SAE J 2544-2000 Plug-In Relay Test Methods.pdf

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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 entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro

2、m, 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.TO PLACE A DOCUMENT ORDER; (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS http:/www.s

3、ae.orgCopyright 2000 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001STANDARDSubmitted for recognition as an American National StandardJ2544ISSUEDSEP2000Issued 2000-09Plug-In Relay Test MethodsTABLE OF CONTENTS

4、1. Scope. 21.1 Purpose 22. References . 22.1 Applicable Documents 22.1.1 SAE Publications 22.1.2 CEI/IEC Publications 22.2 Related Publications 22.2.1 Relay Engineers Handbook. 23. Definitions. 24. Technical Requirements. 24.1 Mounting Conditions. 24.2 Test Methods 34.2.1 Parametric (Electrical) 34.

5、2.2 Environmental/Mechanical/Electrical Tests 75. Notes 155.1 Key Words 15SAE J2544 Issued SEP2000-2-1. ScopeThis SAE Standard covers standard test methods for environmental, mechanical, and electricaltesting of plug-in relays used in surface vehicle electrical systems.1.1 PurposeThis proposal speci

6、fies standard test conditions for the evaluation of plug-in relays used in surfacevehicle applications.2. References2.1 Applicable PublicationsThe following publications form a part of this specification to the extent specifiedherein. Unless otherwise specified, the latest version of SAE publication

7、s shall apply.2.1.1 SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SAEJ1113-42Electromagnetic CompatibilityComponent Test ProcedureConducted TransientEmissions2.1.2 CEI/IEC PUBLICATIONAvailable from International Electrotechnical Commision, 3 rue de Vaembe, Gene

8、va,SwitzerlandCEI/IEC 529 (Code IP)Degrees of Protection by Enclosures2.2 Related PublicationsThe following publication is provided for information purposes only and is not requiredpart of this document.2.2.1 NATIONAL ASSOCIATION OF RELAY MANUFACTURERS PUBLICATIONAvailable from National Association

9、ofRelay Manufacturers (NARM), Milwaukee, WI 53217.Relay Engineers Handbook3. Definition3.1 UOSUnless otherwise specified.4. Technical Requirements4.1 Mounting ConditionsTo ensure proper function and to avoid physical damage, it is recommended to mountthe relays in connectors/test fixtures so that:a.

10、 The relay insertion force does not exceed the retention force of the weakest relay terminal (100 N for2.8 to 6.3 mm, 150 N for 9.5 mm).b. The relay terminals do not bend.c. There is a minimum 5 mm gap to the next relay (for heat dissipation).d. The wire size is appropriate for the load to dissipate

11、 heat from the relay (see Table 1 for wire sizerecommendations). NOTEThe wire size, type, and length information is recommended as the default if not otherwisespecified by the end user.SAE J2544 Issued SEP2000-3-4.2 Test Methods4.2.1 PARAMETRIC (ELECTRICAL)4.2.1.1 Test Set-Up for 12 V Systems4.2.1.1

12、.1 Power SupplyThe power supply shall comply with the following specification:a. Output currentCapable of supplying the continuous and surge currents of the design loads.b. Regulation1. DynamicThe output voltage at the supply shall not deviate more than 1.0 V from 0 to a maximumload (including inrus

13、h current) and shall recover within the area generated by the equation (Eq. 1)2. StaticThe output voltage at the supply shall not deviate more than 2% with changes in static loadfrom 0 to maximum (not including inrush current) for static line voltage variations.c. Ripple VoltageMaximum 75 mV peak-to

14、-peak4.2.1.2 General Test Conditionsa. Ambient temperature23 C 5 Cb. All measurements are to be performed with the relay oriented in the same position.c. Relay shall not be in close proximity to metal surfaces.d. Condition ContactsCycle with any suitable test current and voltage up to rated load for

15、 a minimum of5 times.e. Monitor ContactsWith any suitable test current up to rated load and open circuit voltage as specifiedfor the rated load.f. Linear ramp-up and ramp-down of coil voltages may be substituted for stepped ramps; however, thismay alter the test data slightly.TABLE 1WIRE SIZE RECOMM

16、ENDATIONS(1)(2)1. The recommended wire type for all set-ups is stranded copper with thin wall cross-linked polyethylene insulation capable of withstanding 125 C.2. The recommended wire length for all connections is 2.5 to 3.0 m.Test Load (amp)AcceptableWire GageMetric(mm2)Acceptable WireGageCustomar

17、y(ga)0.5 - 15.0 1.0 1615.1 - 20.0 2.0 1420.1 - 30.0 3.0 1230.1 - 40.0 5.0 1040.1 - 55.0 8.0 81.0V 1 e tT(), T100 s=SAE J2544 Issued SEP2000-4-4.2.1.3 Pull-in Voltage4.2.1.3.1 DefinitionMinimum voltage applied to the relay coil that causes the relay contacts to close (switch on).4.2.1.3.2 Test Method

18、a. Apply a voltage across the coil terminals, starting with an applied voltage of 0 to 3.0 V. Increment up at0.10 to 0.25 V increments and record contact closure (pull-in voltage).NOTERamp-up rate of 0.1 to 5.0 V/s.b. Contact closure is defined as the voltage drop across the contacts being less than

19、 or equal to 10% ofthe applied voltage.4.2.1.4 Seal Voltage4.2.1.4.1 DefinitionMinimum voltage applied to the relay coil that causes the armature to rest against the core(full travel).4.2.1.4.2 Test Methoda. Apply a voltage across the coil terminals, starting with an applied voltage of 0 to 3.0 V. I

20、ncrement up at0.10 to 0.25 V increments and record contact closure (pull-in voltage).NOTERamp-up rate of 0.1 to 5.0 V/s.b. Monitor coil current using a suitable oscilloscope and current probe or other suitable current monitoringmethods.NOTEInductance change, results in a negative current spike.4.2.1

21、.4.3 Alternate Methoda. Apply a voltage across the coil terminals, starting with an applied voltage of 0 to 3.0 V. Increment up at0.10 to 0.25 V increments and record contact closure (pull-in voltage).NOTERamp-up rate of 0.1 to 5.0 V/s.b. Increase the voltage to nominal voltage then reduce the volta

22、ge until the relay drop outs.c. Increase the voltage to the pull-in voltage from step “a” and reduce the voltage until the relay dropsout. If the difference between this voltage and the voltage from step “b” is minimal, typically 1V, theseal voltage is the pull-in voltage.d. If the drop-out voltage

23、difference is not minimal, increase the voltage to a level above the pull-involtage and repeat step “c”. If this voltage results in a minimal difference in the drop-out voltage, thenthis voltage is the seal voltage.e. Repeat step “d” until a minimal difference in drop-out voltage occurs.4.2.1.5 Drop

24、-Out Voltage4.2.1.5.1 DefinitionMaximum voltage applied to the relay coil that causes the relay contacts to open (switch-off).4.2.1.5.2 Test Methoda. Apply a voltage greater than the seal voltage across the coil to insure the armature is sealed. Ramp orstep down based on power supply at 0.1 to 5.0 V

25、/s at 0.1to 0.25 V increments until contacts open.b. Contact opening is defined as the voltage drop across the contacts being greater than 10% of theapplied voltage.SAE J2544 Issued SEP2000-5-4.2.1.6 Coil Resistance (or equivalent)4.2.1.6.1 DefinitionThe coil circuit DC resistance as measured from t

26、he relay coil.4.2.1.6.2 Test Method I(No semiconductor components are present)a. Directly apply the probes of a digital or analog multi-meter to relay terminals.b. Measure and record the resistance.All measurements shall be made before powering the coil or after sufficient cooling time to assure the

27、device is at ambient temperature. The resistance of the test leads shall be subtracted from themeasurement value, unless a four wire “Kelvin” method is utilized. The multi-meter used shall becapable of reading 0.1 or less.4.2.1.6.3 Test Method II(Semiconductor components are present)a. Apply rated v

28、oltage across the relay coil terminals.b. Measure and record the total current draw as the voltage drop across a 1 1% precision seriesresistor or digital ammeter, then calculate equivalent resistance using ohms law.All measurements shall be made on the device after it has stabilized at ambient tempe

29、rature. Theresistance of the test leads and semiconductor shall be subtracted from the measurement value, unlessa four wire “Kelvin” method is utilized.4.2.1.7 Contact Voltage Drop4.2.1.7.1 DefinitionVoltage drop arising from the contact resistance of contacts when a current has been appliedto the r

30、elay.4.2.1.7.2 Test Methoda. Apply a constant current of 0.5 A at rated voltage through each set of relay contacts.b. Measure and record the voltage drop with a digital or analog multi-meter or any other methods ofmonitoring voltage at the output terminals after the contacts stabilize. (The multi-me

31、ter must have aresolution of 0.0001 V.c. Repeat steps a and b with rated load or 10 Amps maximum for devices rated greater than 0.5 A.4.2.1.8 N.O. Contact Bounce 4.2.1.8.1 DefinitionThe time elapsed from the relay energizing until the contacts stabilize.4.2.1.8.2 Test Methoda. Apply one channel of t

32、he oscilloscope across the relay coil terminals.b. Apply another channel of the oscilloscope across B+ and normally open contact terminals. Trigger onapplication.c. Apply rated voltage across the coil terminals to switch the rated load current or 10 A maximum. NOTESignal must be bounce free.d. Measu

33、re and record the time in milliseconds from coil energization until contacts stabilize.SAE J2544 Issued SEP2000-6-4.2.1.9 N.C. Contact Bounce4.2.1.9.1 DefinitionThe time elapsed from the relay de-energizing until the contacts stabilize.4.2.1.9.2 Test Methoda. Apply one channel of the oscilloscope ac

34、ross the relay coil terminals.b. Apply another channel of the oscilloscope across B+ and normally closed contact terminals. Triggeron application.c. Apply rated voltage across the coil terminals for at least 50 ms.d. Instantaneously remove the rated voltage across the coil terminals.e. Measure and r

35、ecord the time in milliseconds from coil de-energization until contacts stabilize.4.2.1.10 Coil Inductance4.2.1.10.1 DefinitionProperty of a coil winding; whereby, it resists any change of current during the build-up ordecaying of a self-induced magnetic field. L Measured in henries.4.2.1.10.2 Prepa

36、rationa. Measuring leads 1 mb. No measuring lead loops permissible4.2.1.10.3 Test Methoda. The relay shall be mounted in its normal operating position on a nonmagnetic plate with noimmediately adjacent metal.b. The relay coil shall be energized through a bounce free contact.c. Block armature in: non

37、-actuated position for minimum reading actuated position for maximum readingNOTEBy measuring the time for the current to reach 63% of its final value, the dc inductance iscalculated as: L=R*t wherewhere:L is the inductance in henriesR is the coil resistance in ohms (no suppression resistor or diode

38、allowed)t is the time in seconds for current to reach 63% of its final value4.2.1.11 Insulation Resistance4.2.1.11.1 DefinitionThis test is to measure the electrical resistance offered by the insulating materials of a relayto an impressed voltage tending to produce a leakage of current through or on

39、 the surface of thesematerials.4.2.1.11.2 RequirementsInsulation resistance requirements should specify:a. Voltage at which the measurement is to be performed; apply one of the following: 440 VRMS (60 HzAC), 500 VRMS (50 Hz AC), 500 V DC.b. Insulated terminations between which measurements should be

40、 takenc. The relay coil should be de-energized.SAE J2544 Issued SEP2000-7-4.2.1.11.3 Preparationa. A megohmeter or megohm bridge shall be used for these measurements, and the instructionsfurnished by the manufacturer shall be followed. The accuracy of measurements, including effects ofparallel leaka

41、ge paths in the wiring and test fixtures, shall be within 10% of the measured value.b. For inspection, relays shall be measured as shipped. Only cleaning representative of the method usedin regular production shall be used during evaluation and qualification testing.4.2.1.11.4 Test Methoda. Test vol

42、tage shall be applied between mutually insulated portions.b. Apply the selected voltage for one minute. The lowest reading observed after two seconds shall beconsidered a measure of the insulating resistance.c. Measure and record the Insulation Resistance.4.2.1.12 Conducted Transient Emissions (Drop

43、out Peak Voltage)4.2.1.12.1 DefinitionConducted emissions of transients, and other electromagnetic disturbances along batteryfeed (B+) or switched ignition inputs of a relay coil.4.2.1.12.2 Test MethodSee SAE J1113-42 for reference.NOTEFor clarification of 8.8 of SAE J1113-42, the worse case reading

44、 of each of the ten readings ofevery relay is used.4.2.2 ENVIRONMENTAL/MECHANICAL/ELECTRICAL TESTS4.2.2.1 Cover Strength4.2.2.1.1 DefinitionLimits of the push force applied to the cover (in direction to engage the connector body)before the cover dislodges or becomes physically impaired.4.2.2.1.2 Tes

45、t Methoda. Support the whole bottom of the relay at the base and apply a vertical force on the centerline with a13mm diameter steel rod having a 0.127-0.381 mm radiused edge, UOS. b. Advance the rod at a rate of 50 mm/min 5 mm/min to increase the force until a specified limit isreached. c. Remove th

46、e rod and visually inspect for physical damage of the relay.4.2.2.2 Cover Retention4.2.2.2.1 DefinitionLimits of the retention force applied to the cover (in direction to disengage the connectorbody) before the cover dislodges or becomes physically impaired.4.2.2.2.2 Test Methoda. Secure the relay t

47、o a base fixture by a suitable means (terminals acceptable) and apply a vertical forceby gripping on the cover as close to the top as possible by a suitable means, UOS. b. Advance the gripping fixture at a rate of 50 mm/min 5 mm/min to increase the force until the specifiedlimit is reached. c. Remov

48、e the gripping tool and visually inspect the cover for physical damage or evidence of dislodging.d. Repeat the test with the grip rotated 90 degrees.SAE J2544 Issued SEP2000-8-4.2.2.3 Bracket Retention4.2.2.3.1 DefinitionLimits of the retention force that the bracket retention feature will withstand

49、 without becomingdislodged or visibly impaired.4.2.2.3.2 Test Methoda. Secure the relay at its cover and apply a force in the direction to disengage the bracket by clamping onthe bracket by a suitable means, UOS. b. Advance the clamping fixture at a rate of 50 mm/min 5 mm/min to increase the force until thespecified limit is reached. c. Remove the clamping tool and visually inspect the bracket/cover for physical damage or evidence ofdislodging.4.2.2.4 Insertion Force4.2.2.4.1 DefinitionLimits of the engage forces appl