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 there
2、from, 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 2009 SAE International All rights reserved. No part of this publication m
3、ay 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: 724-776-4970 (outside USA)
4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SURFACE VEHICLE RECOMMENDED PRACTICE J2044 AUG2009 Issued 1992-06 Revised 2009-08 Superseding J2044 SEP2002 (R) Quick Connect Coupling Specification for Liquid Fuel and Vapor/Emissions Systems RATIONALE This revision
5、 is to encompass changes in fuel and emission technology and clarification of test procedures. TABLE OF CONTENTS 1. SCOPE 2 2. REFERENCES 3 2.1 Applicable Publications . 3 2.1.1 SAE Publications . 3 2.1.2 ASTM Publication 3 2.2 Related Publication . 3 2.2.1 SAE Publication 3 3. DEFINITIONS . 4 3.1 U
6、nexposed Coupling . 4 3.2 Lot . 4 3.3 Dimensions . 4 4. SIZE DESIGNATION 4 5. TEST TEMPERATURES 4 6. FUNCTIONAL REQUIREMENTS . 4 6.1 Leak Test (In-Process) 5 6.1.1 Low Pressure Leak Test Procedure . 5 6.1.2 Low Pressure Leak Acceptance Criteria . 5 6.1.3 High Pressure Leak Test Procedure (Liquid Fue
7、l Only) . 5 6.1.4 High Pressure Test Acceptance Criteria . 5 6.1.5 Vacuum Leak Test Procedure (Vapor Systems only at Customers Request) . 5 6.1.6 Vacuum Test Acceptance Criteria 5 6.2 Assembly Effort . 8 6.2.1 Test Procedure (New Parts) . 8 6.2.2 Test Procedure (Connectors after Section 7 Exposure)
8、. 8 6.2.3 Acceptance Criteria . 8 6.3 Pull-Apart Effort . 10 6.3.1 Test Procedure 10 6.3.2 Acceptance Criteria . 10 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2044 Revised AUG2009 Page 2 of
9、 23 6.4 Side Load Capability . 12 6.4.1 Test Procedure 12 6.4.2 Acceptance Criteria (Side Load Leak Test) 12 6.4.3 Acceptance Criteria (Side Load Fracture Test) 12 6.5 Electrical Resistance . 13 6.5.1 Test Procedure 13 6.5.2 Acceptance Criteria . 13 6.6 Resistance to Evaporative Emissions . 13 7. DE
10、SIGN VERIFICATION/VALIDATION TESTING . 13 7.1 Corrosion . 13 7.1.1 Test Procedure 13 7.1.2 Acceptance Criteria . 13 7.2 Zinc Chloride Resistance 14 7.2.1 Test Procedure 14 7.2.2 Acceptance Criteria . 14 7.3 External Chemical and Environmental Resistance . 14 7.3.1 Test Procedure, Fluid or Medium 14
11、7.3.2 Acceptance Criteria . 15 7.4 Fuel Compatibility 15 7.4.1 Test Procedure 15 7.4.2 Test Fuels . 15 7.4.3 Test Requirement 16 7.4.4 Acceptance Criteria . 16 7.5 Life Cycle 16 7.5.1 Test Procedure 16 7.5.2 Vibration Frequency 16 7.5.3 Acceleration 16 7.5.4 Vibration Duration . 17 7.5.5 Fluid Press
12、ure . 17 7.5.6 Fluid Flow (Liquid Fuel Quick Connect Couplings Only) 17 7.5.7 Test Duration . 17 7.5.8 Test Cycles . 18 7.5.9 Acceptance Criteria . 19 7.6 Elevated Temperature Burst . 20 7.6.1 Test Procedure 20 7.6.2 Acceptance Criteria . 21 8. DESIGN VERIFICATION/VALIDATION AND IN-PROCESS TESTING M
13、ATRIX 21 9. NOTES 22 9.1 Marginal Indicia . 22 APPENDIX A PROCEDURE FOR MEASURING MATING TUBE ENDFORM BEAD WIDTH . 23 1. SCOPE This SAE Recommended Practice defines the minimum functional requirements for quick connect couplings used for supply, return, and vapor/emission fuel system connections. Th
14、is document also defines standard male tube end form dimensions, so as to guarantee interchangeability between all connector designs of the same male tube end form size. This document applies to automotive and light truck applications under the following conditions: a. Gasoline and diesel fuel deliv
15、ery systems or their vapor venting or evaporative emission control systems. b. Operating pressure up to 500 kPa, 5 bar, (72 psig). Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2044 Revised AU
16、G2009 Page 3 of 23 c. Operating vacuum down to 50 kPa, 0.5 bar (7.2 psi). d. Operating temperatures from 40 C (40 F) to 115 C (239 F). Quick connect couplings function by joining the connector to a mating tube end form, then pulling back to assure a complete connection. The requirements stated in th
17、is document apply to new connectors in assembly operations unless otherwise indicated. For service operations, the mating tube should be lubricated with SAE 30-weight oil before re-connecting. Vehicle OEM fuel system specifications may impose additional requirements beyond the scope of this general
18、SAE document. In those cases, the OEM specification takes precedence over this document. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications shall apply
19、. 2.1.1 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 J526 Welded Low-Carbon Steel Tubing SAE J527 Brazed Double Wall Low-Carbon Steel Tubing SAE J1645 Fu
20、el Systems and ComponentsElectrostatic Charge Mitigation SAE J1681 Gasoline, Alcohol, and Diesel Fuel Surrogates for Materials Testing SAE J1737 Test Procedure to Determine the Hydrocarbon Losses from Fuel Tubes, Hoses, Fittings, and Fuel Line Assemblies by Recirculation SAE J2045 Performance Requir
21、ements for Fuel System Tubing Assemblies SAE J2587 Optimized Fuel Tank Sender Closure 2.1.2 ASTM Publication Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 117 Method of Salt Spray (Fog) Testing 2.2 R
22、elated Publication The following publication is provided for information purposes only and is not a required part of this specification. 2.2.1 SAE Publication Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-497
23、0 (outside USA), www.sae.org. SAE J30 Fuel and Oil Hoses Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2044 Revised AUG2009 Page 4 of 23 3. DEFINITIONS 3.1 Unexposed Coupling One that has not
24、been used or deteriorated since manufacture. 3.2 Lot A group of couplings that can be traced to a single assembly set-up or material lot. No more than one week production in a lot. 3.3 Dimensions Unless otherwise specified all dimensions are in millimeters (mm). 4. SIZE DESIGNATION The size of quick
25、 connect couplings in this document are designated by three dimensions, and presented as g304 x g533 x g302, defined in Figure 1 below. Dimension g304 designates the nominal male endform diameter. Dimension g533 designates the tubing or hose size suited for the stem end of the coupling. Dimension g3
26、02 designates the minimum straight length, of nominal diameter tubing, behind the male endform bead, required for proper installation and removal of the fitting. EXAMPLE: 9.5 mm x 8 mm x 12 mm connector couples with a 9.5 mm male tube end, is inserted into an 8 mm flexible tube or hose and requires
27、12 mm clearance behind the bead on the tube end. FIGURE 1 - CONNECTOR NOMENCLATURE Details for standard coupling sizes and dimensions for standard tube end forms are shown in Table 1 and Figure 2. NOTE: On metal or plastic tubing the OD is used to designate size. On flexible hose the ID is used to d
28、esignate size. 5. TEST TEMPERATURES Unless otherwise specified, all tests will be performed at room temperature 23 C 2 C (73.4 F 4 F). 6. FUNCTIONAL REQUIREMENTS This section defines the minimum functional requirements for quick connector couplings used in flexible tubing fuel systems. NOTE: New con
29、nector designs using the same materials as previously tested connectors may use the original results as surrogate data for 7.1 Corrosion, 7.2 Zinc Chloride Resistance, 7.3 External chemical and Environmental Resistance, and 7.4 Fuel Compatibility. Copyright SAE International Provided by IHS under li
30、cense with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J2044 Revised AUG2009 Page 5 of 23 6.1 Leak Test (In-Process) In accordance with stringent emissions regulations, including CARB PZEV, and safety regulations, quick connector couplings must be free o
31、f leaks and micro-leaks. Production leak testing is performed to assure conformance to the requirement. Compressed air leak testing is a proven technique which provides required leak sensitivity as well as a proof test for pressure resistance. Depending on the application, test conditions for Low Pr
32、essure (vapor), high pressure (liquid) and vacuum systems are described below. NOTE: Leak test acceptance criteria for this document are in customary leak units of flow (cc/min) or mass flow (scc/min). In the fuel system industry, an alternate leak test criteria, based on units of equivalent channel
33、 dimension rather than flow rate, have been applied. For example, see SAEJ2587 for leak criteria for fuel pump module tank interface joint. The equivalent channel specification is especially appropriate for parts such as fuel tanks with large internal volume, with high deformation with applied press
34、ure or vacuum and where use pressures are low. Leak tests for such parts include vacuum, pressure, and accumulation methods. It can be difficult to compare the indicated leak rates for various techniques, so an equivalent channel criteria is established. The equivalent channel dimension specificatio
35、n is based on test data indicating that fuel system micro-leaks will plug over time. Effectively, micro-leaks plug to a near zero hydrocarbon emission level. The high pressure leak tests defined in 6.1.3 have been demonstrated, with experiment and analysis, to satisfy an equivalent channel of 15 mic
36、ron diameter and 3 mm length. No further testing is recommended to validate the equivalent channel criteria. Standard leak rate conditions are defined as 101.325 kPa (14.696 psia) and 293 K (20 C). 6.1.1 Low Pressure Leak Test Procedure a. Insert leak test pin, shown in Figure 3, into the connector.
37、 b. Pressurize between the seals (for single seal connectors, the stem must be capped or sealed) with suitable air leak test equipment to 69 kPa 7 kPa, 0.69 bar 0.07 bar (10 psig 1 psig). 6.1.2 Low Pressure Leak Acceptance Criteria Maximum leak rate 2 scc/min (1.19 cc/min) at stabilization. 6.1.3 Hi
38、gh Pressure Leak Test Procedure (Liquid Fuel Only) a. Insert leak test pin, shown in Figure 3, into the connector. b. Pressurize between the seals with suitable air leak test equipment to 1034 kPa 35 kPa, 10.34 bar 0.35 bar (150 psig 5 psig). 6.1.4 High Pressure Test Acceptance Criteria Maximum leak
39、 rate 5 scc/min (0.45 cc/min) at stabilization. NOTE: Appropriate safety precautions should be taken when testing with high-pressure air. Not required for vapor/emission quick connector couplings. Vapor connectors are not generally used for high pressure applications. 6.1.5 Vacuum Leak Test Procedur
40、e (Vapor Systems only at Customers Request) a. Insert leak test pin shown in Figure 3 into connector. b. Apply a vacuum of 7 kPa (1.02 psig) with suitable vacuum leak test equipment. 6.1.6 Vacuum Test Acceptance Criteria Maximum leak rate 2 scc/min (2.14 cc/min) at stabilization. Stabilization can b
41、e determined by viewing a graphic output of actual leak rate. This will vary by connector size and leak test method. Permeation is not the same phenomenon as leaks. Permeation tests measure permeation rate. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproducti
42、on or networking permitted without license from IHS-,-,-SAE J2044 Revised AUG2009 Page 6 of 23 TABLE 1 - STANDARD TUBE END-FORM DIMENSIONS (NOMINAL) H(K) LBASIC A B C D E F G TANGENT BLEND TANGENTTUBE DIA. SEAL DIA. BEAD DIA. LENGTH BEAD WIDTH I.D. Clearance GAUGE DIA. RADIUS RADIUS RADIUS*See NoteR
43、EFERENCE3/16“, 4.78 0.08 4.63 0.06 7.10 0.15 19.93 0.25 *1.57/1.93 2.20/2.70 6.9 6.08 0.5/1.0 0.5 0.3/0.51/4“, 6.35 0.08 6.30 0.06 8.75 0.15 20.91 0.25 *1.57/1.93 3.60/4.10 9.5 7.75 0.5/1.0 0.6 0.4/0.85/16“ 8mm, 7.94 0.08 7.89 0.06 10.98 0.15 21.12 0.25 *1.57/1.93 4.70/5.20 12.0 9.39 0.5/1.0 0.9 0.4
44、/0.83/8“, 9.53 0.08 9.49 0.06 12.94 0.21 21.12 0.25 *1.57/1.93 6.30/6.80 14.3 10.92 0.5/1.0 1.1 0.4/0.810mm 0.08 9.89 0.06 13.42 0.21 24.74 0.25 * 2.34 / 2.74 6.60/7.10 15.0 11.34 0.5/1.0 1.2 0.4/0.87/16“, 11.11 0.10 11.05 0.10 14.80 0.25 26.62 0.50 * 2.34 / 2.74 7.00/7.50 16.5 12.5 0.5/1.0 1.3 0.4/
45、0.812mm 0.10 11.80 0.10 16.51 0.25 26.62 0.50 * 2.34 / 2.74 7.50/8.00 18.0 13.25 0.5/1.0 1.6 0.4/0.81/2“, 12.70 0.10 12.61 0.10 16.51 0.25 26.62 0.50 * 2.34 / 2.74 8.10/8.60 18.0 14.1 0.5/1.0 1.3 0.4/0.85/8“, 15.88 0.10 15.82 0.10 19.18 0.25 26.62 0.50 * 2.34 / 2.74 11.10/11.90 24.0 17.27 0.5/1.0 1.
46、1 0.4/0.83/4“, 19.05 0.10 18.90 0.10 22.33 0.25 26.62 0.50 * 2.34 / 2.74 13.20/14.00 28.5 20.35 0.5/1.0 1.1 0.4/0.87/8“, 22.23 0.15 22.70 0.15 25.7 0.5 29.50 0.50 * 2.34 / 2.74 16.00/16.80 33.0 24.15 0.5/1.0 1.2 0.4/0.81“, 25.40 0.15 25.50 0.15 28.2 0.5 29.50 0.50 * 2.34 / 2.74 19.00/19.80 38.0 26.9
47、5 0.5/1.0 0.7 0.4/0.81 1/8“, 28.58 0.15 28.42 0.15 32.3 0.5 42.50 0.50 * 2.34 / 2.74 22.70/23.70 43.0 29.87 0.5/1.0 1.3 0.4/0.8PA Coated Endforms1/4“, 6.35 0.08 6.30 0.06 8.750.15 21.31 0.25 *2.15 0.17 3.60/4.10 9.5 7.75 0.5/1.0 0.6 0.4/0.85/16“ 8mm, 7.94 0.08 7.89 0.06 10.980.15 21.12 0.25 *2.15 0.
48、17 4.70/5.20 12.0 9.39 0.5/1.0 1.1 0.4/0.83/8“, 9.53 0.08 9.49 0.06 12.940.21 21.12 0.25 *2.15 0.17 6.30/6.80 14.3 10.92 0.5/1.0 0.9 0.4/0.810mm 0.08 9.89 0.06 13.420.21 24.74 0.50 *2.15 0.17 6.60/7.10 15.0 11.34 0.5/1.0 1.2 0.4/0.812mm 0.10 11.80 0.10 16.510.25 26.62 0.50 *2.15 0.17 7.50/8.00 18.0 13.25 0.5/1.0 1.7 0.4/0.8NOTE: *Bead Width based on 0.028” (0.71 0.08 mm) wall steel tubing for formed endforms. *Bead Width based on 0.042” (1.07 0.102 mm) wall
