1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards METHOD OF CONNECTOR TEST Do Not Use on New Programs. Being Replaced by GMW3191 EDS-T-5507 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 1/10 ISSU
2、ED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW3191. 1. PURPOSE This standard aims at helping test personnel perform
3、tests in an accurate way by standardizing methods of connector testing performed by the electrical testing part. 2. SCOPE This standard applies to connectors for automobiles used and tested by GMDAT. (However, when there are separate standards, or drawings of a higher order, they shall prevail.) 3.
4、DEFINITION 3.1. Connector: Connecting devices (including parts) for electrical connection between circuits or devices. 3.2. Adapter: A device to connect two or more plugs or receptacles 3.3. Contact: Electrical connection of connectors 3.4. Insulator: Materials that provide electrical insulation bet
5、ween contacts, or between the contact and the conductor. 3.5. Guide: A device used to provide a desirable state of connection by correcting the error of each connector to the connection axis with a proper orientation. 3.6. Cap: A device used to provide a desirable state of connection by correcting t
6、he error of each connector to the connection axis with a proper orientation. 3.7. Shell: A exterior case that incorporates insulators and contacts to help the shaping of the connector. 3.8. Splicing nut: A box nut that forms a part of coupling and is used to help the shaping of the connector. 3.9. L
7、ocation of insulators: Location of an insulator relative to a shell 3.10. Coupling: A general term referring to parts that electrically or mechanically connect a connecter to another connector. 3.11. Splicing sleeve: A steel piece with a bayonet lock groove that forms a part of a coupling and helps
8、to connect connectors and maintain a distance between connectors. 3.12. Stud: A projected piece that forms a part of a coupling and connects with the splicing sleeve to maintain a EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 2/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO
9、Auto & Technology distance between connectors and help connection of connectors and help connection of connectors. 3.13. Splicing pitch: The distance between the printed circuit board of an adjacent contactor and the contacting part. 3.14. Holding force of contacting part gauge: A force required to
10、hold the male gauge specified by the spring contact pressure with the female contacting part. 3.15. Elasticity of contacting part: Elasticity of female contacting part 3.16. Cable holding part: A part of a connector that holds coaxial cables or wines 4. TYPES 4.1. Symbol The symbolization of types s
11、hall conform to the following. 4.1.1. Connector: The symbol indicating a connector shall be CN. 4.1.2. Type: Symbol indicating types shall be as shown in Table 1. Table 1 Symbol Type C 01 Coaxial connectors mainly used for high frequency circuits Q 01 Square connectors mainly used for low frequency
12、circuits R 01 Cylindrical connectors mainly used for low frequency circuits P 01 Connectors used for printer switch boards 4.1.3. Shape of connector: Symbol indicating connector shapes shall be as shown in Table 2. Table 2 Symbol Shape of connector SP Plugs whose coupling axis lies parallel with the
13、 cable insert axis LP Plugs whose coupling axis lies perpendicular to the cable insert axis SR Receptacles whose coupling axis lies parallel with the attaching surface LR Receptacles whose coupling axis perpendicular to the attaching surface SA Adapters whose two coupling axis lies parallel with eac
14、h other LA Adapters whose two coupling axis lies perpendicular with each other TA Adapters whose three coupling form T shape 4.1.4. Shape of contact: Symbol indicating contact shapes shall be as shown in Table 3. EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 3/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2
15、008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Table 3 Symbol Type M Electrical contacting parts are male shape E Electrical contacting parts are female shape X Electrical contacting parts are of the shape other than the above two 4.1.5. Number of contacts: Symbol indicating the number of contac
16、ts shall be as shown in Table 4. Table 4 Symbol No. of contacts Symbol No. of contacts 001 1 028 28 002 2 030 30 003 3 032 32 004 4 036 36 005 5 040 40 006 6 044 44 007 7 048 48 008 8 052 52 009 9 056 56 010 10 060 60 012 12 065 65 014 14 070 70 016 16 075 75 018 18 080 80 020 20 085 85 022 22 090 9
17、0 024 24 095 95 026 26 100 100 4.1.6. Special structures: Symbol indicating special structures shall be as shown in Table 5. Table 5 Symbol Special structure W Water-proof structure that can be used outdoors. P Air-tight structure that can be used for pressure-resistance purpose. H A structure that
18、resists high voltage. T A structure that resists high or low temperature. 5. PERFORMANCE EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 4/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 5.1. Electrical performance 5.1.1. Insulation resistance: The insulation
19、resistance between contacts or between contacts and other conductors shall conform to Table 10. Table 10 Insulation resistance / Unit: 100 1,000 500 5,000 5.1.2. Withstand voltage: The withstand voltage shall be selected in Table 11. (Here, the voltage application time shall be 1 minute.) Table 11 W
20、ithstand voltage(AC effective value) /Unit: V 160 1,600 315 3,150 800 8,000 1,000 10,000 5.1.3. Contact resistance: The contact resistance between contacts shall conform to Table 12. Table 12 Contact resistance / Unit: m 3.15 16 5 50 10 - 6. CONNECTOR TEST METHOD 6.1. Test condition 6.1.1. Standard
21、atmospheric condition Unless otherwise specified, tests and measurement shall be performed at a standard temperature condition(room temperature: 535), a standard humidity condition(relative humidity: 4585, and a standard atmospheric pressure(8601060 mBAR). 6.1.2. Evaluation condition Evaluation cond
22、ition A (Temperature class 2: 20 / humidity class 2: 60 70 /atmospheric pressure: 860 1060) 6.2. Appearance, structure and dimension test 6.2.1. Appearance, structure test Appearance and structure test shall be performed with naked eyes. EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 5/10 ISSUED DATE: 199
23、1. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.2.2. Dimension test Dimension test shall conform to vernier caliper, micro meter, gage, projector and tool microscope and for screws, limit gage for metric coarse thread an limit gauge for metric fine thread shall be used.
24、 6.2.3. Interchangeability test The test shall be performed by connecting and disengaging the one randomly selected among connectors having suitable connecting part. 6.2.4. Indication Indication test shall be performed with naked eyes. 6.3. Electrical performance test 6.3.1. Voltage resistance: The
25、voltage tester whose voltage can be gradually increased up to the test voltage and voltage precision shall be within 5%. When applying the specified voltage in the respective standard to between adjacent contacts of connectors to be tested or a contact and other adjacent metals for 1 minute 5 second
26、s, inspect the presence of abnormalities such as insulation damage and burr. After voltage shall be slowly increased from zero to the specified value at the rate of about 500V for minute as evenly as possible. 6.3.2. Insulation resistance: Insulation resistance tester whose measuring precision is 10
27、 shall be used. Insulation resistance shall be measured by applying the voltages in Table 13 to between adjacent contacts of connectors to be tested or a contact and other adjacent metals for 1 minute 5 seconds. Table 13 Test voltage (direction current) 100 10 / 500 50 / 1000 100 6.3.3. Contact resi
28、stance: Measurement circuit shall be a contact resistance tester as shown in Fig. 1 or Fig. 2. Figure 1. Voltage Dropping Method EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 6/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Figure 2 Measure the contact resi
29、stance by connecting suitable wire to the contact part of the connectors to be tested as used in normal condition. Where) In case shown in Fig. 1, calculate test current and test voltage. 6.3.4. Low voltage & low current contact resistance The test specimen of 20 mV voltage at its open circuit shall
30、 be used, which random direct current of 1050mV can be applied to and shall be 10% in the measurement precision of contact resistance value. Voltage drop method shall be as shown figure 3. Figure 3 Contact resistance shall be calculated by measuring voltage between measuring points when Random curre
31、nt of 10-20mA is applied by connecting the connector as used in normal condition to make the contact part of group 10 connected in series and adjust the voltage open circuit at 20mV. 6.4. Mechanical performance test 6.4.1. Vibration resistance Apply vibration in vertical 3 directions including conne
32、cted axis for 2 hours respectively. Make final measurement for the items specified in respective standard. 6.4.2. Gage holding force of contact part After plugging and unplugging the gage three times into the contact part of the connector to be tested up to the usual depth, the holding force of unpl
33、ugged direction shall be measured by inserting the measuring gage. EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 7/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.4.3. Elasticity of contact part The contact part to be tested shall be fixed to the jig turni
34、ng during the test as shown in Fig. 57 to keep the connected axis of contact part even and shall be slowly turned 360by inserting it to the specified depth, and then the gage holding force of contact part in 8.4.2 shall be measured. Where) Contact part shall be fixed so that it may not be turning wi
35、thin the connector. Figure 5. Jig Giving Bending Moment (quenched steel) Figure 6. Holding Jig for Testing the Connector Figure 7. Jig for Testing the Connecting Part Pinched into the connector 6.4.4. Total plugging and unplugging force Remove the unnecessary part of the connector to be tested and m
36、easure the plugging and unplugging force 5 times consecutively by plugging and unplugging the connector in the axis direction. EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 8/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.4.5. Strength of cable holding pa
37、rt After attaching the cable suitable for the connector to be tested to the attachment device of general use and then applying tensile force in the axis direction of the cable for the specified time, measure the displacement at the attachment point. 6.4.6. Connecting strength of connecting part Conn
38、ect the connecter to be tested used in normal condition and attach it to the tester. Examine the presence of abnormalities in connecting function by applying the specified tensile force for the specified hour in the connected axis direction. 6.4.7. Strength of the attaching part of the connector Att
39、ach the connector to be tested as used in normal condition to the panel and chassis. Examine the presence of abnormalities in the attachment function by applying the specified tensile force and torque. 6.5. Environment test 6.5.1. Salt spray (KS C6022) Concentration of salt water shall be 51%. Test
40、time shall be 48 hours or 96 hours. Post treatment and individual measurement shall be done. 6.5.2. Temperature cycle (KS C6011) Unless specified in drawings or test specification, perform the test as follows Perform 5 cycles according to table 14 with stage 1 to 4 as one cycle. After taking out the
41、 connector from chamber and then leaving it at the standard condition for one to two hours, perform the final measurement for the items specified in the respective standard. Table 14 Stage Test type 1 2 3 4 Temperature () - 25 3 5 35 85 2 5 35 A Time (min) 30 10 15 30 10 15 Temperature () -40 3 5 35
42、 1002 5 35 B Time (min) 30 10 15 30 10 15 Temperature () -65 3 5 35 1253 5 35 C Time (min) 30 10 15 30 10 15 Temperature () -55 3 5 35 852 5 35 D Time (min) See KS C6011 Within 5 See KS C6011 Within 5 Temperature () -55 3 5 35 1253 5 35 E Time (min) See KS C6011 Within 5 See KS C6011 Within 5 Temper
43、ature () -25 3 5 35 2004 5 35 F Time (min) See KS C6011 Within 5 See KS C6011 Within 5 6.5.3. Moisture resistance Maintain the temperature and relative humidity at 402 and 9095%. After performing the test for the EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 9/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2
44、008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology exposure time specified in Table 15, conduct the postreatment and the final measurements. Table 15 Exposure time / Unit: time 96(4 days), 240(10 days), 504(21 day), 1344(56 days) 6.5.4. Moisture cycle (Temperature humidity cycle) Perform the test as
45、 shown in Fig. 8 for 10 cycles with 24 hours as one cycle. Figure 7 EDS-T-5507METHOD OF CONNECTOR TEST PAGE: 10/10 ISSUED DATE: 1991. 01. 25 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.5.5. Waterproof Perform the test according to DIN 40050. 6.5.6. Airtightness Put the entire
46、 part of a connector into a chamber by applying the atmospheric pressure specified in the respective standard to the connect to be tested and then remove the blow holes attached on the surface. After leaving it for 20 seconds or more, examine the presence of leaking blow holes. In this case, the atmospheric pressure shall be a gauge pressure of 0.18 or 3.5 kgf/cm. 6.5.7. The lessoning of pressure Make final measurements specified in respective standard by leaving test piece in lessoned pressure for five minutes after coming to the pressure specified in respective standard.
