1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2010 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside US
4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J1742_201003SURFACEVEHICLERECOMMENDEDPRACTICEJ1742 MAR2010 Issued 1998-03Revised 2010-03 Supers
5、eding J1742 DEC2005 Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements RATIONALEThe changes are intended to correct errors in the test sequence, the table numbering, and notes to the test sequence table.TABLE OF CONTENTS 1. S
6、COPE 32. REFERENCES 42.1 Document Hierarchy . 42.2 Part Drawing . 42.3 Product Design Specification 42.4 Test Request/Order 42.5 Other Referenced Documents 42.5.1 SAE Publications . 42.6 Related Publications . 42.6.1 SAE Publications . 43. DEFINITIONS AND ABBREVIATIONS . 53.1 Definitions . 53.2 Abbr
7、eviations 54. GENERAL REQUIREMENTS . 64.1 Equipment . 65. TEST AND ACCEPTANCE REQUIREMENTS 65.1 General . 65.1.1 Circuit Continuity Monitoring . 65.2 Terminal - Mechanical Tests . 65.2.1 Terminal-to-Terminal Engage/Disengage Force 65.2.2 Terminal Bend Resistance 65.2.3 Terminal to Conductor Attachme
8、nt (crimp) Pull-out Force . 65.2.4 Procedure 75.2.5 Acceptance Criteria . 85.3 Terminal - Electrical Tests 85.3.1 Voltage Drop . 85.3.2 Maximum Test Current Capability . 105.3.3 1008 Hour Current Cycling . 135.4 Connector - Mechanical Tests 135.4.1 Terminal - Connector Insertion/Extraction Force 13S
9、AE J1742 Revised MAR2010 Page 2 of 265.4.2 Connector-Connector Mating/Un-mating Force (Non-mechanical Assist Connectors) 145.4.3 Connector to Connector Mating and Un-mating Forces (Connectors with Mechanical Assist) . 145.4.4 Polarization Feature Effectiveness . 145.4.5 Miscellaneous Component Engag
10、e/Disengage Force . 145.4.6 Vibration/Mechanical Shock 145.4.7 Connector-to-Connector Audible Click . 145.4.8 Connector Drop Test . 145.4.9 Cavity Damage Susceptibility . 145.5 Connector - Electrical Tests 145.5.1 Isolation Resistance 145.5.2 Dielectric Withstand Voltage . 145.6 Connector Environmen
11、tal Tests 155.6.1 Thermal Shock 155.6.2 Temperature/Humidity Cycling 165.6.3 High Temperature Exposure . 165.6.4 Fluid Resistance 165.6.5 Submersion . 165.6.6 Pressure/Vacuum Leak . 165.7 Special Tests . 165.7.1 Header Pin Retention 165.7.2 Connector Mounting Feature Mechanical Strength 165.8 Severe
12、 Duty Tests . 165.8.1 High Pressure Spray . 165.8.2 Severe Vibration 165.9 Test Sequence 175.9.1 General Notes . 175.9.2 General Test Flow Chart . 186. NOTES 226.1 Marginal Indicia . 22APPENDIX A TESTS RECOMMENDED FOR NEW TOOLING, TOOL TRANSFER, OR MATERIAL CHANGE . 23APPENDIX B 25APPENDIX C DESIGN
13、NOTES . 26FIGURE 1 CONNECTION RESISTANCE MILLIVOLT LEAD LOCATIONS 9FIGURE 2 CURRENT RESISTANCE TEST SET-UP 10FIGURE 3 SET-UP FOR MAXIMUM TEST CURRENT . 11FIGURE 4 METHOD OF CONNECTING LEADS FOR ISOLATION RESISTANCE TEST . 15FIGURE 5 GENERAL TEST FLOW CHART 18TABLE 1 EQUIPMENT . 6TABLE 2 PULL-OUT FOR
14、CE REQUIREMENTS 8TABLE 3 TERMINAL-CONNECTOR MINIMUM EXTRACTION FORCE 13TABLE 4 DIELECTRIC WITHSTAND VOLTAGE 15TABLE 5 MINIMUM HEADER PIN DISPLACEMENT FORCE 16TABLE 6 SECTIONS 5.9.3 TERMINAL MECHANICAL, 5.9.4 TERMINAL ELECTRICAL, AND5.9.5 CONNECTOR SYSTEM MECHANICAL TEST SEQUENCES . 19TABLE 7 SECTION
15、S 5.9.6 CONNECTOR SYSTEM ELECTRICAL, 5.9.7 SEALED CONNECTORSYSTEM ENVIRONMENTAL, AND 5.9.8 UN-SEALED CONNECTOR SYSTEM ENVIRONMENTAL TEST SEQUENCES . 20SAE J1742 Revised MAR2010 Page 3 of 26NOTE: No electrical connector, terminal, or related component may be represented as having met SAE specificatio
16、ns unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts. If testing is performed by another source, it does not relieve the primary supplier of responsi
17、bility for documentation of all test results and for verification that all samples tested met all applicable Acceptance Criteria. See Section 4. 1. SCOPE Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analys
18、is of electrical terminals, connectors, and components that constitute the electrical connection systems in high power road vehicle applications that operates at either 20 V to 600 volts regardless of the current applied or any current greater than or equal to 80 A regardless of the voltage applied
19、These procedures are applicable only to terminals used for In-Line, Header, and Device Connectors and for cable sizes up to 120 mm2(4/0).In cases where power levels are mixed in the same connector, (i.e. sensing or normal 14.5 volt system circuits with High Power Contacts) the High Power Contacts mu
20、st pass J1742 requirements, and all other contacts must pass SAE J2223-2 requirements. The connection system (housing and high power contacts) shall meet J1742 requirements.The requirements and procedures in this document are not intended for connections internal to electrical/electronic modules or
21、complete subassemblies. This document does not contain a test for EMI/EMC since these parameters must be tested as a combination of cable and connector. These are considered system level requirements. Determination of the need and type of test must be considered at that level. See Appendix C, Design
22、 Notes for further information. IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before
23、 they can be considered acceptable for actual vehicle application. By way only of example, this includes products that may be subjected to temperatures beyond the extremes of Class 5 in Table 2 of SAE J2223-2, or may be subjected to shock or vibration in the un-sprung portions of a vehicle, such as
24、the wheel hub. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what t
25、ests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and for authorizing any deviations to the equipment, procedures and/or acceptance requirements contai
26、ned in this specification. Any such deviation must be documented and included in the final test report and on the part print. The following are examples of appropriate print notations: Example 1: Test value per SAE J2223-2, Revision 1, paragraph 5.4.2 Connector Mating/Un-mating Force mating force va
27、lue = 85 N. Example 2: SAE J2223-2, Revision 1, paragraph 5.4.9 Cavity Damage Susceptibility not applicable to this design. Agreement to waive or alter test procedures and Acceptance Criteria must be made between customer and supplier. Guidance as to the recommended tests for selected purposes is gi
28、ven in the charts in Appendix A and B. In the absence of contrary direction from the Authorized Person in the test request/order, all electrical connectors and their associated terminals and other components are required to meet all applicable portions of this document with the following exception:
29、Specific tests that are not required or additional test requirements as specified in any document in the hierarchy of Section 2. SAE J1742 Revised MAR2010 Page 4 of 262. REFERENCES 2.1 Document Hierarchy In the event there is a conflict between performance specifications, part drawings, and other re
30、lated standards or specifications, the requirements shall be prioritized as follows: 1st Applicable FMVSS requirements and other applicable state and Federal requirements 2nd Applicable part drawings 3rd Applicable product design specification(s) 4th Automotive Industry Action Group (AIAG) Productio
31、n Part Approval Process (PPAP) 5th Applicable SAE performance specifications 6th Other applicable standards and specifications 2.2 Part Drawing See SAE J2223-2 for part drawing information. 2.3 Product Design Specification See SAE J2223-2 for Product Design Specification information. 2.4 Test Reques
32、t/Order Refer to SAE J2223-2 for Test Request information. 2.5 Other Referenced Documents 2.5.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J1127 Low Vol
33、tage Battery Cable SAE J1128 Low Voltage Primary Cable SAE J2223-2 Connections for On-Board Road Vehicle Electrical Wiring HarnessesPart 2: Tests and General Performance Requirements SAE/USCAR-23 Road Vehicles60 V and 600 V Single Core (ISO/Metric) CablesDimensions, Test Methods and Requirements2.6
34、Related Publications The following publications are provided for information purposes only and are not a required part of this document. 2.6.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-49
35、70 (outside USA), www.sae.org.SAE J1654 High Voltage Primary Cable SAE J1673 High Voltage Automotive Wiring Assembly Design SAE J1742 Revised MAR2010 Page 5 of 263. DEFINITIONS AND ABBREVIATIONS 3.1 Definitions Terms defined in the definitions or abbreviations sections are capitalized (i.e. Room Tem
36、perature, PLR, etc.) See SAE J2223-2 for additional definitions applicable to this document. 3.1.1 BREAKDOWN The failure of the dielectric of an insulation under the effect of an excessive electric field and/or by physical or chemical deterioration of the dielectric material. 3.1.2 CONNECTOR A compo
37、nent which terminates conductors for the purpose of providing connection and disconnection to a suitable mating component. Connectors are designed to be connected and disconnected in the de-energized state unless otherwise specified. See Appendix C. 3.1.3 CONNECTOR HOUSING The part of a connector in
38、to which the insert and contacts are assembled. 3.1.4 CONTACT Conductive element in a component that mates with a corresponding element to form an electrical path. 3.1.5 HIGH POWER CONNECTOR Any connector containing one or more High Power Contacts. Connectors fitting this description shall meet the
39、requirements of SAE J1742. 3.1.6 HIGH POWER CONTACT Terminal assembly contained within a connector that operates at either 20 V to 600 volts regardless of the current applied or any current greater than or equal to 80 A regardless of the voltage applied.for any portion of their duty cycle. 3.1.7 RAT
40、ED VOLTAGE Voltage level at which a device is designed to operate. 3.1.8 HIGH POWER CONNECTOR Any connector contact designed to carryt either 20 V to 600 volts regardless of the current applied or any current greater than or equal to 80 A regardless of the voltage applied 3.2 Abbreviations See SAE J
41、2223-2 for abbreviations. SAE J1742 Revised MAR2010 Page 6 of 264. GENERAL REQUIREMENTS See SAE J2223-2 for General Requirements. 4.1 Equipment Equipment is required per J2223-2. In addition, the items found in Table 1 are required for testing High Voltage Connection Systems. TABLE 1 - EQUIPMENT Ite
42、m Description Requirements 1 High Potential Tester with load meter AC 1000 V rms (50-60 Hz or DC 1600 V 5. TEST AND ACCEPTANCE REQUIREMENTS 5.1 General See SAE J2223-2 for General Test and Acceptance Requirements. All sections of J2223-2 apply to the testing and validation of high Power connections
43、systems except as noted in this document. Certain additional testing as described herein shall also be conducted. 5.1.1 Circuit Continuity Monitoring Where Continuity Monitoring is required, follow the Circuit Continuity Monitoring procedures in SAE J2223-2. No Circuit Continuity Monitoring is requi
44、red during any conditioning procedure for contacts operating above 20 volts. 5.2 Terminal - Mechanical Tests 5.2.1 Terminal-to-Terminal Engage/Disengage Force Conduct the Terminal-to-Terminal Engage/Disengage Force per SAE J2223-2. 5.2.2 Terminal Bend Resistance Conduct the Terminal Bend Resistance
45、Test per SAE J2223-2. 5.2.3 Terminal to Conductor Attachment (crimp) Pull-out Force 5.2.3.1 Purpose This procedure details a standard method to measure the retention capability of crimped connections. NOTE: Pull-out force test shall not be used to determine electrical performance of the crimp applic
46、ation. It is used only to determine the mechanical limits of the crimp application for handling purposesSAE J1742 Revised MAR2010 Page 7 of 265.2.3.2 Equipment 1. Measuring device capable of measuring crimp heights and widths. 2. De-crimping tool, or other suitable means of opening insulation crimps
47、 without damaging the cable conductor. (Note: it is acceptable to make the samples with the insulation crimp not crimped to avoid this step.) 3. Force Tester. 4. Cable strippers, long-nose pliers and/or side cutters. 5.2.4 Procedure 1. A minimum of 20 samples is required to be tested for each produc
48、tion crimp height. Data shall be obtained and recorded for minimum, maximum, and nominal production crimp heights. 2. Samples shall be applied to appropriate cable with overall length no less than 150 mm. 3. Pull-out force test shall be performed on leads with the insulation crimp wings open (not cr
49、imped). 4. Pull-out force test shall be performed on taut leads (i.e., remove slack in cable before performing pull-out test to prevent incorrect test results due to “jerking”). 5. Measure and record the conductor crimp and insulation crimp heights and widths in millimeters for each sample. 6. If the insulation crimp is not already open, open the insulation crimp with the de-crimper or other suitable tool so that the pull-ou
