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

1、PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS SAE/USCAR-2 REVISION 7 February 2020 ISBN:978-1-4686-0163-3 SAE/USCAR-2 REVISION 7 Issued 1997-08 Revised 2020-02 INTERNATIONAL PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS Notice about interim rev1s1ons:U

2、pdates may be made as interim revisions.Interim revisions are available at:https:/ewcap.uscarteams.orq/revisions.html.1.2.3.3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 4.4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5.5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.2 5.2.1 5.2.2 TABLE OF CON

3、TENTS SCOPE.4 TEST SEQUENCE.4 REFERENCED DOCUMENTS.4 Document Hierarchy.4 Part Drawing.5 Product Design Specification.5 Test RequesUOrder.5 Samples,Test Type,and Special Tests.5 Test RequesUOrder Instructions.5 Performance and Durability Test Instructions.5 Documents Mentioned in This Specification.

4、5 GENERAL REQUIREMENTS.6 Record Retention.6 Sample Documentation.6 Sample Size.6 Test Conditions and Tolerances.6 Equipment.7 Measurement Resolution.7 Test Repeatability and Calibration.7 Conformance Determination.7 Disposition of Samples.8 Part Endurance.8 TEST and ACCEPTANCE REQUIREMENTS.8 General

5、.8 Performance Requirements.8 Dimensional Characteristics.8 Material Characteristics.8 Classifications.8 Testing Headers and Direct Connect Components.10 Terminal Sample Preparation.11 Connector and/or Terminal Cycling.11 Visual Inspection.11 Circuit Continuity Monitoring.12 Mat Seal Sample Preparat

6、ion.14 Terminal Mechanical Tests.15 Terminal to Terminal Engage/Disengage Force.15 Terminal Bend Resistance.16 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

7、Automotive Research(USCAR)certifies the compliance of any products with the requirements of nor makes 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

8、 is applicable for their purposes.Copyright 2020 USCAR Printed in U.S.A.All rights reserved.QUESTIONS REGARDING THIS DOCUMENT:(248)273-2470 FAX(248)273-2494 TO PLACE A DOCUMENT ORDER:(724)776-4970 FAX(724)776-0790 SAE/USCAR-2 REVISION 7 Revised 2020-02-2-PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELEC

9、TRICAL CONNECTOR SYSTEMS 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 5.4.12 5.4.13 5.4.14 5.4.15 5.5 5.5.1 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.7 5.7.1 5.8 5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5 5.9.6 5.9.7 5.9.8 5.9.9 Terminal-Electrical

10、 Tests.18 Dry Circuit Resistance.18 Voltage Drop.20 Maximum Test Current Capability.22 Current Cycling.25 Connector-Mechanical Tests.27 Terminal-Connector Insertion/Retention and Forward Stop Force.27 Connector-Connector Mating/Un mating/Retention/Lock Deflection Forces(Non-Assist).30 Connector to C

11、onnector Mate/Unmate Forces(Mechanical Assist).33 Polarization Feature Effectiveness.36 Miscellaneous Component Engage/Disengage Force.37 Vibration/Mechanical Shock.41 Connector-to-Connector Audible Click.47 Connector Drop Test.4 7 Cavity Damage Susceptibility.48 Terminal/Cavity Polarization Test.49

12、 Connector Mounting Feature Mechanical Strength.50 Mechanical Assist Integrity(Connectors with Mechanical Assist Only).52 Connector Seal Retention-Unmated Connector.53 Connector Seal Retention-Mated Connector.54 Airbag lnflator Connector Self-Rejection Assessment.55 Connector-Electrical Tests.57 Ins

13、ulation Resistance.57 Connector Environmental Tests.58 Thermal Shock.58 Temperature/Humidity Cycling.58 High Temperature Exposure.59 Fluid Resistance.60 Submersion.61 PressureNacuum Leak.62 High Pressure Spray.64 Tests for Headers.66 Header Pin Retention.66 Severe Duty Tests.67 Test Sequence.67 Gene

14、ral Notes on Test Sequence.67 Test Sequence Chart.68 Terminal Mechanical Test Sequence.68 Terminal Electrical Test Sequence.68 Connector System Mechanical Test Sequence.68 Connector System Electrical Test Sequence.70 Sealed Connector System Environmental Test Sequence.71 Unsealed Connection System E

15、nvironmental Test Sequence.72 Stand-Alone Sealing Performance Test Sequence.72 SAE/USCAR-2 REVISION 7 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS Revised 2020-02-3-APPENDIX A DEFINITIONS.73 APPENDIX B ABBREVIATIONS USED.77 APPENDIX C TESTS FOR MOVED TOOLS,ADDITIONAL TOOLS,A

16、ND MATERIAL CHANGES.78 APPENDIX D TESTS FOR NEW TERMINAL,CONNECTOR,AND SEAL DESIGNS.80 APPENDIX E SOURCE LIST FOR AUTOMOTIVE FLUIDS USED IN TESTING.82 APPENDIX F DESIGN NOTES-TEMPERATURE AND CURRENT RATING.83 APPENDIX G REVISIONS.84 SAE/USCAR-2 REVISION 7 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELE

17、CTRICAL CONNECTOR SYSTEMS 1.SCOPE Revised 2020-02-4-Procedures included within this specification are intended to cover performance testing at all phases of development,production,and field analysis of electrical terminals,connectors,and components that constitute the electrical connection systems i

18、n low voltage(0 to 20 VDC)road vehicle applications.These procedures are only applicable to terminals used for In-Line,Header,and Device Connector systems.They are not applicable to Edge Board connector systems,twist lock connector systems,20 VAC or DC,or to eyelet terminals.No electrical connector,

19、terminal,or related component may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented.All required verification and documentation must be done by the supplier of the part or parts.If testing

20、 is performed by another source,it does not relieve the primary supplier of responsibility for documentation(DVP&R)of all test results and for verification that all samples tested met all applicable Acceptance Criteria.See 4.3.NOTICE:If the products tested to this specification are or may be subject

21、ed to conditions beyond those described in this document,they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application.The Authorized Person is the final authority as to what tests are to be performed on his or

22、 her parts and for what purpose these tests are required.He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any variance(with supporting data)to the equipment or procedures contained in this specification.Any such deviation m

23、ust be documented and included in the final test report.Guidance as to the recommended tests for selected purposes is given in the charts in Appendices C and D.2.TEST SEQUENCE See Appendices C and D for required tests and 5.9.2 for test procedures.The tests in each section must be performed in the o

24、rder given unless otherwise specified in the test request/order.Construction details for selected test fixtures and equipment are provided in this specification.A glossary of terms is provided in Appendix B.Terms defined in the definitions or glossary are capitalized(i.e.,room temperature,steady sta

25、te,PLR,etc.).A list of definitions is provided in Appendix A.For the purposes of this specification,there are only two types of electrical connectors:sealed and unsealed.3.REFERENCED DOCUMENTS 3.1 Document Hierarchy In the event there is a conflict between performance specifications,part drawings,an

26、d other related standards or specifications,the OEM must reconcile the differences.Any variance for any reason where the USCAR-2 procedure or criteria is not used must be noted any place where a reference is made to the connector being USCAR-2 compliant.Requirements that typically have priority over

27、 conflicting USCAR specifications at North American OEMs are listed below for reference only:1.Applicable FMVSS or other state and federal requirements 2.OEM-released Applicable part drawing(s)3.OEM-released product design specification(s)How to identify a connector as being USCAR-2 compliant:Connec

28、tor makers are encouraged to identify when a connector has passed USCAR testing.The following wording is to be used when identifying USCAR compliance:Connector passes performance requirements of USCAR-2 revision _.Exceptions to documented USCAR tests are:(list if applicable).Connector systems that h

29、ave met the requirements of previous revision levels of USCAR 2 may not meet the requirements of later levels.These components are compliant to the prevailing revision at the time of release of component part.To claim compliance to a newer revision level requires testing and acceptance to the revise

30、d version of all changed requirements.SAE/USCAR-2 REVISION 7 PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 3.2 Part Drawing The part drawing for each connection system component should contain or reference:Dimensional requirements(which must be in GD&T format).Performance req

31、uirements.Component part number.Reference to applicable portions of this specification.The quantity and part number of terminals used.The typical mating connector.Revised 2020-02-5-Maximum permissible Temperature Sealing,Vibration,and Ergonomic class(per 5.1.4)for which the part is intended or has b

32、een successfully tested.3.3 Product Design Specification The product design specification may or may not be an integral part of the part drawing.Instructions must be included in the product design specification for any special tests required for the associated part and for any exceptions or modifica

33、tions to the general specifications and requirements in this document.3.4 Test RequesUOrder 3.4.1 Samples,Test Type,and Special Tests The laboratory test requesUorder shall provide location and documentation of test samples,identify the type of test to be performed(development,validation,special purpose,etc.)and describe any special tests that are not a part of this specification.Any required revi