------------------------------------- 29
RADIATOR FAN MOTOR
12. THERMAL / ENVIRONMENTAL REQUIREMENTS --------------------------------------------- 30

12.1 Operating Temperature ---------------------------------------------------------------------------------------------------------------- 30
12.2 Storage Temperature ------------------------------------------------------------------------------------------------------------------- 30
12.3 Operating humidity --------------------------------------------------------------------------------------------------------------------- 30
12.4 Storage humidity ------------------------------------------------------------------------------------------------------------------------- 30
12.5 Altitude ------------------------------------------------------------------------------------------------------------------------------------- 30
13. OTHER REQUIREMENTS ---------------------------------------------------------------------------- 31
13.1 Noise ----------------------------------------------------------------------------------------------------------------------------------------- 31
13.2 Efiiciency------------------------------------------------------------------------------------------------------------------------------------ 31
13.3 PWM controlled motor (Optional Requirement) ------------------------------------------------------------------------------- 32
14. TEST REQUIREMENTS ------------------------------------------------------------------------------- 33
14.1 Performance / Functional tests ------------------------------------------------------------------------------------------------------ 33
14.1.1 No Load test ------------------------------------------------------------------------------------------------------------------------------- 33
14.1.2 Starting voltage test--------------------------------------------------------------------------------------------------------------------- 34
14.1.3 Starting behaviour test ----------------------------------------------------------------------------------------------------------------- 34
14.1.4 System performance test -------------------------------------------------------------------------------------------------------------- 35
14.1.5 Motor characteristic tests ------------------------------------------------------------------------------------------------------------- 36
14.1.6 Temperature rise test------------------------------------------------------------------------------------------------------------------- 37
14.1.7 Locked rotor test ------------------------------------------------------------------------------------------------------------------------- 38
14.1.8 Tri-voltage tri-temperature test ----------------------------------------------------------------------------------------------------- 38
14.1.9 General characteristic tests ----------------------------------------------------------------------------------------------------------- 40
14.1.9.1 Visual examination --------------------------------------------------------------------------------------------------------------- 40
14.1.9.2 Robustness of terminations, mounting fasteners etc. ----------------------------------------------------------------- 41
14.1.9.3 Conductor tensile strength ---------------------------------------------------------------------------------------------------- 41
14.1.9.4 Forces on connector ------------------------------------------------------------------------------------------------------------- 42
14.1.10 Environmental tests --------------------------------------------------------------------------------------------------------------------- 43
14.1.10.1 High & Low temperature storage -------------------------------------------------------------------------------------------- 43
14.1.10.2 Thermal shock test (air to air) ------------------------------------------------------------------------------------------------ 45
14.1.10.3 Thermal shock with splash water test -------------------------------------------------------------------------------------- 48
14.1.10.4 Water spray test ------------------------------------------------------------------------------------------------------------------ 50
14.1.10.5 Dust test ----------------------------------------------------------------------------------------------------------------------------- 51
14.1.10.6 Corrosion resistance test ------------------------------------------------------------------------------------------------------- 53
14.1.10.7 Fluid resistance test -------------------------------------------------------------------------------------------------------------- 55
14.1.10.8 Damp heat steady state test -------------------------------------------------------------------------------------------------- 57
14.1.10.9 Dynamic test ----------------------------------------------------------------------------------------------------------------------- 58
14.1.10.9.1 Sine vibrations ----------------------------------------------------------------------------------------------------------------- 58
14.1.10.9.2 Random vibrations ----------------------------------------------------------------------------------------------------------- 60
14.1.10.9.3 Mechanical shock test ------------------------------------------------------------------------------------------------------- 62
14.1.10.9.4 Resonance point detection & vibration endurance test ---------------------------------------------------------- 64
14.1.10.9.5 MEOST test --------------------------------------------------------------------------------------------------------------------- 65
14.1.10.10 Over voltage test ----------------------------------------------------------------------------------------------------------------- 67
RADIATOR FAN MOTOR
14.1.10.11 Dielectric Strength test --------------------------------------------------------------------------------------------------------- 68

14.1.10.12 Insulation resistance test------------------------------------------------------------------------------------------------------- 69
14.1.11 EMI / EMC test ---------------------------------------------------------------------------------------------------------------------------- 70
14.1.12 Fuse blow off test – For Self Protecting Fuse in motor ----------------------------------------------------------------------- 71
14.1.13 Endurance test ---------------------------------------------------------------------------------------------------------------------------- 72
14.1.13.1 Intermittent test ------------------------------------------------------------------------------------------------------------------ 72
14.1.13.1.1 Life test -------------------------------------------------------------------------------------------------------------------------- 72
14.1.13.1.2 Start - stop test ---------------------------------------------------------------------------------------------------------------- 73
14.1.13.2 Continuous test - Low temperature endurance test ------------------------------------------------------------------- 74
14.1.14 Vehicle fitment & Functional test --------------------------------------------------------------------------------------------------- 75
15. SUPPLIER TECHNICAL DELIVERABLES --------------------------------------------------------- 75
15.1 Product Technical Specification ----------------------------------------------------------------------------------------------------- 75
15.2 2D Drawing -------------------------------------------------------------------------------------------------------------------------------- 76
15.3 Service Manual --------------------------------------------------------------------------------------------------------------------------- 76
15.4 DV and PV Report ------------------------------------------------------------------------------------------------------------------------ 76
16. DEVELOPMENT SUPPORT -------------------------------------------------------------------------- 77
17. TERMINOLOGY ---------------------------------------------------------------------------------------- 78
RADIATOR FAN MOTOR
1. General
1.1 Scope
This document contains a detailed specification of the requirements of PMDC brush type of motor
used for driving the Radiator cooling fans installed in the engine compartment for TML PVBU (12V system)
vehicles. The purpose of this technical specification is to establish the performance, durability and quality
of the Radiator cooling fan motors supplied to TML.
This technical specification is a supplement to the released drawing on the Radiator fan motor and
all requirements herein must be met in addition to all other requirements of the component drawing.
System designers and prospective suppliers are the intended audience.
1.2 General Conditions
Suppliers are requested to meet the requirements specified on this technical specification while
responding to an RFQ, while developing the Radiator cooling fan motor for any of the TML applications.
However Supplier can propose an alternate solutions in Product technical specifications, Product
Validation Conditions, Part Commonization, etc which will lead to reduce the product cost (Part,
Development, or any other form of cost) or to improve the Product Quality. The same has to be shared
while answering for an RFQ itself.
Also any sort of non-conformance against the specification needs to be formally communicated to
TML while answering for an RFQ failing which supplier needs to meet the requirements stated on the
specification without any cost addition within the stipulated program development timeline.
1.3 VA/VE Proposals

Suppliers are free to share the VA/VE proposal during each new RFQ review and subsequent
program development. VA/VE can be in any form like cost saving, Quality improvement, warranty cost
reduction, Process cost saving, weight reduction, commonization strategy, etc.
Suppliers are requested to propose minimum 5% VA/ VE proposal per year on the above category.
This will be reviewed and evaluated during the end of the each financial year.
1.4 Samples and Document retention requirements

Supplier must ensure the following retention periods during the new product development life
cycle.
Retention Period in Years
Description
Actual Samples Relevant Documents
RFQ Response (Concept Verification) Till SOP Till SOP
Concept Proto (A Sample) Till SOP Till SOP
Design Validation (Proto Sample – B Sample) Till Vehicle Program Life Till Vehicle Program Life
Process Validation (Off tool, Off Process – C Sample) Till Vehicle Program Life Till Vehicle Program Life
PPAP Master Sample Till Vehicle Program Life Till Vehicle Program Life
SOP – First Batch Master Sample Till Vehicle Program Life Till Vehicle Program Life
RADIATOR FAN MOTOR
1.5 Product Identification requirements on Motor
Product identification must be inline with TML Specification ref: 2921 02 2 16 A0119. Supplier must
be in a position to track the EOL performance data of the given Radiator Cooling Fan Motor during the any
point of the Vehicle life program.
Minimum required information’s on the motor Label:
1.6 Raw Material Specific requirements

Supplier must declare the raw materials and its manufacturer during the design review which will
be held after sourcing nomination is confirmed. Refer “Annexure-2” (Product definition sign-off) for more
details about the information sharing.
If any change in raw material grade or raw material supplier, Supplier must get formal approval
from TML prior to introduction.
1.7 Plastic Parts

Supplier must use V0 grade (Refer Standard UL 94 for details) raw material for all the plastic
components associated with TML products. Material must comply with UL 94 Standard and ensure doesn’t
catch or spread the flame to vehicle environment under any circumstances.
Marking on the plastic parts must be as per VDA 260 and recycling must be as per ISO 14021
Standard.
1.8 Rubber Parts

Supplier must select the rubber grade under the guidance of TML standard TS 5562. The part must
be capable of performing at both minimum to maximum operating temperature indicated on the Radiator
cooling fan motor outline drawing. Part should not show any deformation on dimensions, hardness and
material properties post environmental durability tests.
RADIATOR FAN MOTOR
1.9 Warranty Specific requirements

During each new RFQ, Supplier must propose a robust product to improve the current IPTV level.
Also it is supplier’s responsibility to highlight the improvement requirements on the system level if any at
the beginning of the project before installation sign-off. No discussions will be entertained related to the
system level improvements like non-standard operating condition, mud water splash, etc if any which is
attributed as root cause to part level failure.
1.10 Warranty Part analysis

A joint analysis (TML + Supplier) will be held at TML to analyze the failure. Supplier’s Engineering +
Quality representatives are must during the joint investigation.
Also a monthly meeting with Supplier’s management will be held at TML with TML management
team to review the actions progress.
1.11 Warranty response Specific requirements

Supplier must follow the deadline indicated below for the warranty analysis,
Action Description Max Permissible Lead time in Days

First level analysis at TML Weekly Once
Within 3 Working days from the date of Part
Preliminary analysis report of failed Part with ICA
receipt
Submission of 8D report with root cause Within 13 Working days from the date of
identified Preliminary analysis report
Design Improvements if any as identified in 8D
Timeline as agreed with TML
report
1.12 Product approval condition

Product design will be reviewed and approved formally through “Clearance report release” on
completion of “design validation tests”. Suppliers are authorized to launch the production tooling on
receipt of the “Clearance report”.
Supplier Process will be validated though “Process validation tests” and formal PV report will be
released. Suppliers are authorized to initiate the PPAP lot on receipt of the PV report.
1.13 Project Review OPL

TML will have a periodic project review with Supplier to review all the open points to ensure the
requirements are met on time. Supplier must update and maintain the OPL to track the project. Refer
“Annexure-3” for details.
RADIATOR FAN MOTOR
1.14 Learnings integration

It is mandatory to integrate the action plan from the past learnings during the each new
development. Supplier must update and track the same during the development stage. Refer “Annexure-8”
for details.
1.15 Component Weight tracking

Suppliers are requested to submit the part weight information to TML during each sample
submission stage. Data must be submitted through the format “Annexure-11” shared along with this RFQ.
1.16 Part Inspection Report and Material Verification Report requirements

Supplier must provide the part dimensional and material verification report along with the samples
as requested below,
Sample Description Required Reports
Dimension : Fitment related

Mock-up Sample (Functional / Fitment samples)
Material : Functional related
Dimension : Complete layout inspection
Alpha Sample (Functional Proto Sample)
Material : For all critical functional parts
Dimension : Complete layout inspection
Beta Sample (Off tool, Off Process)
Material : For all critical functional parts
PPAP Sample
SOP – Pilot lot Sample
1.17 Change Management requirements

Supplier must track the changes in the product the design freeze stage to Vehicle product life.
Formal request to be submitted for any change (Design, Process, Raw material, tool renewal, etc)
with the following supporting documents,
 Change register “Annexure-12”

 Design Change Summary Sheet “Annexure-4”
 DRBFM “Annexure-5”
 FMA “Annexure-6”
1.18 Product Design and Development Cost

Cost related to Product design, development, validation, project management, etc needs to be
shared upfront along with the RFQ answer. Refer “Annexure-9” for details.
RADIATOR FAN MOTOR
2. RFQ Response
Supplier must submit the Technical Proposal as per the “Annexure-1” which is shared part of this
RFQ pack. Supplier must share the first version of the Techno-Commercial Proposal within 15 working days
or as agreed with TML team. Supplier must fill all the necessary information’s requested on this “Annexure-
1” and submit the same along with the RFQ response document.
Following informations are required to be captured on the RFQ response sheet.
a. RFQ response_Technical Review

b. VA VE Proposal
c. Bill of Material
d. Benchmarking
e. Development Plan
f. NVH Test Results of any equivalent application
g. Anneure-1,2,3,etc
All indicated results on the RFQ response sheet must be supported with the documents. If any
indicated data needs to be validated by TML, Supplier must support with the relevant data or samples as
free of cost.
Supplier must attend the “Design reviews” at TML to sign-off the Technical Specification
agreement. Following Process flow will be followed during from RFQ release to Technical Sign-off,
Proposed
RFQ response from OK
Product is
Supplier Technical Review with
RFQ release meeting all Technical Sign-off
Techno-Commercial Supplier
Technical
Proposal
requirements?
NOT OK
Maximum 3 technical reviews will be carried out with each Supplier with defined interval. Supplier
must update the design wherever applicable to meet the technical requirements of RFQ within 3 attempts
and specified timeline.
RADIATOR FAN MOTOR
3. Product Design Requirements
3.1 Product Development Cycle Overview
a. Development Cycle milestone Overview

Supplier must follow the key steps indicated below during the new product development and
adhere to the milestones indicated below. All Supplier correspondences (Development Plan, Sample
Report, Sample Labelling, etc) must contain the milestone description for better understanding
b. Design Phase
During Design Phase, Supplier must align with program milestone to complete the Design
Validation. Following are the key deliverables expected for each steps during this phase,
Activity Description Expected Deliverables

RFI Response – Technical Supplier’s technical response document + Face to face design
Review review meeting
RFQ Response – Technical Supplier’s technical response document + Face to face design
Review review meeting
Mock-up Sample (A) for Concept Validation on Vehicle or Bench.
Concept Validation – Mock-up
For certain new projects, this sample may require even before
or Concept Sample (A)
nomination (LOI) to Supplier.
Detailed Design review will be held at TML to review the design
Design Review (DFMEA, CAE, requirements cascading mechanism from TML System level
CTQ, AOI Sign-off) DFMEA => Supplier Component Level DFMEA to prepare and
Sign-off CAE, CTQ and AOI.
To validate the Complete Design through design intended proto
Design Validation – Alpha sample (Proto Parts, Proto Process). Vehicle level (Alpha
Sample (B) Vehicles) validation will also be carried out with these samples.
Supplier to support for the
Design Validation results review and Sign-off with Supplier. TML
Design Validation Sign-off
will release Green Report for tooling kick-off clearance.
RADIATOR FAN MOTOR
c. Development Phase
During Development Phase, Supplier must align with program milestone to complete the Process
Validation. Following are the key deliverables expected for each steps during this phase,

Tooling kick-off clearance from TML. Supplier CAE analysis report
Tooling Kick-off
sign-off, Design review open points closure document
C-Sample build witness at Supplier and Process review sign-off
with Supplier – Must be off tool, off process sample. Equivalent to
Beta-Sample Build Witness
a day production must be run on the regular production line to
pick-up the random samples for process validation.
To validate the process robustness through off tool, off process
Process Validation – Beta
sample (Beta Sample). Vehicle level validation (Beta Vehicles) will
Sample
also be carriedout on these samples at TML.
Process Validation results Process Validation results review and Sign-off with Supplier. TML
review and Sign-off will release formal report for process clearance.
d. Production Phase
During Production Phase, Supplier must align with program milestone to complete the PPAP Sign-
off. Following are the key deliverables expected for each steps during this phase,

TML will visit critical Suppliers (will be decided during the initial
design reviews) to perform detailed Process audits. Equivalent to a
Sub-Supplier Process audit day qty to be produced during the process audit. Detailed audit
report with action plan will be signed-off with Supplier and Sub-
Supplier.
TML will perform the re-audit (Continuation to Beta Sample build)
Supplier Process audit to validate the Supplier process. A formal sign-off will be done
with Supplier with observations to decide the action plan.
Equivalent to a day qty to be produced during the process audit.
Mass Production Run at
Random inspections and validation will be performed from this
Supplier end
batch as component level and Vehicle level.
A formal PPAP Sign-off will be done based on the above mass
PPAP Sign-off
production run at Supplier end.
TML team will participate to validate and approve the first Pilot
Pilot Build review and Sign- build lot at Supplier end. Random inspections and validation will
off be performed from this batch as component level and Vehicle
level. If required, this will be extended to Sub-Supplier also.
SOP Start of Production
RADIATOR FAN MOTOR
3.2 DFMEA + PFMEA requirements

a. System boundary information
TML will share the system level boundary informations during the Technical review and system
level DFMEA review. Supplier must cascade the same into their component level DFMEA to capture the
potential noise factors expected to occur from Vehicle. Supplier must ensure the system level DFMEA’s
failure modes along with its severity are cascaded to their component level DFMEA.
TML will have a detailed review with supplier for DFMEA and PFMEA to identify the potential
failure modes and action plan. A formal sign-off will be done post review to track the actions identified
during the meeting. Supplier must communicate to TML if any updation on component level DFMEA.
b. DFMEA threshold targets

Suppliers are requested to follow the TML Specification for the DFMEA threshold targets. Supplier
must get the formal approval from TML if any deviation on this regard.
c. Failure mode avoidance (FMA)
Apart from DFMEA, Suppliers are requested to review FMA during new development, any design
change, Process change, etc. “Annexure-6” to be followed.
d. SC, CC requirements list

TML will cascade the Significant Characteristics (SC), Critical Characteristics (CC) requirements
through System level DFMEA cascade sheet. Also TML will share the SC, CC requirements standards which
Supplier needs to follow to address requirements on their Component level DFMEA. Suppliers are free to
add additional SC, CC requirements as per their own standard / own experience.
Classification in DFMEA Rule Characteristics Symbol on Drawing

YC (Yield Critical) S>9 Critical
YS (Yield Significant) 5 < S < 8 AND O > 3 Major
Blank 1<S<4 Minor No Symbol
e. CTQ Inputs
CTQ’s will be identified during the detailed System level and Component level DFMEA along with
Supplier. Also CTQ’s will be identified based on the past experience of both TML and Supplier.
Post DMEA sign-off, a formal CTQ sign-off will be done with Supplier by TML FMQ team. Supplier
must submit the Process capability, dimension report and material test report for all the CTQ’s Parameters
along with each sample submission to TML. Refer “Annexure-7” for details.
Samples received without proper CTQ’s report will be considered as non-qualified samples for
testing.
RADIATOR FAN MOTOR
3.3 2D + 3D requirements
Supplier must submit the 3D model in ‘.igs’ or format which is compatible with CATIA V5. All the
data transfer must be routed through TML FTP Server. TML approval is required if the data to be shared
through e-mail. Data sharing through physical disk is forbidden. File name must contain TML part number
for easy reference.
Detailed packaging study will be carriedout and various iterations from Supplier may required to
freeze the design. Once the final version is cleared, a formal packaging clearance report will be signed-off
between TML and Supplier. Data sharing through physical disk is forbidden. File name must contain TML
part number for easy reference.
All the SC, CC requirements needs to be formally indicated on the drawing. A formal drawing
approval will be provided by TML and approved drawing will be submitted to Supplier prior to PPAP
approval.
Any change in product design, Raw Material change, Supplier process, Supplier change, Vehicle
Level change, etc which will affect the outline drawing must be reviewed and 2D drawing needs to be
submitted to TML for formal approval.
Supplier must submit the drawing in TML Specific drawing format “Annexure-10” for the approval.
The informations requested on the drawing are minimum and Supplier can add further according to the
need. The views and informations to be maintained on the requested sheet / position for better
comparison.
During each drawing submission supplier share the formally filled and signed copy of the difference
list “Annexure-14” along with the drawing for approval. Without formally signed “Annexure-14”, drawing
will not be reviewed for approval.
3.4 Technology roadmap requirements

TML is committed to serve its Customers through upgraded technology through technological
innovation. Supplier must adhere to this requirement and requested to share the detailed technology
roadmap during each RFQ technical review meeting.
Supplier must constantly upgrade their technologies to improve the product quality, reliability,
cost, Performance and weight, etc.
3.5 Benchmarking requirements

Suppliers are expected to share the detailed benchmarking report during RFQ technical review
meeting. Also Supplier must share the action plan to overcome the weakness if any identified during
benchmarking. TML will indicate suitable benchmarking vehicles for Suppliers to execute the detailed
benchmarking activities.
Benchmarking data to be captured on the TML Specific format which is part of TML RFQ response
document “Annexure-1”.
RADIATOR FAN MOTOR
3.6 Design review requirements

TML will conduct a detailed Design Review meeting with Suppliers during the new development,
any changes (Supplier process, Supplier change, Vehicle Level change, etc) during the product life cycle.
Supplier must share the change details on specific format (Design Change Summary Sheet) shared by TML.
Also a detailed DRBFM (Design review based on failure mode) will be carriedout to identify the
product validation requirements. Refer “Annexure-5” for more details.
Following steps will be carriedout during the DRBFM review,
1. Review the impact of this design change with reference to the existing failure modes identified
on the existing DFMEA (System level + Component level)
2. Review and identify whether this Design Change will bring out any new failure modes?
3. Review and identify whether this Design Change will bring out any new Noise factors?
3.7 Samples support (Proto and Production Samples)

Supplier must support with the samples for all Vehicle level validation which will be executed under
various milestones indicated below,
 Mock-up / Concept Sample (A Sample) – Concept Samples required to verify the Technical
aspects proposed by the Supplier prior to Design freeze. Sample may required prior to sourcing
nomination or post source nomination but to design freeze. Samples must contain the relevant
documents requested on this document. 2 Samples out of this lot have to be preserved as
“Master Samples” till SOP.
 Alpha Sample (B Sample) – Proto Samples required to verify the freezed design prior to tooling
launch. Samples must be made out of design intended proto parts + proto Process. Samples must
contain the relevant documents requested on this document. 5 samples out of this lot have to be
preserved as “Master Samples” till the Vehicle program life.
 Beta Sample (C Sample) – Production / Process Samples required to verify the process
robustness prior to PPAP Sign-off. Samples must be made out of final design intended mass
production parts + mass production process. Samples must contain the relevant documents
requested on this document. 5 samples have to be preserved as “Master Samples” till the Vehicle
program life.
 PPAP Samples – Random Samples (Selected by TML team) from PPAP lot needs to be submitted
to TML for Vehicle level validation. These samples will be validated on the Vehicle level for
performance, Noise and Startability Criteria. Samples must contain the relevant documents
requested on this document. 5 samples out of this lot have to be preserved as “Master Samples”
till the Vehicle program life.
 Pilot lot Samples – Random Samples (Selected by TML team) from Pilot lot needs to be submitted
RADIATOR FAN MOTOR
 SOP Samples – Random Samples (Selected by TML team) from first SOP lot needs to be submitted
A detailed discussion will be held with Supplier to define the DVP (Component level + Vehicle level)
to validate the samples submitted under various milestones. Detailed test specification is shared on this
specification. Each test specification is indicated with no of samples required for validation. The indication
is only for the reference and the requirement will be reviewed during the DFMEA/Design review stage.
Finalized sample requirements will be part of DVP / PVP which needs to be signed between TML and
Supplier. Refer “Annexure-13” for detailed sampling plan.
3.8 Design Simulation Requirements
In order to ensure the robustness product development and to reduce the product development
time, Supplier must have the following Design simulation capabilities to execute the product development,
 FEA analysis wherever applicable.
 Stress and fatigue calculation wherever applicable.
 Electro-mechanical Simulation.
 In-rush Current simulation with reference to various Battery profile.
 Operating current and speed simulation with reference to Engine behaviour at various
environmental conditions.
 Prediction of brush life, Magnet life, spring life and life of other subcomponents as applicable.
Supplier must show the above analysis report to TML during the design reviews.
3.9 Digital Validation Requirements
In order to ensure the robustness product development and to reduce the physical product
validation (both component and Vehicle) time, Supplier must have the following Digital Validation
capabilities to execute the product development,
 Product durability simulation with reference to the Vehicle application inputs.
 Noise simulation analysis data with overall radiator assembly.
Supplier must show the above analysis report to TML during the Design reviews.
RADIATOR FAN MOTOR
3.10 Anti rotation requirements for motor assembly

All the fasteners associated with motor assembly must have anti-rotation provision to avoid
movement during the tightening and removal process. TML RFQ will insist anti rotation arrangements for
the fasteners accessed at TML for assembly. It is supplier’s responsibility to ensure the anti rotation
arrangement for their internal parts which will be accessed in after market during servicing.
3.11 Mating Connectors information

Wiring harness connections and its orientation details will be shared along with the RFQ. Also RFQ /
Technical specification will contain mating connectors/terminals material, thickness and platting details. It
is Supplier’s responsibility to confirm the suitability of the same to their proposed product functionalities. If
any change required on the mating connector design (material, dimension, platting, etc), formal
information to be shared during the RFQ review meeting or any other Design review meeting.
As an alternate, Supplier can propose suitable and reliable mating connectors for TML’s review and
consideration.
3.12 Water drain hole requirements & Colour of Motor

The drain / vent hole requirement for the motor is a specific vehicle program dependent. The
supplier shall provide the drain / vent hole(s) based on the application study and 3D packaging studies. The
component when mounted in vehicle, the drain/vent hole should be at the bottom most position of the
motor. The drain/vent holes are used to drain out any moisture that gets accumulated inside the motor
and to vent the gases formed by arcing in case of sealed motors.
The colour of the motor should be same as per the fan shroud assembly.
RADIATOR FAN MOTOR
4. Product Validation – TML Specific
4.1 Validation test result report requirements

All the relevant test reports must contain minimum the following informations,
1. Detailed test description, Test condition, Test set-up photo, Environmental conditions,
2. Test equipment used for testing
3. Observations of key parameters – before, during and after test
4. Part analysis results along with standards and acceptance criteria
Each test mentioned on this specification is containing the specific requirements to be captured on
the report. It is mandatory to capture those informations on the reports which will be shared with TML.
4.2 Product Definition Sign-off

In each stage of product validation, Supplier has to arrange product bill of material sign-off with
TML. Refer “Annexure-2” for detailed informations which need to be signed-off.
4.3 Vehicle level Validation requirements

A detailed test plan will be made to validate the product on vehicle level. TML will review and sign-
off the detailed vehicle level validation plan with supplier. It is supplier’s responsibility to identify and
propose any additional vehicle level test which will enhance the product quality & reliability with reference
to Supplier’s past field experience.
4.4 Part Validation requirements (Design validation and Process validation)

A detailed test plan will be made (as on outcome of DFMEA review) to validate the product as
component level. TML will review and sign-off the detailed part level validation plan with Supplier. It is
supplier’s responsibility to identify and propose any additional tests which will enhance the product quality
& reliability with reference to Supplier’s past field experience.
Part Validation to be executed during the below stage of product development milestones.
RADIATOR FAN MOTOR
Development Milestone Type of Validation Expected Output

Concept Validation prior to Sourcing Nomination –
Concept Validation (Prior to
Basic Performance, Noise Measurement, Cranking Concept evaluation
Sourcing Nomination)
Performance, etc
Design Validation Design Validation prior to Concept freeze to execute Concept Design
(Concept Sample) detailed design Freeze
Complete Design Validation Green Design +
Complete Design Validation
(Alpha Sample) Tooling Clearance
Process Validation
Complete Production part and Process Validation Process Clearance
(Beta Sample)
PPAP Lot Validation PPAP performance Validation PPAP clearance
Pilot Lot Validation Pilot Lot Performance Validation Pilot Lot Clearance
SOP Validation SOP Validation SOP lot Clearance
4.5 Periodic Validation requirements (Design and Process)

A detailed test plan will be made along with the DVP and PVP to validate the product quality
periodically during the mass production throughout the program life. It is Supplier’s responsibility to ensure
the product quality is inline with the design which was validated.
If any issue, Supplier to share the comparison analysis report of the specific batch where the issue is
reported with reference to the master design samples.
RADIATOR FAN MOTOR
5. Reference documents / Standards

The supplier is requested to refer to the latest versions of the following documents. Vehicle
program specific references are not listed below. Such references shall be generated as per the program
requirements.
5.1 TML Documents

S No DOCUMENT ISSUE DESCRIPTION
1 TS 11414 Please Design for Recycling – Guidelines
refer to
Declaration of Part Material Weight Data &
2 TS 11420 the latest
Control of Hazardous Heavy Metals
issue
5.2 National / International Standards

S No DOCUMENT ISSUE DESCRIPTION
Road Vehicles – Environmental Conditions and Testing for
5 ISO 16750
Electrical and Electronic Equipment
6 IEC 60068 Environmental Testing
International Standard – Degrees of protection provided by
7 IEC 60529
enclosures (IP code)
Vehicles, Boats and Internal Combustion Engines – Radio
Disturbance Characteristics – Limits and Methods of
8 CISPR 25
Please Measurement of Radio Disturbance Characteristics for the
refer to Protection of On – Board Receivers
the latest Road Vehicles – Electrical Disturbances from Conduction
9 ISO 7637
issue and Coupling
Electromagnetic Radiation from Automotive Vehicle –
10 AIS 004
Permissible Levels & Methods of Tests
11 JIS D 1601 Vibration Testing Methods for Automobile Parts
Mechanical Vibration – Balance Quality Requirements for
12 ISO 1940
Rotors in a Constant (Rigid) State
Test for flammability of plastic materials for parts in Devices
13 UL 94
and application
Resolution of conflicts within this document:

In the event of a conflict between the text of this specification and one of the referenced
documents called by this document, the text of this specification takes precedence. However, in the event
of a conflict between this document and any applicable laws and regulations in countries where the vehicle
is marketed, the laws and regulations of those countries take precedence.
RADIATOR FAN MOTOR
6. Environmental Concerns
6.1 Use of Green Materials

As TML is committed towards green environment, we encourage our suppliers to increase the
usage ratio of the “Green Material” during each new development. Each new product must have increased
ratio of recycling materials.
6.2 Prohibited Materials

Supplier must consider the exclusion of prohibited materials like Mercury, lead, cadmium, 3TG
(Tungsten, Tantalum, Tin & Gold) and hexavalent chromium. Supplier must obtain a written permission
from TML if they need to use these prohibited material.
6.3 Platting Specific requirements

Supplier must select the platting considering the green environment and operating requirements
specified in this RFQ. Use of hexavalent platting is prohibited by TML and hence Supplier is not authorized
to use the same for any of the TML specific parts.
Supplier must share the platting Supplier details for each child part wise which is being used in all
the TML for approval and record. Supplier must obtain formal approval from TML if any change is required
on the platting supplier or platting process during the change in the mass production.
RADIATOR FAN MOTOR
7. Sub-Suppliers development requirements
As a part of the development, TML will visit the Sub-suppliers (Tier-2 and Tier-3) to perform the
detailed design review (product and tooling), process review, process audit and full day production run.
This audit will be performed at regular intervals during the product development period.
It is the TML’s direct Supplier responsibility to ensure the sub-supplier’s development capability in
line with TML requirements.
Following are the minimum requirements expected from the Sub-Supplier during the part
development for TML applications,
a. DFMEA and Design Review mechanism

b. Simulation Capabilities (Mold flow analysis, Pressure die casting flow analysis, etc)
c. Process FMEA and Process Capability for critical parameters
d. Basic Quality Systems (Control Plan, FIFO, Clear Work Instructions, etc) on Shop floor
e. CTQ and AOI Sign-off with Tier-1 Supplier.
RADIATOR FAN MOTOR
8. Serviceability requirements
Suppliers must ensure the product service support post warranty period during the complete
Vehicle Program life. Supplier must ensure the adequate service centres all over the India to support post
warranty requirements. List of authorized Service Centres and the contact details must be shared along
with the RFQ response sheet “Annexure-1”.
Supplier must share the list of serviceable parts along with RFQ response. Also Supplier must
prepare and sign-off the Complete Service Procedure before PPAP sign-off with TML.
8.1 Service Manual

The supplier shall provide the product service manual along with the technical proposal. This shall
include Radiator fan motor assembly procedure, failure analysis for the dealers to identify root cause.
8.2 Service Network to support serviceability

One of our mission is to provide best and quick service support to our royal Customers. To achieve
this we expect a broader service network from Suppliers to offer best and quick service to our Customer all
over India. Suppliers are requested to share the service network informations during the RFQ answering.
9. Product Logistics packing requirements – Regular Supply and Spare Parts
Supplier must prepare the logistics packing requirements inline with TML Logistics (Qty, weight,
identification, delivery lots, etc) and obtain the formal sign-off from TML before PPAP lot.
Similarly supplier must prepare the spares packing as per the TML spares (Qty, Weight,
identification, delivery lots, etc) and obtain the formal sign-off from TML before PPAP lot.
TML will validate the actual packing (OE + Spares Supply) during the PPAP lot as per the agreed
packing sign-off copy.
RADIATOR FAN MOTOR
10. Electrical requirements
10.1 Voltage
It should be able to operate between extreme systems voltage limits of 8V to 16V. Deviations in the
operating voltage, if required, shall be mutually agreed between TML ERC E&E and the supplier based on
specific vehicle program requirements –“Annexure-1”.
10.2 Current
The current requirements of the motor shall conform to drawing as per application specification-
vehicle program dependent “Annexure-1”. The supplier shall define the Inrush current, No-load current,
Running current and Stall current of the motor as measured at motor terminals shall be specified in the
drawing.
Typical plots are as shown in Fig. 1 and Fig. 2
10.3 Input power

The input power drawn by the motor shall conform to drawing as per application specification-
vehicle program dependent “Annexure-1”. The supplier shall provide the input power drawn by the motor
as specified in the drawing. Typical plot is as shown in Fig. 3
Fig. 3: Input power Vs Torque characteristics

RADIATOR FAN MOTOR
10.4 Armature resistance

The supplier shall provide the armature resistance value of the motor at 25⁰C and it shall conform
to drawing as per application specification “Annexure-1”.
10.5 Armature Inductance

The supplier shall provide the armature inductance value of the motor at 25⁰C and it shall conform
to drawing as per application specification “Annexure-1”.
10.6 Electrical time constant

Electrical time constant is the time required to reach 63.2% of final value of current in locked rotor
condition at 25⁰C. The supplier shall provide electrical time constant of the motor and it shall conform to
drawing as per application specification “Annexure-1”.
10.7 Motor back emf constant

The supplier shall provide the motor back emf constant at 25⁰C and it shall conform to drawing as
per application specification “Annexure-1”.
10.8 EMI / EMC requirements

The motor shall meet the EMI / EMC requirements as per application specification “Annexure-1”.
10.9 Demagnetization
The motor shall be able to withstand the worst case maximum current draw at a temperature most
susceptible to demagnetization at -30⁰C.
RADIATOR FAN MOTOR
11. Mechanical requirements
11.1 Output power

The motor power output requirement shall conform to drawing as per application specification
“Annexure-1”. Typical plot is as shown in Fig. 4.
Fig. 4: Output power Vs Torque characteristics
11.2 Torque speed characteristics

The torque-speed characteristic requirements of the motor shall conform to drawing as per
application specification“Annexure-1”. The supplier shall define the starting torque, no load torque,
running torque/speed and stall torque of the motor in the drawing. Typical plot is as shown in Fig. 5.
Fig. 5: Speed Vs Torque characteristics
11.3 Axial play

The axial play in the motor shall meet the requirements specified in the drawing as per application
specification “Annexure-1”.
RADIATOR FAN MOTOR
11.4 Radial play

The radial play in the motor shall meet the requirements specified in the drawing as per application
specification “Annexure-1”.
11.5 Shaft run-out

The circular run-out deviation (Total Indicator Run-out) in the armature shaft shall conform to
drawing as per application specification “Annexure-1”.
11.6 Rotor Inertia

The supplier shall provide rotor inertia of the motor and it shall conform to drawing as per
application specification “Annexure-1”.
11.7 Frictional constant

The supplier shall provide frictional constant of the motor and it shall conform to drawing as per
11.8 Mechanical time constant

The Mechanical time constant is the time required to reach 63.2% of speed under no load
condition with rated voltage applied at the motor terminals. The supplier shall provide mechanical time
constant of the motor and it shall conform to drawing as per application specification “Annexure-1”.
11.9 Motor time constant

The supplier shall provide the motor torque constant and it shall conform to drawing as per
11.10 Speed torque gradient (Speed regulation)

The supplier shall provide the speed torque gradient of the motor and it shall conform to drawing
as per application specification “Annexure-1”. Typical plot is as shown in Fig. 6.
Fig. 6: Speed Torque gradient
RADIATOR FAN MOTOR
11.11 Maximum axial load

The supplier shall provide the maximum axial load that the motor can withstand and it shall
conform to drawing as application specification “Annexure-1”.
11.12 Maximum radial load

The supplier shall provide the maximum radial load that the motor can withstand and it shall
conform to drawing as application specification “Annexure-1”.
11.13 Motor Mounting

The motor mounting shall be sufficiently rigid for the loads that it can encounter in the vehicle
environment. The mounting shall be done based on the application study and 3D packaging studies.
11.14 Shaft coupling requirements

The shaft coupling requirements of the motor is a specific vehicle program dependent. These
requirements shall be arrived based on the application study. The supplier shall propose the appropriate
shaft configuration for the application (Example: D shaft, H shaft etc) based on the application study.
11.15 Residual unbalance

The residual unbalance in the motor shall be within the limits as specified in ISO 1940 unless
otherwise the drawing states a different value as per application specification “Annexure-1”.
11.16 Blade unit retention

There should not be any loosening of blade unit when a torque is applied on the blade unit with
restrained shaft movement.
 Blade unit retained through pin and/or nut has to withstand 6 times the motor starting torque at
rated voltage.
 Blade unit retained through twist lock has to withstand 2 times the motor starting torque at rated
voltage.
11.17 Motor terminals

All the terminals should be able to withstand a push/pull force of 90 N, a bending force of 10 N and
a torsional force of 0.3 Nm. The orientation and sealing of the motor terminals shall be based on the
application study and 3D packaging studies.
RADIATOR FAN MOTOR
12. Thermal / Environmental requirements
12.1 Operating Temperature

The motor shall be able to operate within the temperatures from -20°C to 120°C unless otherwise
the drawing states a different operating temperature limits. Deviations in the operating temperature if
required shall be mutually agreed between TML ERC E&E, ERC Engines and the supplier based on vehicle
program requirements “Annexure-1”.
12.2 Storage Temperature

The motor shall be able to store under the temperatures from -30°C to + 130°C, unless otherwise
the drawing states a different storage temperature limits. Deviations in the storage temperature if required
shall be mutually agreed between TML ERC E&E, ERC Engines and the supplier based on vehicle program
requirements “Annexure-1”.
12.3 Operating humidity

The motor shall be able to operate within the humidity range as specified in the application
specification “Annexure-1”, unless otherwise the drawing states a different operating humidity limits.
Deviations in the operating humidity if required shall be mutually agreed between TML ERC and the
supplier based on vehicle program requirements. The humidity range shall be specified in the vehicle
program requirements.
12.4 Storage humidity

The motor shall be able to store within the humidity range as specified in the application
specification “Annexure-1”, unless otherwise the drawing states different storage humidity limits.
Deviations in the storage humidity if required shall be mutually agreed between TML ERC and the supplier
based on vehicle program requirements. The storage humidity range shall be specified in the vehicle
program requirements.
12.5 Altitude
The motor shall be able to operate within the altitude range as specified in the application
specification “Annexure-1”, unless otherwise the drawing states different altitude range. Deviations in the
altitude range if required shall be mutually agreed between TML ERC and the supplier based on vehicle
program requirements. The altitude range shall be specified in the vehicle program requirements.
RADIATOR FAN MOTOR
13. Other requirements
13.1 Noise
The sound level measurement shall be done inside an anechoic chamber on the solo motor
oriented as per vehicle condition at no load condition at 13.5 ± 0.2V. The motor shall be suspended at a
height of 1m from ground. Position of sound level meter microphones at five locations: one at 10cm axially
from the shaft end of the motor, second one at 10cm axially from the rear end (the other end of the shaft)
of the motor and remaining three at 10cm radially to the side of the motor centered on the frame. The
sound level shall be measured based on A – weighted measurements. The supplier shall provide the sound
pressure level Vs frequency plots and shall quantify the brush noise, bearing noise, gear noise etc. The
noise level measurement procedure and the limits are specific vehicle program dependent “Annexure-1”.
The Radiator fan motor shall be subjected to vehicle level noise tests. The noise generated during
the operation shall be subjectively assessed by TML NVH Jury. The motor with best noise perceived by TML
NVH Jury shall be kept at supplier location as master sample for future noise comparison.
13.2 Efiiciency
The efficiency of the Radiator fan motor at rated operating point has to be 70% minimum. The
supplier shall provide the efficiency plots for the motor. Deviations if any shall be mutually agreed between
TML ERC E&E and supplier based on specific vehicle program requirements. Typical plot is shown in Fig. 7.
Fig. 7: Efficiency Vs Torque characteristics
RADIATOR FAN MOTOR
13.3 PWM controlled motor (Optional Requirement)

The supplier shall provide the details of the form factor (ratio of rms to average value) with which
the motor can operate continuously without any overheating. Typical plot of the input current drawn by
the motor under steady state is as shown in Fig. 8.
The supplier shall provide the details regarding the EMI / EMC aspects of the motor with the
addition of PWM controller. Deviations if any shall be mutually agreed between TML ERC E&E and supplier
based on specific vehicle program requirements.
Fig. 8: Steady state Input current Vs Time characteristics with PWM controller
RADIATOR FAN MOTOR
14. Test requirements
The Radiator cooling fan motor shall fully comply with the Environmental and EMI / EMC test
requirements as defined in this specification. Also the Radiator cooling fan motor shall fully comply with
the test requirements specified in this section. Deviations if any between test conditions and level of
acceptance, addition / deletion of any other tests shall be mutually discussed and agreed between TML ERC
and the supplier.
DV testing and PV testing shall be carried out as per the test plan mentioned in “Annexure-13”. PV
testing shall be carried out after the Process establishment at both Motor and Radiator supplier end.
Supplier shall provide detailed test plan and keep it always updated. TML reserves the right to attend one
or various tests and jointly carry out analysis on samples under test.
During the program life, TML shall randomly pick up Radiator cooling fan motor from the
production line and shall carry or shall ask supplier to carry out any of the tests mentioned in this
specification. The Radiator cooling fan motor shall pass the test(s).
14.1 Performance / Functional tests
14.1.1 No Load test
Test condition:
The test is to be conducted on the Radiator cooling fan motor at no load oriented as per vehicle
condition with rigid mounting. The Radiator cooling fan motor is made to run for 60 seconds at rated
operating voltage of 13.5 ± 0.2V and at ambient temperature of 23 ± 5°C without any external load on the
motor shaft. The current drawn and the corresponding speed are measured.
Acceptance criteria:
The current drawn and the corresponding speed measured shall be within the limits as specified in
the drawing.
Test report Requirements:

 Test Results recorded during the testing.
• If any external and/or internal damage is observed photographs of the damage must be
provided.
 Details of test setup including photographs and parameters.
RADIATOR FAN MOTOR
14.1.2 Starting voltage test
Test condition:
The test is to be conducted on the Radiator cooling module assembly oriented as per vehicle
condition with rigid mounting. Starting with null voltage, increase the voltage in intervals of 0.1V at the
terminals of motor and at ambient temperature of 23 ± 5°C and measure the voltage at which fan start
rotating.
The component must start rotating for a voltage level of 3 V maximum.

• If any external and/or internal damage is observed photographs of the damage must be provided.
14.1.3 Starting behaviour test
Test condition:
The test is done on the Radiator cooling module assembly oriented as per vehicle condition with
rigid mounting and at rated operating voltage of 13.5 ± 0.2V as applied at motor terminals at ambient
temperature of 23 ± 5°C. The peak current is recorded during the starting and a graph is plotted between
current and time as shown in Fig. 9. Typical values of T1 and T2 are 75 ms and 150 ms respectively. Data
recording frequency must be in steps of 1mSec.
Fig. 9: Starting current Vs Time characteristics
RADIATOR FAN MOTOR
The peak current draw during starting shall be within the limits as stated on the drawing.

 If any external and/or internal damage is observed photographs of the damage must be
provided.
 Details of test setup including photographs and parameters
14.1.4 System performance test
Test condition1:
a. The motor is made to run at rated operating voltage of 13.5 ± 0.2V & 12.0 ± 0.2V with a design
intended fan and shroud without heat exchanger load.
b. The current draw, air flow, pressure rise and the corresponding speed are measured.
Test condition2:
a. The motor is made to run at rated operating voltage of 13.5 ± 0.2V & 12.0 ± 0.2V with a design
intended fan and shroud on the core envisaged.
b. The current draw, airflow, pressure rise and the corresponding speed are measured.
The above test shall be done at Both High Speed and Low Speed of the Motor at Different
Temperatures (i.e. -20⁰C, -10⁰C, 25⁰C, 90⁰C & 120⁰C) and the system shall deliver the minimum airflow
performance required as per vehicle requirements.
The current draw at different speeds and voltages shall be within the limits stated on the drawing.
The torque-speed characteristic requirements of the motor, airflow and pressure rise requirements at
different voltages shall be within the limits stated on the drawing.

 Results of the functional testing carried out.
provided.
 Measurements have been tabulated at different temperatures (Pressure, Flow, Speed, Current,
and Efficiency).
RADIATOR FAN MOTOR
14.1.5 Motor characteristic tests
Test condition:
a. The motor is made to run at rated operating voltage of 13.5 ± 0.2V and at ambient temperature
of 23 ± 5°C without blade unit on a test bench and a braking torque is applied such that the
motor rotates at the rated speed as specified in the drawing. The power output and current draw
of the motor is measured at this operating point.
b. Apply braking torque such as to bring motor to specified speed and measure maximum power
output and current draw.
c. Increase the braking torque in steps until the motor reaches the standstill condition, at each step
the current draw and speed are measured at that applied braking torque and a graph is plotted
as shown in Fig. 10.
Fig. 10: Motor characteristics
Minimum 5 points to be captured in-between No load to stall condition. The above test shall be done
at Both High and Low Speed of the Motor and the motor shall deliver the minimum performance required
as per vehicle requirements.
The current drawn at different speeds shall be within the limits stated on the drawing. The torque-
speed characteristic requirements of the motor shall be within the limits stated on the drawing. The motor
power output shall meet the requirement as per drawing.

 Results of the functional testing carried out.
• If any external and/or internal damage is observed photographs of the damage must be provided.
 Measurements have been tabulated at different temperatures (Torque, Speed, Current, and
Efficiency).
RADIATOR FAN MOTOR
14.1.6 Temperature rise test
Test condition:
The test is to be conducted on the motor with rated torque applied to shaft at test voltage of 13.5
V as applied at motor terminals with ambient temperature of 120 ± 5°C. The motor is made to run
continuously for 1 Hr. During the test, temperature measurements need to be carried out at different
locations in the motor as mentioned in below table and supplier has to share this information.
Max. Temp Continuous Peak Peak Temp Time

On +Ve Brush
On -Ve Brush
On +Ve Brush
On -Ve Brush
On Brush Plate
On End Cover Bush/Bearing
On Motor Body
There should not be any failure, distortion or damage which could be detrimental to the operation
of motor. The temperature rise allowed on the motor windings shall be decided based on specific vehicle
program requirements “Annexure-1”. All the motor samples are torn down and evaluated for any signs of
abnormal wear or potential failure. If any concerns arise, they should be documented.

 Results of Performance before and after testing.
provided.
 Measurements have been tabulated.
RADIATOR FAN MOTOR
14.1.7 Locked rotor test
Test condition:
The motor shall be activated with locked rotor condition oriented as per vehicle condition with
rigid mounting at ambient temperature of 23 ± 5°C with rated voltage of 13.5 ± 0.2V as applied at motor
terminals. The test is continued till the motor fails. The time duration till the motor fails shall be recorded.
The power supply shall be capable of supplying sufficient current to avoid current limiting under high in-
rush conditions The motor shall be stripped open for the failure analysis after the test and the same shall
be submitted to TML. This is a data generation test.
The failure mode shall confirm that it will not cause any thermal incidence in the vehicle
environment.

• The time duration at which the motor fails.
 The current drawn by the motor and temperatures at various locations in the motor like on the
yoke, brush box, commutator, bearings, end plates etc.
14.1.8 Tri-voltage tri-temperature test
Test Conditions:
The Functional/Parametric test shall be performed at three different ambient temperatures (low,
room and high) and three different power supply operational voltages (low, nominal and high) as specified
in the validation test. The temperature shall be stabilized for at least 0.5 hours prior to the
Functional/Parametric Test.
The power supply shall be capable of supplying sufficient current to avoid current limiting under
high in-rush conditions.
All Functional/Parametric tests must be conducted with actual vehicle loads or simulated loads.
The Simulated loads require the approval of TML, ERC Pune.
Parametric test at:

Temperature (°C) Power Supply (12V)
+120 8V, 13.5V, 15V
+25 8V, 13.5V, 15V
-20 8V, 13.5V, 15V
Precondition the Device at test temperature

Minimum dwell time before starting the electrical tests at each temperature shall be 1 hour.
RADIATOR FAN MOTOR
Fig. 11: Definition of parametric temperature-voltage points
Test Procedure:
The Device were parametrically tested at the nine temperature-voltage points defined in Fig 11
prior to and post environmental exposure.
Performance of the Device is measured against limits established in the Performance & Verification
Document done by the supplier and also to be implemented within the manufacturing test system
software.
• Motor must meet all functional requirements during Pre and Post-test without any distortion.

 Test Results of Speed and Current during Pre and Post-test.
 Results of Speed and Current during the testing at different temperatures and voltages.
• Results of external and internal analysis before and after testing.
provided.
RADIATOR FAN MOTOR
14.1.9 General characteristic tests
14.1.9.1 Visual examination

Test condition:
Before testing, the component must comply in all respects with the drawing and be free of visible
faults such as scratches, spots of adhesive, deformed sub components, etc. Following aspects to be
validated during this examination:
A. Drawing requirements
• All dimensions within tolerances
• Material specification
B. Housing and Cover

• Visible cracking or weakened points
• Discolouration
• Warpage
• Melting
C. Connectors
• Plastic cracks
• Bent/damaged pins
• Excessively loose
• Warpage
• Discolouration
• Damaged connector body features
D. Minor external cosmetic damages – Housing, cover and connectors

• Scratching/Scuffing of surface
• Dented corners
• Visible hairline cracks
E. Labels
• Fading of label
• Discolouration
• Text on label smudges
• Text on label becomes illegible
• Label no longer adheres to housing (adhesive weakens)
• Label melts
• Part must meet all the above criteria’s as per drawing specification.
RADIATOR FAN MOTOR
14.1.9.2 Robustness of terminations, mounting fasteners etc.
Test condition:
The terminal should withstand a push/pull force of 90 N; bending force of 10 N and torsional force
of 0.3 Nm. Device shall meet the mounting fastener torque requirements.
 No damage or anomalies on visual inspection after the test.
• Device shall meet functional parametric requirements after the test.
• Deformation of parts that can adversely affect the performance of the component is not
permitted.

 Test Results of Performance before and after testing.
provided.
14.1.9.3 Conductor tensile strength
Test condition:
The component should withstand a tensile force of 100 N on each pre-wired bunch of conductors
in the direction in which they leave the component and at 90°.
 Device shall meet functional parametric requirements after the test.
 All the items should be operational.

provided.
RADIATOR FAN MOTOR
14.1.9.4 Forces on connector

Inspection:
Before starting the environmental test the Device have to pass the initial performance tests and
may not show any mechanical damage on the visual inspection.
Test condition:
Reference document : IEC 512: Part 8
Pressure at the connector : (110 ± 5) N for 1 minute (for mating and retention of connector)
Tensile force per connector/cable: (100 ± 5) N for 1 minute
Test temperature : 23±5°C
Operating mode : No lines are connected to the Device
 The Device may not show any mechanical damage like crack or deformation. A displacement of
the plug in the housing or a loosening of the connection plug to housing is not allowed.

provided.
RADIATOR FAN MOTOR
14.1.10 Environmental tests
14.1.10.1 High & Low temperature storage
Reference Document: IEC 60068-2-1, A
Purpose:
The purpose of this test is to verify that a component or system can withstand the effects of
extremely low and high temperatures encountered in vehicles or in storage.
Test condition:
Testing shall be in accordance with this document and IEC 60068-2-1, A
Test parameters:
Minimum Temperature (Tmin) -20°C ± 3°C for 48 hour
Maximum Temperature (Tmax) 120°C ± 3°C for 48 hour
Room Temperature at 23°C 1 hour in operating condition at High speed
Total Test Duration 97 hours
Number of Test Cycle (NCycle) 1
Temperature Reference Point Ambient temperature (Chamber temperature)
Operating temperature range -20°C to +120°C
Table 1: Test Parameters - High and low temperature storage
Fig. 12: Definition of High and Low temperature storage

RADIATOR FAN MOTOR
Initial Evaluation of Test:
Functional check and visual check shall be conducted before loading the Device. Visual check shall
be done after the loading.
Test procedure:
 At the beginning of the test the Device shall be at the ambient temperature of 23 ± 5°C the
laboratory.
 Place the Device in a temperature chamber.
 Subject the Device to NCycle according to the test cycle profile given above.

 No critical housing deformations.
 There should not be any change in noise level after the test.
 Results of the functional testing carried out before and after testing.
 Results of external and internal analysis before and after testing.
 If any external and/or internal damage is observed, photographs of the damage must be
provided.
RADIATOR FAN MOTOR
14.1.10.2 Thermal shock test (air to air)
Reference Document: IEC 60068-2-14
Purpose:
The purpose of this test is to verify that the component or system is able to operate in the changing
temperature conditions encountered in a vehicle environment. Typical failures experienced are due to
different coefficients of expansion of materials, bad solder joints, die bond separation, and temperature
related problems attributable to circuit design or weak components. This test is not a life test (50 % of the
Device are tested without housing, if the devices utilize PCB technology. Device without housing (opened)
shall not be subjected to any further testing.
Test condition:
Testing shall be in accordance with this document and IEC 60068-2-14
Test description:
Temperature at start of test Room Temperature at 23°C
Upper Temperature 120°C
Lower Temperature -20°C
Operation mode No lines are connected to the Device
Storage time at upper temperature (Tmax) 30 minutes
Transfer time ≤ 3 Minutes
Storage time at lower temperature (Tmin) 30 minutes
Number of cycles (N cycle) 100
Recovery time at 23°C 1hour
Device Operating temperature range -20°C to 120°C
Table 2: Test Parameters – Thermal shock test
RADIATOR FAN MOTOR
Fig. 13: Definition of Thermal shock test
Functional check and visual check shall be conducted before the loading the Device. Visual check
shall be done after the loading.
Test Procedure:
 At the beginning of the test, the Device shall be at ambient temperature of the laboratory
 Place the Device in a dual zone thermal shock chamber with mating connectors and adjust the
temperature to zones to Tmin and Tmax
 Maintain the Device at temperature Tmin for 30 minutes
 Transfer the Device from the Tmin zone to the Tmax zone within 3 minutes
 Maintain the Device at temperature Tmax for 30 minutes
 Transfer the Device from the Tmax zone to the Tmin zone within 3 minutes
 Repeat the thermal cycles (steps 3 through 6) for 100 cycles
 The Device shall then remain for the 1 hour under standard atmospheric conditions for the
attainment of temperature stability
RADIATOR FAN MOTOR
 No damage or anomalies on visual inspection after the test
 Device shall meet functional parametric requirements after the test
 No critical housing deformations
 No anomalies in visual tear down analysis
 Full functionality of electrical and mechanical junctions.

 Results of the functional testing carried out before and after testing
 Results of external and internal analysis before and after testing
provided
RADIATOR FAN MOTOR
14.1.10.3 Thermal shock with splash water test
Reference Document: ISO 16750-4
Purpose:
This test simulates a thermal shock induced by cold water and is applicable to components in the
splash areas of the vehicle. The purpose is to simulate cold water splashing over a hot system/component,
as can happen when a vehicle is driven on wet roads in winter. Failure modes are mechanical cracking of
materials or seal failures caused by differential thermal expansion coefficients. An additional failure mode
is a loss of water tightness and the intrusion of water into the system/component.
Test Condition: Testing shall be in accordance with this document and ISO 16750-4.
Test Parameters:
Temperature at start of test 120°C
Water specification De-ionized water
Exposure time at 120°C t1 = 60 minutes
Electrical operation at 120°C t2 = 30 minutes
Splashing period t3 = 1 minute
Systems/components with function and activation in high
Operation mode
speed operating mode
Amount of water to be splashed 300ml / cycle (At least 3 points on the motor)
Orientation of the Device As in the vehicle.
Number of cycles(Ncycle) 10
Splash water temperature (Ts) 5 to + 10°C
Table 3: Test Parameters – Thermal shock with splash water test
Fig. 14: Thermal shock with splash water

RADIATOR FAN MOTOR

Test Procedure:
 Place the sample in a hot air oven at Tmax of 120°C for time t1.
 Operate the sample as per normal vehicle operation in high speed for time t2.
 Then splash the water on sample for time t3.
 The splash coverage should represent the splash direction (s) that is likely to occur in the vehicle
but the splash width should always be greater than the sample width
 No damage or anomalies on visual inspection after the test
 Device shall meet functional parametric requirements after the test
 No critical housing deformations
 No anomalies in visual tear down analysis

provided
RADIATOR FAN MOTOR
14.1.10.4 Water spray test

Purpose: The resistance of the Device against penetration of spray water is tested.
Test condition: According to TS. Spec. 75009 (IS 9000 part 16).
Test Parameters:
Test Duration (t1) 8 Hours
Number of Test Cycle (’N’ Cycles) 1
Device Temperature (TDevice) Room Temperature at 23°C
Test Equipment Water jet nozzle 6.3 mm diameter as per ISO 20653
Distance between Nozzle and Device 2.5 m to 3m
Rotation Speed Turn Table 2 rpm
Device Test Position In-vehicle mounting orientation
Operation/Monitoring Mode All lines are connected according to vehicle installation,
but no voltage is applied
Water Temperature (T Water) TDevice ± 5 °C
No of nozzles 8
Water Flow Rate 12.5 l/min ± 5%
Water Pressure at spray nozzle Approx. 200 kPa
Table 4: Test Parameters – Water spray test
Test Procedure:
 Connect original connectors to the Device unless still connected from the preceding dust test.
 Do not open the Device before the following functional/parametric test.
 Adjust the flow rate of the high-velocity water according the parameter given above.
 Each Device shall be attached to the spray chamber turntable in-vehicle mounting orientation.
 Subject each Device to the high-velocity water while rotate the Device.
 At the end of the test, the seals of the Device must not be impaired in their function.
 The Device should meet requirements of performance test after the testing.

provided
RADIATOR FAN MOTOR
14.1.10.5 Dust test

Purpose: The resistance of the Device against penetration of dust is tested.
Test condition: As per TS75010 (IS 9000 part 12).

Test Parameters:
Total Test Duration

Engine compartment 8 hours
Passenger compartment 2 hours
Test Temperature (T) In dry environment (Dust to be heated to 40±3 °C before
use)
Relative Humidity (RH) (25 to 75) %
Test Equipment size 1 cubic meter
Dust Type ISO 12103-A2 acc. to ISO 12103-1 (fine test dust)
Temperature Reference Point Ambient temperature (chamber temperature)
Device Test Position In vehicle mounting orientation
Operation/Monitoring Mode All lines are connected according to vehicle installation, but
no voltage is applied
Number of Test Cycles (‘N’ Cycles) 20
Test Cycle Duration, 15 min
Dust Settling Time (t2)
Air/Dust Mixture Circulation Time(t1) 5 s
Table 5: Test Parameters – Dust test
Test Procedure:
 Connect original connectors to the Device.
 At room temperature RT, place the Device in a dust chamber oriented to represent the in-vehicle
mounting orientation.
 Circulate the air/dust mixture for the time t1, followed by a settling period of time t2. Repeat this
cycle for ‘N’ Cycles.
 Following the test, remove the Device from the chamber and remove accumulated dust by
brushing, wiping or shaking, care being taken to avoid introduction of additional dust into the
Device. Under no circumstances shall dust be removed by either air blast or vacuum cleaning.
RADIATOR FAN MOTOR
 At the end of the test, the seals of the Device must not be impaired in their function.
 The Device should meet requirements of performance test after the test.

 If any external and/or internal damage is observed, photographs of the damage must be provided.
RADIATOR FAN MOTOR
14.1.10.6 Corrosion resistance test

Purpose:
The corrosion resistance of the Device against salt spray fog and salt water is tested.
Test condition:
As per TS 75005 (IS 9000 part 11).
Initial evaluation of test:

Test Parameters:
Total Test Duration 150 hours
Test Cycle Duration 24 hours
Number of Test Cycle (’N’ Cycles) 6
Test Cycle One cycle consists of 25 hrs (Salt spray for 24hrs and 1hr rest).
In 24hrs, 4Hrs Function is OFF and 1Hr ON. Repeat this for 5
times. See below figure.
Test Temperature (T) (35 ± 2) °C
Salt Solution NaCl concentration: (5 ± 1)%
pH, value at RT: 6.5 to 7.2 (acc. IEC 60068-2-11)
Operation/Monitoring Mode As shown in below figure.
Table 6: Test Parameters – Corrosion resistance test
Fig. 15: Test cycle for salt spray

RADIATOR FAN MOTOR
Test Procedure: (Refer Fig 15 for test cycles)
 All surfaces shall be clean and free from oils, greases or other protective materials not part of the
design.
 Place the Device in a salt spray chamber at temperature T in their in-vehicle mounting orientation
(reference the definition of axis as per drawing). The samples shall not be in contact with each
other or with other metal parts, and shall be so arranged as to exclude any influence of one part
upon another.
 Spray the Device for 24 h, and then stop spraying for a rest period of 1hr.
 Open the top hood during the rest period of last 1hr in each cycle.
 Repeat the spray cycles (step 3) for a total number of ’N’ Cycles.
 At the completion of the test, the samples shall be washed in running tap water for minimum 2
minutes until all residues of salt solution on the surface are removed or if this is not possible for a
maximum of 5 minutes. The temperature of the water used for washing shall not exceed +35 °C.
Then subject the Device to air blast at a pressure not exceeding 200 kPa and at a distance of
approximately 300 mm to remove droplets of water and dry.
 The samples shall be stored at room temperature for 24hr prior to performing any post-test
measurements.
 At the end of the test, the Device must not be impaired in their function
 There shall not be any red corrosion on any part of motor.
 Maximum performance deterioration is allowed to 10%
• There should not be any change in noise level after the test.

• Results of the functional testing carried out before and after testing.
provided.
 Corrosion level – Red, white and rust status of all parts.
RADIATOR FAN MOTOR
14.1.10.7 Fluid resistance test

Purpose:
The resistance of a Device to various chemical agents is tested. Components and associated parts
that can come into contact with the specified chemical agents shall be resistant to those agents. They shall
be tested with all agents they are likely to come into contact with, except for those materials which can be
shown by documentary evidence to be immune to the contaminant, which need to be tested.
Test condition: Testing shall be in accordance with this document.
Initial evaluation of test:

Functional check and visual check shall be conducted before the test. Visual check shall be done
after the test. Execution of the test with the unaided ametropic eye with normal colour perception and
from a normal distance at sufficient illumination.
Test Parameters:
Test Temperature 23°C

Storage Time (t1) at T 24 hours
Temperature Reference Point Ambient temperature
Operation/Monitoring Mode All lines are connected according to vehicle installation,
but no voltage is applied
Table 7: Test Parameters – Fluid resistance test
Application Method:
Application by Description
Spray Spray the Device with the chemical agent.
Table 8: Application method for Fluid resistance test
Test Procedure:
The sample shall be subjected to the following conditions in non-operating mode,
General Fluid temperature: 27 ± 5 °C
Duration of application of fluids: 5 minutes
Test Method:
The samples shall be mounted as per vehicle level conditions. Sealed samples shall have their
harness connectors mated and fully sealed. The samples shall be tested for resistance to contaminants.
Maximum 2 samples shall be used to validate below tests. The samples shall be tested for applicable fluids
based on installation area identified in below Table.
RADIATOR FAN MOTOR
S. No Testing fluid / chemical / oil Specification

1 Brake / Clutch fluid DOT3/DOT 4
2 Diesel Fuel BS EN 590 1993, IS: 1460.
3 Electric grease Connector
4 Engine bay lacquer
5 Engine Cleaning Solvent Gunk
6 Engine Oils ASTM D-471
Oil1
7 Engine coolant
8 Manual Gearbox / Hypoid Oil ASTM D-471 Oil 3
9 Unleaded Petrol 50 % Toluene, 50% Tri-Methyl, Pentane
Table 9: Contaminants (Availability of contaminants)
 Normally visible areas shall not have suffered any noticeable degradation or loss of clarity of
markings.
 The Device should meet requirements of performance test after the test.

provided.
 Photographic evidence showing the state of the Device after testing as either confirmation of no
change or showing the nature of any change that has occurred.
RADIATOR FAN MOTOR
14.1.10.8 Damp heat steady state test

Reference document: ISO 16750-4
Purpose:
The purpose of this test is to determine the effect of high humidity at a constant temperature,
without condensation on the sample.
Test Conditions:
Test to be performed in accordance with ISO 16750-4, 2010 Clause 5.7 Standard. Also refer IEC
60068-2-30 for equipment and cycle details.
Test Parameters:
Total Test Duration 21 days
Maximum Temperature (Tmax) (40 ± 2) °C
Relative Humidity (RH) 93 % ± 3%
Operation/Monitoring Mode Systems/components with function and activation in
high speed operating mode
Table 10: Test parameters – Damp heat steady state

Before starting the environment test the Device shall pass the preceding functional/parametric
tests and may not show any mechanical damage on the visual inspection.
Test Procedure:
 Place the Device in a climatic chamber at temperature (25 ± 2) °C and relative humidity (95 ± 3)
RH.
 Perform the test by adjusting climatic chamber +40 °C at 95 % RH for 21 days.
 On completion of the test, Device shall be removed from the chamber and shall be kept under
standard atmospheric conditions for a period of 24 h before the specified post-
functional/parametric tests shall be done.
 The test sample must be fully capable of functioning during and after the test.
 The sample shall display no visible deleterious effects such as cracking, warping, swelling or
softening. No critical housing deformations.

provided.
RADIATOR FAN MOTOR
14.1.10.9 Dynamic test

The motor along with a design intended fan, shroud and heat exchanger is mounted on a test rig
simulator oriented as per vehicle condition is installed on vibration bench retaining at the same points and
using same means as on vehicle. The motor assemblies must be analysed for any signs of mechanical
damage after the test. Mechanical damage is broadly described as any kind of failure ranging from hairline
cracks to the most obvious of fractures and cracks, including but not limited to loose endplates, bearings,
endplay exceeding design limits, mounting flange movement, etc., anywhere on the motor (internal or
external) which includes either mechanical or electrical failure of the motor.
14.1.10.9.1 Sine vibrations

Reference document: IEC 60068-2-6
Purpose:
The vibrations occurring on an internal combustion engine are composed of the two following types:
 Excitation with sinusoidal vibrations resulting from piston movement &
 Excitation with wide band random vibrations resulting from all other movements.
Test Conditions: Testing shall be in accordance with this document and IEC 60068-2-6
Test Parameters: (Refer Table 11, Table 12 & Fig. 16 for Test conditions)
Test Cycle Duration 8 hours for each plane of the Device

Number of Test Cycle (’N’ Cycles) 1 cycle each axis
Maximum Temperature (Tmax) 120 °C
Minimum Temperature (Tmin) 25 °C
Device Test Position/Orientation As mounted in vehicle
High speed operating mode
Sweep rate 10 Minutes
Voltage - 12V System 13.5V
Table 11: Test condition – Sine vibrations
Frequency Amplitude of acceleration Time at Each

(Hz) (m/s2) Frequency (Min)
100 100 1
150 150 2
200 200 2
240 200 2
255 150 2
440 150 1
Table 12: Amplitude parameters – Sine vibrations
RADIATOR FAN MOTOR
Fig. 16: Sinusoidal vibration
 All functions of device should perform as designed during and after exposure to disturbance.
 The Device shall be inspected visually after the environmental test. Mechanical damage like
cracks or deformations is not allowed.
 No disturbing noise may occur for any operating type.
 No anomalies in visual tear down analysis.
 Part must be fully functional after the test.

 Performance test results carried out before and after testing.
 Plots of Device acceleration.
 Logs of monitored parameters made during the test.
provided.
 Vibration profile.
 Fasteners tightening torque before and after the test.
RADIATOR FAN MOTOR
14.1.10.9.2 Random vibrations

Purpose: The equipment should withstand random vibration induced by rough-road-driving.
Inspection:
Test Condition: Perform the test according to IEC 60068-2-64.
Test Parameters: (Refer Table 13, Table 14 & Fig. 17 for Test conditions)
Test Cycle Duration 8 hours for each plane of the Device

Number of Test Cycle (’N’ Cycles) 1 cycle each axis
Maximum Temperature (Tmax) 120 °C
Minimum Temperature (Tmin) 25 °C
Device Test Position/Orientation As mounted in vehicle
RMS Acceleration 28 m/s2
Voltage - 12V System 13.5V
Table 13: Test condition – Random vibrations
Fig. 17: Random vibration
RADIATOR FAN MOTOR
Frequency (Hz) PSD ((m/s²)²/HZ)

10 20
55 6.5
180 0.25
300 0.25
360 0.14
1000 0.14
Table 14: PSD values – Random vibrations

provided.
RADIATOR FAN MOTOR
14.1.10.9.3 Mechanical shock test

Purpose:
The fast driving over curbstones and deep potholes is simulated.
Test Conditions:
Testing shall be in accordance with IEC 60068-2-27.
Test Parameters:
Shock Form (Pulse Shapes) Half-sinusoidal

Shock Pulse Duration (nominal) 11 ms
Acceleration 150 m/s²
Temperature Reference Point 23 °C
Device Test Position As mounted in vehicle
Pulse direction Same direction as for the Device installed in the vehicle
Total number of shocks/axis 20 (10 positive + 10 negative)
Table 15: Test condition – Mechanical shock test
The Device to be exposed to half sine mechanical shock pulses, ten in each opposite direction of
each perpendicular axis as per table given below. The tests shall be performed on all three perpendicular
axes and in both directions.

Test Procedure:
The mechanical support of the cable harness has to be on the vibration fixture. A cable harness
true to the original cable harness in the vehicle has to be used (same cable width like in the vehicle; no
additional cables in the harness are allowed. The mechanical support of the cable harness has to be on the
vibration fixture. Vibration/pulse control is on the vibration fixture. Demonstrative acoustical behaviour
(noise, rattling) has to be documented.
The Device shall be fixed on the shaker in a direction to generate the effect of acceleration in the
same direction as it occurs in the vehicle use. Acceleration resulting from the shock in the test shall be in
the same direction as the acceleration of the shock that occurs in the vehicle.
The cable harness has to be reinforced (fixed) in a distance of (15 ± 2) cm to the connector. Apply a
half-sine shock pulse (number of shocks, direction and test temperature see table 15).
RADIATOR FAN MOTOR
 There should be no change in contact path.

provided.
RADIATOR FAN MOTOR
14.1.10.9.4 Resonance point detection & vibration endurance test

Test condition:
The resonant frequencies in all the three axes shall be determined by varying the vibration
frequency from 5 to 400 Hz with a sweep time of 20 minutes minimum at an acceleration of 5 to 45 m/sec2
and total amplitude of 0.4mm max as per JIS D1601.
Vibration endurance test:-
Test condition 1 [Where there is no resonance]:

The test is done at an acceleration of ± 4.5g at test table on the motor at a frequency of 33 Hz for
duration of 4h in vertical axis and 2h each in transverse and longitudinal axis as per JIS D1601.
Test condition 2 [Where there is a resonance]:

 The vibration endurance test is carried out at the resonance frequency of the part and at
amplitude as specified in JIS D1601 for a duration of 4h in Z axis and 2h each in X and Y axis.
 After endurance at resonance frequency is carried out, the component is subjected to endurance
at an acceleration of ± 4.5g at test table on the motor at a frequency of 33 Hz for duration of 3h
in vertical axis and 1.5h each in transverse and longitudinal axis as per JIS D1601.
The vibration level is specific vehicle program dependent “Annexure-1” if the drawing states a
different value same needs to be followed as per the requirement.

provided.
RADIATOR FAN MOTOR
14.1.10.9.5 MEOST test

Purpose:
The purpose of this test is to validate the Radiator fan Motor robustness against the multi
environment operating conditions.

Before starting the environment test the Device shall pass the preceding functional/parametric
tests and may not show any mechanical damage on the visual inspection.
Test Conditions:
Refer below individual test criteria for detailed set-up.
Note:-Above tests are carried out as per the test conditions specified in this document with relevant test
RADIATOR FAN MOTOR
Test Procedure:
 Execute the test as per the sequence listed below,
 No Part replacement, dismantling and reassembling is allowed in between the test cycle.
 Test cycle to be continued as per the flow without any abnormal break in between the tests.
 Tests are classified to two different operating groups and 2 Radiator Fan Motor samples to be
tested as per each group requirement.
 The test sample must be fully capable of functioning during and after the test.
 No visual deterioration or degradation should occur.

provided.
RADIATOR FAN MOTOR
14.1.10.10 Over voltage test

Purpose:
The purpose of the test is to verify Device immunity to higher than normal operations and surges
that may occur during over voltage. This test simulates over voltage conditions produced by Fails of
generator regulator.
Test conditions: As specified in ISO 16750-2:2003 section 4.3.
The test conditions shall be applied to all the relevant inputs of the device simultaneously.
Fail of generator regulator:

- The test shall be done at T= 100⁰C
- The voltage shall be applied to all relevant inputs of the device following the conditions shown in
Table
Power Supply System Test Temperature Voltage applied Test Time
12V T= 100⁰C 18V 1 hour
Table 16: Test conditions over voltage test (generator regulator fails)
Device operating modes:

• Electronic modules and active modules shall be tested at least in two modes: device normal
operation (device in RUN MODE) and Standby or Sleep mode (device in KEY ON MODE)
• Electronic modules shall be tested in RUN MODE in all the different speed configurations,
otherwise specified in the test plan. The Electronic modules shall be tested also in KEY ON MODE.
Test procedure: As specified in ISO 16750-2.
Calibration: A special calibration is not required to perform this test. All the instrumentation used to
perform the test shall be within its calibration period.
• Set the Device in a room temperature at T= 100⁰C

• Set the programmable power supply in order to obtain the voltage level shown in the Table 16
depending of the Device power supply system (12 V).
• Apply the voltage to all the Device power supply lines during 1 hour.
• Monitoring all the Device parameters and the associated loads during the test.
 All functions of a device/system perform as designed during exposure. However, one or more of
them can go beyond specified tolerance. All functions return automatically to within normal
limits after exposure is removed.
 There should not be malfunction during the test.
 Function should have no abnormality.
RADIATOR FAN MOTOR
Test report requirements:

• Photos of the test setup
• Device operation mode during the test.
• Description of the Device inputs lines under test.
• Data table with the following parameters measured during the test: Power supply voltage
applied during the test, input lines of the Device tested, test time, test temperature and Device
performance.
• A description of the failure (if apply) specifying the Device performance during the test, test
temperature, input voltage applied and the performance of the associated loads.
14.1.10.11 Dielectric Strength test
Purpose:
The purpose of this test is to ensure the dielectric withstand voltage capability of circuits with
galvanic isolation. This test is required only for Device which contain inductive elements (relays, motors,
coils) or connected to the circuit with inductive loads.
This test stresses the insulation system and checks the ability of the dielectric materials to
withstand the higher voltage caused by switching of inductive loads.
Test Conditions:
• The Device shall be tested at a severity level of 1000 Volts AC, 40 to 60 Hz, to 12 V Devices.
• Before start the test, perform a “Test 1: damp heat cyclic” test in accordance with ISO 16750-
4:2006.
• The Device shall remain 0.5 hour at room temperature after the damp heat test.
• The test shall be performed over a non-conductive surface.

This test shall be carry out in OFF mode (Device not supplied and not connected to the harness)
Test procedure:
Calibration:
A special calibration is not required to perform this test. All the instrumentation used to perform
the test shall be within its calibrated state.
Test:
• Apply the disturbance during 60 seconds:
- Between terminals without galvanic isolation
- Between terminals and housing with electrically conductive surface with galvanic isolation
- Between terminals and an electrode wrapped around the housing (Metal foil for example) in
the case of plastic material housing (Before carrying out this test between body and each of the
terminals, if any of the terminals are internally ground the earth connection should be
disconnected).
RADIATOR FAN MOTOR
• Power up the Device to the nominal voltage until it reaches its normal performance and performs
a functional verification.
• No arcing or puncturing of insulation is allowed.
• To satisfy functional performance after the test.
• One or more functions do not perform as designed during exposure but returns automatically to
normal operation after exposure is removed. Malfunctioning is not permissible.
• Leakage current should not be more than 5mA.

• Photos of the test setup.
• Data table with a description of the terminals or lines tested in each case and the leakage current
value between the terminals.
• Any abnormal behaviour of the Device after the test shall be reported.
14.1.10.12 Insulation resistance test

Purpose:
This test ensures a minimum value of ohmic resistance required to avoid current flow between
galvanically isolated circuits and conductive parts of the Device. The test gives an indication of the relative
quality of the insulation system and material.
Test conditions:
• The Device shall be tested at a severity level of 500 Volts DC, for 12 V and 24 V Devices.
• Before start the test, perform a “Test 1: damp heat cyclic” test in accordance with ISO 16750-
4:2006.
• The Device shall remain 0.5 hour at room temperature after the damp heat test.
• The test shall be performed over a non-conductive surface.

This test shall be carry out in OFF mode (Device not supplied and not connected to the harness)
Test procedure:
Calibration:
A special calibration is not required to perform this test. All the instrumentation used to perform
the test shall be within its calibrated state.
Test: Apply the voltage to the Device for 60 Seconds or during the time needed to obtain a stable
measurement, as follows:
- Between terminals with galvanic isolation
- Between terminals and housing with electrically conductive surface with galvanic isolation
- Between terminals and an electrode wrapped around the housing (e.g. metal foil) in the case of
made of plastic material.
RADIATOR FAN MOTOR
• The insulation resistance shall be greater than 10 MΩ.

• Photos of the test setup.
• Data table with a description of the terminals or lines tested in each case and the insulation
resistance value measured.
14.1.11 EMI / EMC test
Radiated Emission, Conducted Emission and Conducted Transient Emission:
Reference Document: CISPR25:2008
Purpose:
The purpose of this test is to verify that the Device unintended emissions do not exceed a level
that will interfere with the operation of other electrical/electronic devices.
Test conditions and Procedure:

The generic test conditions and procedure are described in the CISPR 25:2008 document in
operating condition (Run mode).
For RE & CE:- The device has to meet Class 3 in all Bands in Peak Measurements.
For CTE:- Positive Transient Emission is max 75V & Negative Transient Emission is max -100V.

 List of equipment used during the test to be specified if spectrum analyzer or scanning receivers
are used.
 RBW (resolution bandwidth at -3 dB or -6 dB), VBW (video bandwidth), Scan time, Step size and
Dwell time used during the measurements.
 Test setup and grounding conditions used.
 Limit lines to meet by the Device. Average detector limit line (for any Device) and Quasi-peak or
Peak detector limit lines.
 Photos of the test setup.
 Load box conditions during all the measurements (data table with all the associated loads
activated).
 Plot of the ambient noise for all the frequency bands specifying frequency and level measured in
dB μV/m.
 Plot of the test measurements for all the frequency bands and for all the lines to be tested
specifying frequency and level measured in dB μV. Numeric results shall be submitted in the case
of failure.
 Table with all the frequency bands and the result of the Device evaluated separately (band to
band).
 Measurement uncertainties.
RADIATOR FAN MOTOR
14.1.12 Fuse blow off test – For Self Protecting Fuse in motor
Test condition:
The motor shall be activated with locked rotor condition oriented as per vehicle condition with
rigid mounting at ambient temperature of -20°C, -10°C, +23°C & +120°C. This test has to be conducted in
Both High speed and Low Speed. The test is continued till Fuse blow off. The time duration till the fuse blow
off shall be recorded. The motor shall be stripped open for the analysis after the test and the same shall be
submitted to TML. This is a data generation test.
In High Speed:-
Temperature Time taken for Current at which Temperature at
Fuse Blow off Fuse Blow off which Fuse Blow off
-20°C
-10°C
+23°C
+120°C
In Low Speed:-
Temperature Time taken for Current at which Temperature at
Fuse Blow off Fuse Blow off which Fuse Blow off
-20°C
-10°C
+23°C
+120°C
The failure mode shall confirm that it will not cause any thermal incidence in the vehicle
environment.

• The time duration at which the fuse blow off.
 The stall current drawn by the motor and temperatures at various locations in the motor like on
the yoke, brush box, commutator, bearings, end plates etc.
RADIATOR FAN MOTOR
14.1.13 Endurance test

14.1.13.1 Intermittent test
14.1.13.1.1 Life test
Test condition:
The motor is made to run continuously as per below,
 Motor 1 & 2 – 2000Hrs (Only in High speed)
 Motor 3 – 2000Hrs (1000Hrs Low speed + 1000Hrs High speed)
The design intended motor with fan, shroud and core assembly oriented as per vehicle condition
with 9 minutes ON and 1 minute OFF at ambient temperature of 100 ± 2°C (with 120 ± 2°C peak for 1 one
hour after every 250 hours) unless otherwise the drawing states a different temperature limits. During test,
temperature measurements are to be carried out at various locations in the motor. The performance of the
motor is monitored in between at frequent intervals during the test.
Note: The duty cycle and duration of the test are specific vehicle program dependent and it has to be
changed as per specific vehicle program requirements. The extreme temperature limits have to be changed
accordingly if the drawing states a different operating temperature limits.
 There should not be any failure, distortion or damage which could be detrimental to operation of
Radiator cooling module assembly and it shall satisfy the end play requirements as per drawing.
 There should not be any visible leakage of grease from the bearings.
 The component shall satisfy the performance tests after the test.
 The performance of the motor should not deteriorate by more than 10%.
 The brush wear should not be more than 25% of the useful length after the test.
 The insulation, commutator, plastic parts, bearings and bushings have to be in good condition
after the test.

provided.
 The measured temperatures at various locations in the motor shall be documented and
submitted to TML.
RADIATOR FAN MOTOR
14.1.13.1.2 Start - stop test
Test condition:
The test is to be conducted on the motor with a design intended fan and shroud fitted and oriented
as per vehicle condition at test voltage of 13.5 V as applied at motor terminals with ambient temperature
of 100 ± 2°C unless otherwise the drawing states a different operating temperature limits. The test is done
for a total of 30,000 cycles. In each cycle the motor is kept ON until it attains its full speed (approx. 1 min)
and kept OFF until the motor comes to rest (approx. 1 min).
after the test.
provided.
submitted to TML.
RADIATOR FAN MOTOR
14.1.13.2 Continuous test - Low temperature endurance test
Test condition:
The motor is made to run continuously for 150h with fan, shroud and core assembly oriented as
per vehicle condition in a chamber at extreme temperature of -20 ± 2°C unless otherwise the drawing
states a different operating temperature limits with test voltage of 13.5 ± 0.2V rated operating voltage
applied at motor terminals. During the test, temperature measurements are to be carried out at various
locations in the motor.
During the test, temperature measurements are to be carried out at various locations in the motor.
The performance of the motor is monitored in between at frequent intervals of every 30hrs during the test.
after the test.
provided.
submitted to TML.
RADIATOR FAN MOTOR
14.1.14 Vehicle fitment & Functional test
Test condition:
Sample shall be checked for fitment and function in normal operating condition of the vehicle. The
following parameters are to be recorded during vehicle fitment trials:
 Motor terminal voltage.

 Current profile which captures the current during starting, running and stall conditions.
 Speed of fan.
 Duty cycle of the motor (Example: In a Mumbai drive cycle, European drive cycle etc).
 Radiator cooling performance (To be certified by Engine team).
 Temperature rise on motor body at minimum five points as mentioned in – 14.1.6 Temperature
rise test.
 Vehicle level noise.
There should not be any mismatch in the mounting points and it should fit in the vehicle as per
design. The fan should function satisfactorily at the vehicle level without any degradation in the
performance. All above parameters recorded has to meet the requirements as per drawing.
Note: Vehicle level tests other than fitment and function like Power train Radiator cooling test, High way
endurance test, City endurance test, Torture track endurance test etc shall be added as per specific vehicle
program requirements / targets.
15. Supplier Technical deliverables
Motor supplier shall provide the following technical documents.
15.1 Product Technical Specification

The supplier shall provide the detailed technical specification of the product along with the formal
technical proposal. The supplier’s product specification shall address all the technical details discussed in
this document and additional specifications that the product may adhere to. Test specifications different
from those referred to in this document shall be explained in detail.
The supplier shall submit his detailed test capability to carry out the tests mentioned in this
specification. The test capability shall include the test rigs explanation with photograph (if applicable) and
the test equipment’s used to capture the test parameters.
RADIATOR FAN MOTOR
15.2 2D Drawing
 Nominal voltage.
 Operating voltage range.
 Performance table. It should contain current (A), speed (rpm), torque (Nm) during starting, no
load, on load and stall conditions at -20°C, +25°C, +60°C, +90°C, +120°C.
 Motor characteristics. It should contain current (A), speed (rpm), torque (Nm), output power (W)
and efficiency (%).
 Operating and storage temperature.
 Dimensional details.
 Residual unbalance in the system.
 Ingress protection class of the motor.
 Weight of the motor.
 Circuit schematic.
 Wiring harness & connector details (Motor + Vehicle side).
 EMI/EMC requirements.
 Regulatory requirements.
 BOM and material table.
 Foot note in the drawing mentioning “This motor shall comply to specification 2921 02 023
A0188 version no”
 Further additional contents as required shall be added.
 Recycle / Prohibited materials.
15.3 Service Manual

The supplier shall provide the product service manual along with the technical proposal where
applicable.
15.4 DV and PV Report

The supplier shall submit exhaustive design validation test and process validation test report, which
consists of the test name, test reference no, acceptance criteria, motor in the test condition photograph,
readings (wherever applicable) like current, voltage, speed, torque, time, temperature plots, traces of
waveforms, dimensions of the subassemblies before and after test, which was taken during the testing, test
results, motor performance plot before and after the test, test conclusion and motor teardown photo.
The supplier shall submit DVPR and PVPR summary as per “Annexure-1”
The DV tested samples as per the plan shall be kept at supplier place under ambient storage till the
program life, which shall be specified. The PV tested samples as per the plan shall be kept at supplier place
under ambient temperature for 3 years.
RADIATOR FAN MOTOR
16. Development support
The motor supplier shall be responsible for all the development and validation activities covered
below through participation of design experts, provision of product technical information, assisting in
technical reviews, participation in system and component DFMEA reviews. Supplier must be familiar with
quality tools like B10 life, DOE, 8D process, FMEA, FTA used in automotive industry and Tier 1 suppliers.
Typical activities are:
 System and Component DFMEA
 D3R (Deep Dive Design Reviews)
 Bench and Vehicle Tests
 Component & System Design Validation
 Motor Validation
 Vehicle Certification
 Prototype activity support
 Quality and Reliability Workshops
 Design and Manufacturing Audits
The above activities are typical in nature and shall not be considered as an exhaustive activity list.
The supplier shall be responsible for the deliverables and TML shall ask for any of the information in-
between the program life. Hence supplier shall retain all the information till the program life.
RADIATOR FAN MOTOR
17. Terminology
TML TATA Motors Ltd

PVBU Passenger Vehicle Business Unit
ERC Engineering Research Centre
E&E Electrical & Electronics
APQP Advanced Product Quality Planning
TS Tata Motors Specification
FMEA Failure Modes & Effects Analysis
FTA Fault Tree Analysis
DOE Design of Experiments
NVH Noise, Vibration and Harshness
CAE Computer Aided Engineering
CAD Computer Aided Design
DVP Design Validation Plan
PWM Pulse Width Modulation
dBA A-weighted decibels
BOM Bill of Material
EMI Electro Magnetic Interference
EMC Electro Magnetic Compatibility
MEOST Multiple Environmental Over Stress Test
TBD To Be Decided
DVP Design Validation Plan
PVP Process Validation Plan
DVPR Design Validation Plan Report
PVPR Process Validation Plan Report
JIS Japanese Industrial Standard
IS Indian Standards
AIS Automotive Industry Standard
SAE Society of Automotive Engineers
ISO International Organization for Standardization
CISPR International Special Committee on Radio Interference

2921 02 023 A0188 - Radiator Cooling Fan Motor - Technical Specification - Version1.4

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2921 02 023 A0188 - Radiator Cooling Fan Motor - Technical Specification - Version1.4

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TECHNICAL SPECIFICATION

RADIATOR FAN MOTOR

RADIATOR COOLING FAN MOTOR

Document Version: 1.4

Issue Date Author E-mail

Issue Date Author Details

1.0 18th June 2010 Ramakrishna Koduru First release

2. RFQ RESPONSE ---------------------------------------------------------------------------------------- 11

4. PRODUCT VALIDATION – TML SPECIFIC ------------------------------------------------------- 19

5. REFERENCE DOCUMENTS / STANDARDS------------------------------------------------------- 21

6. ENVIRONMENTAL CONCERNS --------------------------------------------------------------------- 22

12. THERMAL / ENVIRONMENTAL REQUIREMENTS --------------------------------------------- 30

14.1.10.11 Dielectric Strength test --------------------------------------------------------------------------------------------------------- 68

1.3 VA/VE Proposals

1.4 Samples and Document retention requirements

1.5 Product Identification requirements on Motor

Minimum required information’s on the motor Label:

1.6 Raw Material Specific requirements

1.7 Plastic Parts

1.8 Rubber Parts

1.9 Warranty Specific requirements

1.10 Warranty Part analysis

1.11 Warranty response Specific requirements

Action Description Max Permissible Lead time in Days

1.12 Product approval condition

1.13 Project Review OPL

1.14 Learnings integration

1.15 Component Weight tracking

1.16 Part Inspection Report and Material Verification Report requirements

Sample Description Required Reports

Dimension : Fitment related

1.17 Change Management requirements

 Change register “Annexure-12”

1.18 Product Design and Development Cost

Following informations are required to be captured on the RFQ response sheet.

a. RFQ response_Technical Review

3. Product Design Requirements

3.1 Product Development Cycle Overview

a. Development Cycle milestone Overview

Activity Description Expected Deliverables

Activity Description Expected Deliverables

Activity Description Expected Deliverables

3.2 DFMEA + PFMEA requirements

b. DFMEA threshold targets

d. SC, CC requirements list

Classification in DFMEA Rule Characteristics Symbol on Drawing

3.4 Technology roadmap requirements

3.5 Benchmarking requirements

3.6 Design review requirements

3.7 Samples support (Proto and Production Samples)

3.8 Design Simulation Requirements

3.9 Digital Validation Requirements

3.10 Anti rotation requirements for motor assembly

3.11 Mating Connectors information

3.12 Water drain hole requirements & Colour of Motor

4. Product Validation – TML Specific

4.1 Validation test result report requirements

4.2 Product Definition Sign-off

4.3 Vehicle level Validation requirements

4.4 Part Validation requirements (Design validation and Process validation)

Development Milestone Type of Validation Expected Output

PPAP Lot Validation PPAP performance Validation PPAP clearance

SOP Validation SOP Validation SOP lot Clearance