USCAR2-7 Performance Specification for Automotive Electrical Connector Systems.pdf

USCAR2-7 Performance Specification for Automotive Electrical Connector Systems.pdf

《USCAR2-7 Performance Specification for Automotive Electrical Connector Systems.pdf》由会员分享，可在线阅读，更多相关《USCAR2-7 Performance Specification for Automotive Electrical Connector Systems.pdf（88页珍藏版）》请在冰豆网上搜索。

PERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMSSAE/USCAR-2REVISION7February2020ISBN:

978-1-4686-0163-3SAE/USCAR-2REVISION7Issued1997-08Revised2020-02INTERNATIONALPERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMSNoticeaboutinterimrev1s1ons:

Updatesmaybemadeasinterimrevisions.Interimrevisionsareavailableat:

https:

/ewcap.uscarteams.orq/revisions.html.1.2.3.3.13.23.33.43.4.13.4.23.4.33.54.4.14.24.34.44.54.64.74.84.94.105.5.15.1.15.1.25.1.35.1.45.1.55.1.65.1.75.1.85.1.95.1.105.25.2.15.2.2TABLEOFCONTENTSSCOPE.4TESTSEQUENCE.4REFERENCEDDOCUMENTS.4DocumentHierarchy.4PartDrawing.5ProductDesignSpecification.5TestRequesUOrder.5Samples,TestType,andSpecialTests.5TestRequesUOrderInstructions.5PerformanceandDurabilityTestInstructions.5DocumentsMentionedinThisSpecification.5GENERALREQUIREMENTS.6RecordRetention.6SampleDocumentation.6SampleSize.6TestConditionsandTolerances.6Equipment.7MeasurementResolution.7TestRepeatabilityandCalibration.7ConformanceDetermination.7DispositionofSamples.8PartEndurance.8TESTandACCEPTANCEREQUIREMENTS.8General.8PerformanceRequirements.8DimensionalCharacteristics.8MaterialCharacteristics.8Classifications.8TestingHeadersandDirectConnectComponents.10TerminalSamplePreparation.11Connectorand/orTerminalCycling.11VisualInspection.11CircuitContinuityMonitoring.12MatSealSamplePreparation.14TerminalMechanicalTests.15TerminaltoTerminalEngage/DisengageForce.15TerminalBendResistance.16Theresearchdata,analysis,conclusion,opinionsandothercontentsofthisdocumentaresolelytheproductoftheauthors.NeithertheSAEInternational（SAE）northeUnitedStatesCouncilforAutomotiveResearch（USCAR）certifiesthecomplianceofanyproductswiththerequirementsofnormakesanyrepresentationsastotheaccuracyofthecontentsofthisdocumentnortoitsapplicabilityforpurpose.Itisthesoleresponsibilityoftheuserofthisdocumenttodeterminewhetherornotitisapplicablefortheirpurposes.Copyright2020USCARPrintedinU.S.A.Allrightsreserved.QUESTIONSREGARDINGTHISDOCUMENT:

（248）273-2470FAX（248）273-2494TOPLACEADOCUMENTORDER:

（724）776-4970FAX（724）776-0790SAE/USCAR-2REVISION7Revised2020-02-2-PERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMS5.35.3.15.3.25.3.35.3.45.45.4.15.4.25.4.35.4.45.4.55.4.65.4.75.4.85.4.95.4.105.4.115.4.125.4.135.4.145.4.155.55.5.15.65.6.15.6.25.6.35.6.45.6.55.6.65.6.75.75.7.15.85.95.9.15.9.25.9.35.9.45.9.55.9.65.9.75.9.85.9.9Terminal-ElectricalTests.18DryCircuitResistance.18VoltageDrop.20MaximumTestCurrentCapability.22CurrentCycling.25Connector-MechanicalTests.27Terminal-ConnectorInsertion/RetentionandForwardStopForce.27Connector-ConnectorMating/Unmating/Retention/LockDeflectionForces（Non-Assist）.30ConnectortoConnectorMate/UnmateForces（MechanicalAssist）.33PolarizationFeatureEffectiveness.36MiscellaneousComponentEngage/DisengageForce.37Vibration/MechanicalShock.41Connector-to-ConnectorAudibleClick.47ConnectorDropTest.47CavityDamageSusceptibility.48Terminal/CavityPolarizationTest.49ConnectorMountingFeatureMechanicalStrength.50MechanicalAssistIntegrity（ConnectorswithMechanicalAssistOnly）.52ConnectorSealRetention-UnmatedConnector.53ConnectorSealRetention-MatedConnector.54AirbaglnflatorConnectorSelf-RejectionAssessment.55Connector-ElectricalTests.57InsulationResistance.57ConnectorEnvironmentalTests.58ThermalShock.58Temperature/HumidityCycling.58HighTemperatureExposure.59FluidResistance.60Submersion.61PressureNacuumLeak.62HighPressureSpray.64TestsforHeaders.66HeaderPinRetention.66SevereDutyTests.67TestSequence.67GeneralNotesonTestSequence.67TestSequenceChart.68TerminalMechanicalTestSequence.68TerminalElectricalTestSequence.68ConnectorSystemMechanicalTestSequence.68ConnectorSystemElectricalTestSequence.70SealedConnectorSystemEnvironmentalTestSequence.71UnsealedConnectionSystemEnvironmentalTestSequence.72Stand-AloneSealingPerformanceTestSequence.72SAE/USCAR-2REVISION7PERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMSRevised2020-02-3-APPENDIXADEFINITIONS.73APPENDIXBABBREVIATIONSUSED.77APPENDIXCTESTSFORMOVEDTOOLS,ADDITIONALTOOLS,ANDMATERIALCHANGES.78APPENDIXDTESTSFORNEWTERMINAL,CONNECTOR,ANDSEALDESIGNS.80APPENDIXESOURCELISTFORAUTOMOTIVEFLUIDSUSEDINTESTING.82APPENDIXFDESIGNNOTES-TEMPERATUREANDCURRENTRATING.83APPENDIXGREVISIONS.84SAE/USCAR-2REVISION7PERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMS1.SCOPERevised2020-02-4-Proceduresincludedwithinthisspecificationareintendedtocoverperformancetestingatallphasesofdevelopment,production,andfieldanalysisofelectricalterminals,connectors,andcomponentsthatconstitutetheelectricalconnectionsystemsinlowvoltage（0to20VDC）roadvehicleapplications.TheseproceduresareonlyapplicabletoterminalsusedforIn-Line,Header,andDeviceConnectorsystems.TheyarenotapplicabletoEdgeBoardconnectorsystems,twistlockconnectorsystems,20VACorDC,ortoeyeletterminals.Noelectricalconnector,terminal,orrelatedcomponentmayberepresentedashavingmetUSCAR/EWCAPspecificationsunlessconformancetoallapplicablerequirementsofthisspecificationhavebeenverifiedanddocumented.Allrequiredverificationanddocumentationmustbedonebythesupplierofthepartorparts.Iftestingisperformedbyanothersource,itdoesnotrelievetheprimarysupplierofresponsibilityfordocumentation（DVP&R）ofalltestresultsandforverificationthatallsamplestestedmetallapplicableAcceptanceCriteria.See4.3.NOTICE:

Iftheproductstestedtothisspecificationareormaybesubjectedtoconditionsbeyondthosedescribedinthisdocument,theymustpassspecialtestssimulatingtheactualconditionstobeencounteredbeforetheycanbeconsideredacceptableforactualvehicleapplication.TheAuthorizedPersonisthefinalauthorityastowhattestsaretobeperformedonhisorherpartsandforwhatpurposethesetestsarerequired.Heorsheisalsothefinalauthorityforresolvinganyquestionsrelatedtotestingtothisspecificationandtoauthorizinganyvariance（withsupportingdata）totheequipmentorprocedurescontainedinthisspecification.Anysuchdeviationmustbedocumentedandincludedinthefinaltestreport.GuidanceastotherecommendedtestsforselectedpurposesisgiveninthechartsinAppendicesCandD.2.TESTSEQUENCESeeAppendicesCandDforrequiredtestsand5.9.2fortestprocedures.Thetestsineachsectionmustbeperformedintheordergivenunlessotherwisespecifiedinthetestrequest/order.Constructiondetailsforselectedtestfixturesandequipmentareprovidedinthisspecification.AglossaryoftermsisprovidedinAppendixB.Termsdefinedinthedefinitionsorglossaryarecapitalized（i.e.,roomtemperature,steadystate,PLR,etc.）.AlistofdefinitionsisprovidedinAppendixA.Forthepurposesofthisspecification,thereareonlytwotypesofelectricalconnectors:

sealedandunsealed.3.REFERENCEDDOCUMENTS3.1DocumentHierarchyIntheeventthereisaconflictbetweenperformancespecifications,partdrawings,andotherrelatedstandardsorspecifications,theOEMmustreconcilethedifferences.AnyvarianceforanyreasonwheretheUSCAR-2procedureorcriteriaisnotusedmustbenotedanyplacewhereareferenceismadetotheconnectorbeingUSCAR-2compliant.RequirementsthattypicallyhavepriorityoverconflictingUSCARspecificationsatNorthAmericanOEMsarelistedbelowforreferenceonly:

1.ApplicableFMVSSorotherstateandfederalrequirements2.OEM-releasedApplicablepartdrawing（s）3.OEM-releasedproductdesignspecification（s）HowtoidentifyaconnectorasbeingUSCAR-2compliant:

ConnectormakersareencouragedtoidentifywhenaconnectorhaspassedUSCARtesting.ThefollowingwordingistobeusedwhenidentifyingUSCARcompliance:

ConnectorpassesperformancerequirementsofUSCAR-2revision_.ExceptionstodocumentedUSCARtestsare:

（listifapplicable）.ConnectorsystemsthathavemettherequirementsofpreviousrevisionlevelsofUSCAR2maynotmeettherequirementsoflaterlevels.Thesecomponentsarecomplianttotheprevailingrevisionatthetimeofreleaseofcomponentpart.Toclaimcompliancetoanewerrevisionlevelrequirestestingandacceptancetotherevisedversionofallchangedrequirements.SAE/USCAR-2REVISION7PERFORMANCESPECIFICATIONFORAUTOMOTIVEELECTRICALCONNECTORSYSTEMS3.2PartDrawingThepartdrawingforeachconnectionsystemcomponentshouldcontainorreference:

Dimensionalrequirements（whichmustbeinGD&Tformat）.Performancerequirements.Componentpartnumber.Referencetoapplicableportionsofthisspecification.Thequantityandpartnumberofterminalsused.Thetypicalmatingconnector.Revised2020-02-5-MaximumpermissibleTemperatureSealing,Vibration,andErgonomicclass（per5.1.4）forwhichthepartisintendedorhasbeensuccessfullytested.3.3ProductDesignSpecificationTheproductdesignspecificationmayormaynotbeanintegralpartofthepartdrawing.Instructionsmustbeincludedintheproductdesignspecificationforanyspecialtestsrequiredfortheassociatedpartandforanyexceptionsormodificationstothegeneralspecificationsandrequirementsinthisdocument.3.4TestRequesUOrder3.4.1Samples,TestType,andSpecialTestsThelaboratorytestrequesUordershallprovidelocationanddocumentationoftestsamples,identifythetypeoftesttobeperformed（development,validation,specialpurpose,etc.）anddescribeanyspecialteststhatarenotapartofthisspecification.Anyrequiredrevi