1、 SAE/USCAR-2 Revision 6 Performance Specification for AutomotiveElectrical Connector SystemsFebruary 2013ISBN: 978-0-7680- - 7998 2_ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor th
2、e United States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document
3、 to determine whether or not it is applicable for their purposes. Copyright 2013 USCAR Printed in U.S.A. All rights reserved. QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SAE/USCAR-2 REVISION 6 Issued August 1997 Re
4、vised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS TABLE OF CONTENTS 1. SCOPE 3 2. TEST SEQUENCE 3 3. REFERENCED DOCUMENTS . 3 3.1 Document Hierarchy 3 3.2 Part Drawing 4 3.3 Product Design Specification 4 3.4 Test Request/Order . 4 3.4.1 Samples, Test Type, and Spec
5、ial Tests 4 3.4.2 Test Request/Order Instructions . 4 3.4.3 Performance and Durability Test Instructions . 4 3.5 Documents MENTIONED IN THIS SPECIFICATION . 4 4. GENERAL REQUIREMENTS . 5 4.1 Record Retention 5 4.2 Sample Documentation . 5 4.3 Sample Size 5 4.4 Default Test Tolerances 5 4.5 Equipment
6、 . 6 4.6 Measurement Resolution 6 4.7 Test Repeatability PDUNVLVVXJJHVWHGLISUDFWLFDO FIGURE 5.1.9.3: GENERAL PATTERN FOR CIRCUIT MONITORING NOTE: Monitored terminals shall not be the same samples used for subsequent Dry Circuit readings for record, since the monitoring equipment may cause the potent
7、ial across the circuit to exceed 20mvolts. Dry Circuit readings, however, may be taken as an aid in root-cause diagnosis. Solder the conductors from each terminal in the CUT in series to form one continuous current path with only two free ends. Solder one of the free conductor ends to a 2 watt, 120
8、1.2 ohm resistor. Solder the “ “ (negative) lead to the free end of the resistor and the “+“ (positive) lead to the remaining free conductor end of the CUT. Connect the Continuity Tester across the resistor, making sure that the negative lead of the CT is connected to the negative side of the resist
9、or. Adjust the power supply to provide 100 mA to the circuit. Set the CT to monitor the current through the resistor and record any instance where that current falls below 95 mA. As an option, the CT may be used to monitor one or more terminal pairs instead of the resistor. A reference illustration
10、of the test set-up is shown in Figure 5.1.9.3. Other suitable continuity monitoring equipment may be used. The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing. X X X X X X X X X X X X X X X SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SP
11、ECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 13 - FIGURE 5.1.9.3: CONNECTOR ENVIRONMENTAL TEST SET-UP 5.1.9.4 Acceptance Criteria Where continuity monitoring is required during any conditioning procedure, there must be no loss of electrical continuity (any instance of the resistor curre
12、nt dropping below 95 mA), for more than 1 microsecond. If one or more terminal pairs are monitored, rather than the series resistor, there must be no instance in which the resistance of any terminal pair exceeds 7.0 : for more than 1 microsecond. Figure 5.1.9.4 illustrates the acceptance criteria gr
13、aphically. 7 ohm Time 1s Contact Resistance Acceptable Not Acceptable FIGURE 5.1.9.4: INTERMITTENCY MEASUREMENT SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 14 - 5.1.10 Multi-cavity (mat) Conductor Seals Sample Preparation 5.1.10.1 Pu
14、rpose This procedure preconditions a multi-cavity (mat) conductor seal of a sealed connection system to ensure the sealing performance within the design intent cable size range and that the terminal does not damage the seal during service operations. 5.1.10.2 Equipment None. 5.1.10.3 Samples Prepare
15、 two (2) sets of 10 CUT samples. Number each connector pair. 1. 10 samples prepared with the number of terminal samples per Section 5.1.6 using the smallest conductor size and insulation thickness applicable to the design of the terminal to be tested and to fully-populate the CUTs. 2. 10 samples pre
16、pared with the number of terminal samples per Section 5.1.6 so that all but one randomly selected cavity in each connector half is populated with a terminal crimped to the largest conductor size. Then fill the remaining cavity in each connector half with the appropriate terminals crimped to the smal
17、lest conductor size. 5.1.10.4 Procedure Select 10 cavities at random among each sample set per 5.1.10.3 and record the connector and cavity numbers. Remove and re-insert the terminals in the selected cavities twice (insert-remove-insert-remove-insert). 5.1.10.5 Acceptance Criteria None. 5.2 Terminal
18、 Mechanical Tests 5.2.1 Terminal to Terminal Engage/Disengage Force 5.2.1.1 Purpose This test determines the engage and disengage forces of compatible male and Female Terminal pairs. Determination of the number of terminals that can be packaged in a given connector design without exceeding allowable
19、 Mating Force limits is dependent on this information. Note that this test is written so that only the first engagement and the last (10th) disengagement are recorded and used to verify compliance with the Acceptance Criteria. 5.2.1.2 Equipment Insertion/Retention Force Tester with peak reading feat
20、ure Polished Steel Gage (optional) 5.2.1.3 Procedure 1. Completely identify and number each terminal to be tested. A minimum of 20 samples (10 male and 10 female) are required. If the optional Step 8 is to be used, at least an additional 10 Female Terminal samples will be required. 2. Fixture one Ma
21、le and one Female Terminal so that proper alignment is achieved during testing. SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 15 - 3. Engage the mating terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied par
22、allel to the centerlines of the terminals. Proper alignment of the terminals is critical to avoid side loads and binding which can adversely affect the force measurement. 4. Record the peak force required to completely engage the terminal to its mating part and use this value to verify conformance t
23、o the Acceptance Criteria of Figure 5.2.1.4. 5. Disengage the mated terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied parallel to the centerlines of the terminals. 6. Repeat Steps 3 value is used to establish “Maximum Test Current“ for the TUT in Section 5.3.4. The maxi
24、mum test current of the specific combination of the terminal and the wire conductor gage and insulation type used is the current that produces an exact or interpolated value of 55C rise in the first increment in which either the condition described in 9 a or 9 b above was achieved, less 10% of that
25、value. 5.3.4 Current Cycling 5.3.4.1 Purpose This test simulates the main function of power terminals over the expected life of the vehicle. Current cycling is an accelerated aging test which electrically heats terminal interfaces and core conductor crimps, then allows them to cool under zero curren
26、t conditions, causing expansion and contraction that may affect connection resistance due to wear, oxidation, inter-metallic growth and stress relaxation. 5.3.4.2 Equipment Digital Multimeter (DMM) DC Power Supply (0-20 VDC 0-150 A, timer controlled) Current shunts (Size as required, 1%) Thermocoupl
27、es (Type “J“ or “T“ typically) Data Logger (as required) 5.3.4.3 Procedure 1. Attach the millivolt leads in positions T1 and T2 as shown in Figure 5.3.1.3. For Header type connectors, T2 is attached to the Header terminal per Section 5.1.5. Millivolt leads must be no larger than 0.22 mm2. 2. Measure
28、 and record the Voltage Drop across 150mm of the conductor to be used for the test, using the maximum test current previously determined (Section 5.3.3.4) for the combination of that conductor size, insulation type and the TUT. For testing Header type connectors, refer to Section 5.1.5 and measure t
29、he millivolt drop across only 75mm of the conductor used. For attachment points exceeding 75 mm per side, the extra wire resistance shall be measured and subtracted. SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 25 - 3. Assemble the ci
30、rcuit shown in Figure 5.3.3.3-2 in a draft free enclosure as described in section 5.3.3.3, except use a timer controlled power supply. Set the power supply to provide 45 minutes on and 15 minutes off at the maximum test current previously determined (Section 5.3.3.3, Step 9) for the combination of t
31、hat conductor size, insulation type and the TUT. Connect a data logger to the Voltage Drop and thermocouple leads. 4. Test the set of sample terminal pairs at 23o+/- 5C. (Room Temperature). An ambient temperature sensor must be placed on the same plane as the test samples, 150 mm min. from the neare
32、st sample. 5. Turn on the power supply, DMMs, and data logger. 6. After 30 minutes into the first on cycle, record terminal crimp and interface millivolt drop readings (T1 to T2 in Figure 5.3.2.3) as well as thermocouple readings for each terminal pair. 7. Complete 1008 cycles taking readings at lea
33、st once daily 30 minutes into the on cycle, and at the conclusion of the test, 30 minutes into the final “on cycle. mV drop readings should be taken at maximum test current. 8. For each set of data, calculate and record the Total Connection Resistance by subtracting the conductor millivolt drop read
34、ing (Step. 4) from the T1 to T2 millivolt drop reading (Step 8) and dividing the result by the test current. 9. Allow the samples to cool to ambient, then measure CUT/TUT as required per appropriate test sequencing table. 5.3.4.4 Acceptance Criteria 1. At the conclusion of the test, verify conforman
35、ce of CUT/TUT per corresponding measurement section as identified in Test Sequence (5.9). 2. The temperature of any terminal interface must not exceed a 55 oC ROA at any time during the test. 5.4 Connector - Mechanical Tests 5.4.1 Terminal - Connector Insertion/Retention and Forward Stop Force 5.4.1
36、.1 Purpose This test is required to in order to measure the Insertion Force of a terminal into its connector cavity. Retention testing is required to ensure that the terminal is retained in its housing with sufficient strength to withstand the rigors of the wiring harness and vehicle assembly proces
37、ses. 5.4.1.2 Equipment Insertion/Retention Force Tester with Peak Reading Feature Temperature/Humidity Chamber capable of 95 to 98% RH at 40C SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 26 - 5.4.1.3 Procedure A. INSERTION FORCE: Un-s
38、ealed Connectors and Sealed Connectors with Individual Cable Seals 1. Prepare terminal samples per section 5.1.6, using the largest gage size conductor and insulation thickness applicable to the design of the terminal to be tested. For connectors with 10 or more terminal cavity locations, use a mini
39、mum of 3 connector housings and prepare at least one terminal for each cavity location. Test each terminal cavity location in the CUT at least once. For connectors with 4 9 terminal cavity locations, use a minimum of 3 connector housings and prepare enough terminal samples to test each cavity locati
40、on in each CUT. For connectors with 3 terminal cavity locations use a minimum of 4 connector housings and prepare enough terminal samples to test each cavity location in each CUT. For connectors with 1 or 2 cavity locations use enough connector housings to obtain at least 10 data points and test all
41、 cavity locations an equal number of times. See table 5.4.1.3.1 NOTE: Use these sample sizes and cavity requirements for insertion, retention, forward stop and after conditioning force measurements. # of Terminal Cavity Locations Minimum # of CUTs Minimum # of Terminal Samples Cavity Locations Teste
42、d Minimum # of Data Points 10 or more 3 = # of Terminal Cavity Locations Each location at least once = # of Terminal Cavity Locations 4 to 9 3 = # of Terminal Cavity Locations times # of CUTs Each location 3X or Same num. CUTs or Each location an same num. of times = # of Terminal Cavity Locations X
43、 # of CUTs 3 4 = # of Terminal Cavity Locations times # of CUTs Each location an equal number of times 12 2 5 10 Each location an equal number of times 10 1 10 10 Each location an equal number of times 10 TABLE 5.4.1.3.1: SAMPLE SIZES AND CAVITY REQUIREMENTS 2. Repeat Step 1 using the smallest condu
44、ctor size and insulation type applicable to the design. 3. Number each connector terminal cavity and, if applicable, each connector. 4. Secure the connector shell in an appropriate fixture. 5. Secure the terminal sample in the force tester by gripping the conductor a minimum of 20mm behind the insul
45、ation grip. SAE/USCAR-2 REVISION 6 Revised 2013-02 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS - 27 - 6. Adjust the force tester to insert the terminal straight into the connector at a uniform rate not to exceed 50 mm per minute. Upon reaching the forward stop, continue app
46、lying force until failure point of the forward stop is reached (plastic failure or terminal damage) . Use a fresh terminal sample for each insertion and test each terminal cavity location until all terminal samples prepared in step 1 have been used. (Where wire buckling and operator sensitivity caus
47、e problems in obtaining test repeatability, one of two alternatives are acceptable. A. Terminals may be crimped to a gage pin, solid core wire or other metal dowel material and used to measure terminal insertion or forward stop push through or B) Terminals may be pushed by cutting the wire off the C
48、UT near the insulation grip and use a rod with a diameter similar to the cut off wire. Push directly on the wire stub. Samples prepared in this manner require additional connector samples and cannot be used for terminal to connector retention tests. 7. Record the force required to insert the termina
49、l into the connector for each terminal sample to be tested and verify conformance to the Acceptance Criteria of Section 5.4.1.4. Connectors with Multi-Cavity (Mat) Seals 1. Complete steps 1 3 above, except prepare at least one additional set of samples. 2. Complete steps 4 and 5 above. 3. Adjust the force tester to insert the terminal straight into the con
