1、_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 the United States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes
2、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 to determine whether or not it is applicable for theirpurposes.Copyright 2014 USCAR Printed in U.S.A.All rights reserved.QUESTIONS
3、REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790TABLE OF CONTENTS1. SCOPE 21.1 Crimping Parameters 22. DOCUMENTS . 32.1 Document Hierarchy . 32.2 Test Request/Order. 32.3 Materials and Process Specifications . 32.4 Referenced Docu
4、ments 33. GENERAL REQUIREMENTS. 43.1 Record Retention 43.2 Sample Documentation. 43.3 Sample Size 43.4 Default Test Tolerances 43.5 Test Default Conditions. 43.6 Equipment . 43.7 Definitions and Glossary . 53.8 Measurement Resolution 53.9 Test Repeatability items of customary laboratory equipment an
5、d supplies will also be required. Use of equipment with a lesser range is acceptable for specific tests where the required range for that test can be met. The equipment range specified does not preclude use of equipment with a larger range, but the accuracy must remain within the specified tolerance
6、.SAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 5 -TABLE 3.6 - EQUIPMENT LISTDESCRIPTION REQUIREMENTSDC Power Supply (Regulated) 020V current sized as requiredMicro-Ohmmeter 0-20 mV maximum open circuit voltage100 mA maximum test current0.0
7、1 m: resolutionDigital Multimeter(DMM)Capable of measuring 0.001-50 Volts DC with accuracy of 0.5% of measurementMillivolt Meter Capable of measuring 0-100 mV DC with accuracy of 0.5 mV Thermocouples Type “J“ or “T“ as required (small size .08mm)Force Tester Capable of an accuracy of 1% of measureme
8、ntTemperature Cycling Chamber -40 C to 125 C, 0% to 98% RHThermal Shock Chamber -40 3 to 125 C (in 5 minutes or less)Forced Air Oven +85 3 CTemperature Chamber -40 3 CTemp. /Humidity Chamber 95 to 98% RH at +65 3 C3.7 Definitions and GlossaryDefinitions for technical terms are listed in Appendix B.
9、Abbreviations and acronyms are listed in Appendix C.3.8 Measurement ResolutionUnless otherwise specified, meters and gages used in measurements of test samples shall be capable of measuring with a resolution one decimal place better than the specified value. For example, wire diameter specified as 0
10、.1 mm might actually be the same as one specified as 0.10 mm, calipers capable of 0.01 mm resolution may be used to measure the first wire but a micrometer with 0.001 mm resolution is required to measure the second wire.3.9 Test Repeatability no strands outside the crimp or broken-off before the cri
11、mp are allowed. For wires 0.8mm stock. (For accurate crimp height measurement, it is recommended that the burr height not exceed the lowest position of the crimp.) The burr must not cause damage to any subsequent operation. Special care must be taken when using mat seals that can be cut by a burr. S
12、eals are validated per USCAR-2 for each connector design.FIGURE 4.3.5-2 - CONDUCTOR CRIMP BURR DETAIL3. Insulation cross-section (with no cable seal) must meet ideal views shown in Figure 4.3.5-3a or acceptable views in Figure 4.3.5.3b. No unacceptable cross-section views as shown in Figure 4.3.5-4c
13、 are allowed. For acceptance criteria on non-standard insulation crimp designs, refer to the terminal manufacturers recommendations; some insulation crimps serve as a functional part of the terminal/cavity retention system and functional failures will result from non-compliance. FIGURE 4.3.5-3A - ID
14、EAL INSULATION CRIMP CROSS-SECTIONS FOR DIFFERENT STYLE DESIGNSFIGURE 4.3.5-3B - ACCEPTABLE BUT NOT IDEAL INSULATION CRIMPSInsulation extruded outward between open insulation wingsIDEAL INSULATION CRIMPS HAVE:Symmetric crimpNo insulation penetrationWings embracing insulation Less than3-point contact
15、Insulation wings contact conductor (no damage allowed)0.1 mm max.LOWEST POINT OF CRIMP(USED FOR CCH MEASUREMENT)SAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 13 -Insulation is splitFIGURE 4.3.5-3C - UNACCEPTABLE INSULATION CRIMPS4. Cable s
16、eals must have no nicks or cuts in the sealing ribs. Minimal nicks or cuts are allowed in the seal neck if functional seal retention requirements are met. Insulation crimp wings are not permitted to penetrate into the seal neck. See Figure 4.3.5-4a for a cross-sectional illustration of a cable seal
17、and Figure 4.3.5-4b for a mat seal. FIGURE 4.3.5-4A - CABLE SEAL CROSS-SECTION (INCLUDING TERMINAL AND WIRE)5. Crimped terminal and wire must be designed to avoid damage (such as nicks and cuts) to the sealing ribs when inserting terminated leads through mat seals. Refer to Figure 4.3.5-4b for a sam
18、ple cross-section view. Functional sealing performance is determined in USCAR-2 testing.FIGURE 4.3.5-4B - MAT SEAL APPLICATIONOne or both wings penetrate strandsOne or both wings penetrate throughSealing RibMat SealPlugged WireSAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABL
19、E-TO-TERMINAL ELECTRICAL CRIMPS - 14 -4.4 Conductor Crimp Pull-Out Force Test4.4.1 PurposeThis procedure details a method to measure the retention capability of crimped connections. The pull-out force test is not be used to determine overall performance of the crimp application. It is intended to be
20、 used for mechanical crimp evaluation only. It will only be used to determine the mechanical limits of the application for handling purposes. Applications may require additional protection to assure the crimped circuit survives the harness handling and vehicle assembly process. 4.4.2 Equipment1. Mea
21、suring device capable of measuring crimp heights and widths2. De-crimping tool or other suitable means of opening insulation crimp wings without damaging the cable conductor (Note: It is acceptable to make the samples with the insulation wings not crimped to avoid this step.)3. Force tester4. Cable
22、strippers, long-nose pliers and/or side cutters 4.4.3 Samples1. A minimum of 20 samples is required to be tested for each tested crimp height (3 crimp heights minimum, 5 are often used to give a wider range of tested crimp heights). Additional samples may be required for crimps with multiple wires o
23、f various sizes (See 4.4.4, steps 7 and 8).4.4.4 Procedure1. Pull-out force test shall be performed on leads with the insulation crimp wings open (not crimped).2. Pull-out force test shall be performed on taut leads (i.e., remove slack in cable before performing pull-out test to prevent incorrect te
24、st results due to “jerking”).3. Measure and record the conductor crimp height and width in millimeters for each sample. Refer to Appendix E, 6-8.4. If the insulation crimp is not already open, open it with a de-crimper or other suitable tool so that the pull-out force will reflect only the conductor
25、 crimp connection.5. Visually inspect the de-crimped area to ensure that none of the conductor strands have been damaged. Do not use any samples that have damaged conductor strands.6. Measure and record pull-out forces in Newtons for each sample.7. Apply axial motion at a rate between 50 and 250 mm/
26、minute (100 mm/min. is recommended).8. For double, triple, or multiple wire crimp setups with conductor sizes within one step, pull the smallest conductor. (e.g. for a 0.35/0.50 double, pull the 0.35 mm2 wire). For double, triple, or multiple wire crimp with conductor sizes more than one size apart,
27、 one of the smallest and one of the largest gage size cables must be tested. (e.g. for a 0.50/1.0 double, pull both wires individually, for a 0.50/1.0/2.0 triple, pull the 0.50 mm2 and the 2.0 mm2 wires, for a 0.50/0.50/2.0 triple, pull one of the 0.50 mm2 and the 2.0mm2wires.) In this case, 20 samp
28、les per wire size tested are required. A new specimen is required for each pull. SAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 15 -9. Calculate the mean and standard deviation using the following formulas (using Excel or other suitable spr
29、eadsheet to calculate the mean and standard deviation of the tensile result obtained in steps 69). Report minimum, maximum, mean ( X ), standard deviation (s), and the mean minus three standard deviations ( X -3s) for each crimp height set.nXniiX 1)(Mean 1(s)Deviation Standard212 nn XXniiWhere X i =
30、 individual pull-out force; n= number of samples.EQUATION 4.4.4-9A AND 4.4.4-9B - MEAN AND STANDARD DEVIATION FOR PULL CRITERIA10. Report any observations from visual examination.4.4.5 Acceptance Criteria:The ( X -3s) value calculated using Equations 4.4.4-9 a and b must meet or exceed the value spe
31、cified in Table 4.4.5.Forces for unlisted wires can be calculated by linear interpolation of values in Table 4.4.5.NOTE: Tensile strength is intended to be an indicator of crimp quality. When the test fails due to the tensile strength of the wire (unrelated to crimp) not meeting the listed values, a
32、n engineering change to a stronger wire is required.TABLE 4.4.5 - PULL-OUT FORCE REQUIREMENT (IN MM AND GAUGE SIZES)ISO(a)(mm2) : $ -3s Pull-out Force (N)0.13(b) 500.22 500.35 500.50 750.75 901 1201.5 1502 1802.5 2103 2404 2655 2906 3208 35010 45010 600(c)Wire GaugeSAE(a)(mm2) :$ -3s Pull-out Force
33、(N)26(b) 0.13 5024 0.22 5022 0.35 5020 0.50 7518 0.80 9016 1 12014 2 18012 3 24010 5 2908 8 35010 600(c)(a) ISO standard sizes based on ISO-6722-1. SAE is based on SAE J1127 and J1128.(b) 0.13mm2 (26 AWG) and smaller require special handling and controls not covered in this document.(c) The requirem
34、ent on 10mm2 is for minimum value only. No pull-to-failure or : $ -3s calculation is required.SAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 16 -4.5 Electrical Performance Tests4.5.1 Electric Current Cycling Test (ECC)4.5.1.1 PurposeCurrent
35、 cycling is an accelerated aging test that emphasizes the effect of expansion and contraction of terminal interfaces and conductor crimps as a result of thermal cycling. This test is optional when run in addition to ENV. With the approval of the customer, it may be used in lieu of ENV (See Table 5.1
36、) but must be noted as such on the drawing and requires customer approval. Typically, the Accelerated Environmental Test (Paragraph 4.5.2) is done and not ECC.4.5.1.2 Samples1. Any engineering development, prototype, or production terminal particularly those intended for high current or “Power” appl
37、ications may be submitted for test.2. Test data will be collected on 10 samples of each crimp height. Data shall be obtained and recorded for minimum, maximum and nominal production crimp heights.3. Where mating terminals are available, apply them to the opposite ends of the test samples. These shal
38、l be 150mm min. The terminal crimps on the mating terminals shall be soldered. Connect to form a continuous series circuit.4. Test sample terminals that have no mating terminals should be applied to one end only of the test cable (a minimum cut length of 150 mm). The opposite stripped ends of the sa
39、mples are then soldered to box or blade of the next sam-ple to form a continuous series circuit.5. Double terminations should be terminated with the test terminal on one end only. A mating terminal may be applied (with the crimp soldered) to the other end of the largest size cable.4.5.1.3 Equipment1
40、. Power supply AC or DC current regulated capable of supplying the test current.2. Cycle timer.3. Ammeter or current shunt/voltmeter.4. Voltmeter.5. Voltage sense lead solid conductor 0.22 mm or smaller diameter (tinned or non-tinned). 6. Welder Tweezer Weld TW-3 or similar device.7. Terminal test b
41、oard.8. Samples (3) with solder added to the conductor crimp for deduct calculation. 4.5.1.4 Procedure1. Perform a visual inspection of components per paragraph 4.5.2.2. Attach voltage sense leads per figure 4.5.1.4. The same location must be used for all samples. The V+ test lead may be connected t
42、o back of insulation wing if wing does not touch the core.SAE/USCAR-21 REVISION 3 Revised 2014-11PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 17 -FIGURE 4.5.1.4 - TEST LEAD ATTACHMENT.3. Attach sense leads to the test cable at a point 75 3 mm from the rear edge of the conducto
43、r crimp.4. Connect in a series circuit.5. Loosely attach the samples to a test board with a minimum of 35mm between single terminals.6. Connect the series test circuit to the ammeter (current shunt) and a timer-controlled power supply. Include the soldered test samples (4.5.1.3-8) in the circuit. Th
44、e test duration shall be 200 8 hours with the test current cycling on for 45 minutes 2 minutes and off for 15 2 minutes.7. Use test currents listed in table 4.5.1.4. The test currents for conductors sizes not listed above can be defined by linear interpolation (i.e. read out from plotted values). Pe
45、rform step 8 if wire is equal to or larger than 8mm2.TABLE 4.5.1.4 - TEST CURRENT FOR CURRENT CYCLING.ISO Wire Size(mm2)Wire Gauge Test Current (A)0.13 26 40.35 22 100.50 20 140.75 18 181 16 221.5 - 262 14 302.5 - 353 12 404 - 525 10 656 - 808 8 Use step 8SAE/USCAR-21 REVISION 3 Revised 2014-11PERFO
46、RMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS - 18 -8. If wire is larger than 8mm2, determine test current using this method (an acceptable alternative to steps a, b, and c is to perform the “Maximum Test Current Capability” test identified in SAE/USCAR-2).a. Attach thermocouples to s
47、amples at a point on the underside and just in front of the conductor crimp. Welding or epoxy is permissible.b. Apply 75% of the estimated current to the circuit at room temperature.c. Allow the circuit to come to steady state temperature. The temperature is stable when the crimp on the sample under
48、 test changes less than 2 C in 5 minutes. d. Measure the temperature, and calculate the temperature rise.If the temperature rise is less than the maximum temperature rise recommended by the terminal supplier or 55qC, whichever is lower, then increase the current in 0.5A steps until that temperature
49、is reached.e. The current at which the maximum temperature rise recommended by the terminal manufacturer or 55 qC, whichever is lower, is reached is the test current.9. Measure voltage drop after 2 1 hours from the start of test and at the completion of the test (200 8 hours). The samples should be energized for a minimum of 30 minutes to allow for temperature stab
