SAE J 3082-2015 Auxiliary Two Conductor Electrical Power Connector for Truck-TrailerHigh Power Jumper Cable.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 entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this

3、publication may 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: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J3082_201511 SURFACE VEHICLE STANDARD J3082 NOV2015 Issued 2015-11 Auxiliary Two

5、 Conductor Electrical Power Connector for Truck-Trailer High Power Jumper Cable RATIONALE Provide a standard for high current connections between a tractor and a (semi-) trailer to provide power to application specific equipment installed on the trailer. 1. SCOPE This SAE Standard provides the minim

6、um requirements for high power two conductor jumper cable plug and receptacle for truck-trailer jumper cable systems. It includes the test procedures, design, and performance requirements. This document covers receptacles rated at more than 30A (Ampere) up to and including 150A and is intended for a

7、 single circuit with one power conductor and one common return conductor. Single conductor high current connectors are not recommended for future designs because of inadequate ground return through 5thwheel / king pin. Cable size selection is to be made by the vehicle OEM for specific applications a

8、nd the specific voltage drop requirements of those applications. This SAE Standard covers two variants of high power two conductor connections: a heavy duty version with horizontally aligned pins, typically for lift-gate battery charging and a medium duty version with vertically aligned pins: typica

9、lly for loads such as power tarpaulins. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE Internat

10、ional, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J560 Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable SAE J2202 Heavy-Duty Wiring Systems for On-Highway Tru

11、cks SAE INTERNATIONAL J3082 NOV2015 Page 2 of 16 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. 2.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15

12、096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J1127 Low Voltage Battery Cable SAE J1908 Electrical Grounding Practice 2.2.2 American Society for Testing and Materials (ASTM) Publications Available from ASTM International, 100 Barr Harbor Drive

13、, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 117 Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM G 153 Standard Practice for Operating Enclosed Carbon Arc Light Apparatus for Exposure of Nonmetallic Materials ASTM G 154 Standard Practice

14、for Operating Fluorescent Ultraviolet (UV) Lamp Apparatus for Exposure of Nonmetallic Materials 2.2.3 International Organization for Standardization (ISO) Publications Copies of these documents are available online at http:/webstore.ansi.org/. ISO 4091 Road Vehicles - Connectors for the Electrical C

15、onnection of Towing and Towed Vehicles - Definitions, Tests and Requirements. ISO 9227 Corrosion Tests in Artificial Atmospheres - Salt Spray Tests. ISO 30013 Rubber and Plastics Hoses - Methods of Exposure to Laboratory Light Sources - Determination of Changes in Colour, Appearance and Other Physic

16、al Properties ISO 22241-1 NOx Reductin Agent AUS 32 - Part 1: Quality Requirements 2.2.4 Federal Motor Vehicle Safety Standards (FMVSS) Available from U.S. Department of Transportation, National Highway Traffic Safety Administration, safety assurance, office of vehicle safety compliance, 400 7thStre

17、et, SW, Room 6111, mail code NSA-30, Washington, DC 20590, www.nhtsa.gov. FMVSS 108 Lamps, Reflective Devices, and Associated Equipment FMVSS 121 Air Brake Systems SAE INTERNATIONAL J3082 NOV2015 Page 3 of 16 3. DEFINITIONS 3.1 AUXILIARY CONNECTOR As used in this document refers to the receptacle an

18、d cable plug that provides power to the low power auxiliary devices on the trailer, but does not provide power to safety lighting and the Antilock Braking System (ABS) as required by FMVSS 108 and/or FMVSS 121. 3.2 AUXILIARY POWER CONNECTOR As used in this document refers to the receptacle and cable

19、 plug that provides high power to auxiliary devices on the trailer, but does not provide power to safety lighting, the Antilock Braking System (ABS), or low power auxiliary devices. 3.3 CABLE PLUG The cable plug is part of the jumper cable assembly. 3.4 COUPLING CYCLE One coupling cycle is coupling

20、and uncoupling the plug and receptacle. 3.5 PRIMARY CONNECTOR As used in this document refers to the receptacle and cable plug that provides power to safety lighting and the ABS as required by FMVSS 108 and FMVSS 121. 3.6 RECEPTACLE The receptacle consists of the connector socket, its housing, and a

21、 cover which latches the cable plug in place. 3.7 SERVICEABLE A serviceable part is one that can be removed with reasonable force and reinstalled without visible damage. 4. IDENTIFICATION CODE DESIGNATION 4.1 Manufacturer Identification Devices conforming to this document shall be identified with th

22、e manufacturers identification. The device may include the model or part number. 4.2 SAE Designation Devices conforming to this document shall be visually differentiated by connector type 4.2.1 SAE J3082 AUX PWR Heavy Duty (Horizontal Pin) This is a heavier duty dual pole connection with horizontall

23、y aligned pins typically used for lift-gate battery charging. The connector shall be identified by either the color red and/or permanently marked with LIFTGATE or AUX PWR. See Table 3 and Figure 1 for wiring function. 4.2.2 SAE J3082 AUX PWR Medium Duty (Vertical Pin) This is a dual pole connection

24、with vertically aligned pins typically used for loads such as power tarpaulins which do not require as high of a current rating as the lift-gate connection. This connector shall be marked by either the color red and/or permanently marked with “AUX PWR”. It is an acceptable option but not recommended

25、 to leave this connection unmarked. The vertical pin alignment prevents mis-mating with heavy duty, higher rating connection. See Table 3 and Figure 4 for wiring function. SAE INTERNATIONAL J3082 NOV2015 Page 4 of 16 4.3 Revision (month and year) of the document to which the device conforms 4.3.1 Ex

26、ample XYZ Corp. SAE J3082 Mo/Yr. 5. TEST EQUIPMENT AND INSTRUMENTATION 5.1 The Power Supply The power supply shall be capable of supplying the continuous current required to perform all tests. 5.2 Voltmeter A direct current (dc) digital Voltmeter (DVM) with an input resistance greater than 1,000:/V

27、(Ohms / Volt) and with a resolution of 0.1Vdc shall be used. To achieve this resolution, the full-scale deflection shall be appropriate to the voltage rating of the system being tested. A DVM having at least a 3-1/2-digit display with an accuracy of r1% plus one digit is recommended for millivolt re

28、adings. 5.3 Ammeter A DC ammeter shall be used for current measurements. The meter range resolution shall be 0.1A. 5.4 Milli-ammeter A DC milli-ammeter shall be used for current measurements. The meter range resolution shall be 1.0mA. 5.5 Hipot (High Potential insulation tester) Capable of detecting

29、 leakage currents of 0.5mA at 500Vac 6. TEST PROCEDURES 6.1 Test Sequences The tests in 6.2, 6.3, and 6.4 are to be tested in the order listed in Table 1. Each test sequence is to be performed on six different production level connector assemblies. No supplemental lubrication or other cleaning of th

30、e terminal pins prior or during the test sequence is permitted. Table 1 - Test sequences Test Order Durability Test Mechanical Test Environmental Test 1 Voltage Drop 6.2.1 Voltage Drop 6.2.1 Voltage Drop 6.2.1 2 Isolation Resistance 6.2.2 Isolation Resistance 6.2.2 Isolation Resistance 6.2.2 3 Therm

31、al Shock 6.4.3 Thermal Shock 6.4.3 Thermal Shock 6.4.3 4 Coupling Force 6.3.1 Vibration 6.2.3 Salt Spray 6.4.2 5 Uncoupling Force 6.3.2 Straight Pull 6.3.4 Fluid Resistance 6.4.1 6 Angular Pull Force 6.3.3 Terminal Retention Force 6.3.6 Voltage Drop 6.2.1 7 Cycle Cover Spring 6.3.7 Voltage Drop 6.2.

32、1 Isolation Resistance 6.2.2 8 Coupling Cycle Test 6.3.8 Isolation Resistance 6.2.2 9 Voltage Drop 6.2.1 Terminal Wire Retention 6.3.5 10 Isolation Resistance 6.2.2 SAE INTERNATIONAL J3082 NOV2015 Page 5 of 16 6.1.1 Test Samples All test samples are to be configured with the mating designed cable un

33、less otherwise noted 6.2 Electrical 6.2.1 Voltage Drop The test is to be conducted in a draft-free room maintained at an ambient temperature of 25C r 5C. Test sample to comprise of a mated SAE J3082 assembly consisting of a receptacle and plug each with their terminals terminated to a 500 to 1,000mm

34、 length of cable 6.2.1.1 Connect a 500 to 1,000mm long cable to the receptacle terminals and another 500 to 1,000mm long (SAE J1127 cable) to the cable plug terminals. Minimum #4 American Wire Gauge (AWG) cable should be used for heavy duty horizontal Pin connection and minimum #6 AWG cable for medi

35、um duty vertical pin connection. 6.2.1.2 Mate the cable plug and receptacle. 6.2.1.3 Connect a power supply and load to the two cable ends in such a way that it applies 100Adc to each circuit. 6.2.1.4 Turn on power supply and wait 15-30 minutes for the circuits to stabilize. 6.2.1.5 Measure the volt

36、age drop across each circuit of the assembly at a convenient point on the wire at least 25mm from the terminal. 6.2.2 Isolation Resistance See SAE J560 for this test procedure 6.2.3 Vibration See SAE J560 for this test procedure 6.3 Mechanical 6.3.1 Coupling Force See SAE J560 for this test procedur

37、e 6.3.2 Uncoupling Force See SAE J560 for this test procedure 6.3.3 Angular Pull Force See SAE J560 for this test procedure 6.3.4 Straight Pull (Cable Plug) See SAE J560 for this test procedure SAE INTERNATIONAL J3082 NOV2015 Page 6 of 16 6.3.5 Terminal Wire Retention This test pertains to the mecha

38、nical connection between the connector terminals and the cable wires. (Usually a crimped, welded, or set screw design). The strength of the connection shall be tested by using a suitable apparatus at a constant speed within the range of 50 to 100mm / minute. If the terminal has a cable insulation cr

39、imp, it shall be rendered mechanically ineffective. All samples are to be pulled to destruction. 6.3.6 Terminal Retention Force within the Plug and Receptacle Both the receptacle and or cable plug terminals shall be subjected to a direct pull and push force of 175 Newton (N) for one minute. The forc

40、e is to be exerted on each terminal without sudden or jerking forces during the test. NOTE: Secondary lock devices should be utilized if part of the design. 6.3.7 Cycle Cover Spring See SAE J560 for this test procedure. 6.3.8 Coupling Cycle Test See SAE J560 for this test procedure. 6.4 Environmenta

41、l 6.4.1 Fluid Resistance See SAE J2202 for this test procedure. 6.4.2 Salt Spray See SAE J560 for this test procedure. 6.4.3 Thermal Shock See SAE J560 for this test procedure. 6.5 Additional Testing 6.5.1 Ultraviolet Effects See SAE J560 for this test procedure. 7. PERFORMANCE REQUIREMENTS 7.1 Test

42、 Sequences The samples shall comply with all the tests in the sequence. Failure of one test during the sequence constitutes a failure of the sample. 7.2 Electrical 7.2.1 Voltage Drop The voltage drop for each circuit shall not exceed 0.001Vdc / Ampere (0.10Vdc at 100A) for the heavy duty connector v

43、ariant and shall not exceed 0.0015Vdc/Ampere (0.075Vdc at 50A) for the medium duty variant. SAE INTERNATIONAL J3082 NOV2015 Page 7 of 16 7.2.2 Isolation Resistance See SAE J560 for this tests performance requirements. 7.2.3 Vibration See SAE J560 for this tests performance requirements. 7.3 Mechanic

44、al 7.3.1 Coupling Force See SAE J560 for this tests performance requirements. 7.3.2 Uncoupling Force See SAE J560 for this tests performance requirements. 7.3.3 Angular Pull Force See SAE J560 for this tests performance requirements. 7.3.4 Straight Pull See SAE J560 for this tests performance requir

45、ements. 7.3.5 Terminal Wire Retention This is a destructive test. The tensile test of paragraph 6.3.5 performed on the terminal/wire interface shall meet the requirements of Table 2. Table 2 - Minimum tensile strength for terminal/wire interface connections Cable Size (AWG) Minimum Tensile Strength

46、(N) 0 600N 2 600N4 400N 6 355NThis pull test serves to evaluate terminal / wire integrity and is not to be construed as specifying conductor cabling used in specific applications. Cabling specifications are made by the vehicle manufacturer. 7.3.6 Terminal Retention Force The terminal shall maintain

47、its original position in the connector after testing in accordance with 6.3.6. 7.3.7 Cycle Cover Spring See SAE J560 for this tests performance requirements. SAE INTERNATIONAL J3082 NOV2015 Page 8 of 16 7.3.8 Coupling Cycle Test See SAE J560 for this tests performance requirements. 7.4 Environmental

48、 7.4.1 Fluid Resistance See SAE J2202 for this tests performance requirements. 7.4.2 Salt Spray See SAE J560 for this tests performance requirements. 7.4.3 Thermal Shock See SAE J560 for this tests performance requirements. 7.5 Additional Tests 7.5.1 Ultraviolet Effects See SAE J560 for this tests p

49、erformance requirements. 8. DESIGN REQUIREMENTS 8.1 Interchangeability The cable plug and receptacle shall be designed to conform to the performance requirements of this document. 8.2 Latch-ability The cable plug shall be designed to mate and latch to any receptacle designed to conform to this document. Cable plugs designed to meet J560 shall not be compatible with receptacles designed to conform to th