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PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
***WARNING 警告*** No electrical connector, terminal, or related component may be represented as having met U

SCAR /EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. At least the minimum applicable sample size set forth in each test must have been tested with no sample in the entire group tested failing to meet all applicable Acceptance Criteria for that test. All required verification and documentation must be done by the supplier of the part or parts . If testing is performed by another source, it does not relieve the primary supplier of responsibility for documentation of all test results and for verification that all samples tested met all applicable Acceptance Criteria. 如果没有完全符合所有 USCAR/EWCAP 的要求并作验证确认和文文件记录, 任何电子连接器、 端子或相关零件都不 能宣称已经符合 USCAR/EWCAP 的规格。 至少要达到最少样品数量要求并且其中所有样品都必须通过该测试所对应 的“接受标准” 。所有要求的确认和文书记录必须由零件供货商完成。如果测试由其它单位完成,供货商并不能豁免 记录所有零件测试结果并符合相应“接受标准”的责任。 1.0 SCOPE 适用范围 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 in low voltage (0 - 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, > 20 VAC or DC, or to eyelet type terminals. 本规范中的程序意在包括端子、连接器及其部件(这些端子、连接器及其部件构成路面交通工具直流 0-20 伏低压电 子连接系统)的在所有研发、生产和现场分析中的性能测试标准。这些规程只适用于线路中连接器系统中、针类连 接器系统中和设备连接器系统中的端子,但不适用于“边板连接器系统” (Edge Board connector systems) ,>交/直 流 20 伏,或针孔(eyelet)型的端子。 Note that this specification does not cover the mechanical assist portions of connectors that include such devices. The Authorized Person must provide details of any additional testing desired to validate these mechanisms as part of the test request/order。 注意本规范并没有包含连接器的辅助机械部份。负责人必须提供相关额外测试的信息以满足这些机械作为测试一部 分的要求。 IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected 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. By way only of example, this includes products that may be subjected to temperatures beyond the extremes of Class 4 in Figure 5.1.4, or may be subjected to shock or vibration in the unsprung portions of a vehicle, such as the wheel hub. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested.

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

重要提示:如果被测试零件是用于一些超过本规范所规定范围的车辆,这些零件必须通过和实际情况的相一致的模 拟测试才能投入正式使用。例如,这些包括在图 5.1.4 中显示的超过 4 级的极端温度、非扭转(unsprung)部分例如 轮轴(hub)的振动及摇摆。已通过本规范测试标准的零件不应在超过其测试条件的条件下使用。 The Authorized Person is the final authority as to what tests are to be performed on his or 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 deviations to the equipment or procedures contained in this specification. Any such deviation must be documented and included in the final test report. 负责人最终决定对零件进行何种测试及测试目的,他/她亦解决任何有关测试的问题并允许设备及程序的偏差。所有 这类偏差都必须有所记录并包括在最终测试报告中。 Guidance as to the recommended tests for selected purposes is given in the charts in Appendix C and D. In the absence of contrary direction from the Authorized Person in the test request/order, all electrical connectors and their associated terminals and other components are required to meet all applicable portions of this document with the following exception. 推荐测试的指导可以在附录 C 和 D 的图表中找到。如果负责人没有相反的指示,所有电子连接器及其相关端子和部 件都需要符合本文的规定,但有以下例外: A. Specific tests that are not required or additional test requirements as specified in any document in the hierarchy of Section 3.0. A. 没有明确要求的测试或在第三部分各层次中规定了额外测试要求的。 2.0 OUTLINE & GLOSSARY OF TERMS 大纲和术语表 2.1 GENERAL 通则 Diagrams are provided where necessary to clarify the details of the various test procedures. The tests in each section must be performed in the order given unless otherwise specified in the test request/order. Construction details for selected test fixtures and equipment are provided in this specification. 在有必要协助明确各测试程序的细节的地方,本文提供图表。除了特别指出之外,所有测试都必须按照给定的顺序 执行。本规则提供测试设备和装置的安装信息。 A glossary of terms is provided in Appendix B. Terms defined in the definitions or glossary are capitalized (i.e. Room Temperature, Steady State, PLR, etc.). A list of definitions is provided in Appendix A. 附录 B 提供术语表。术语单词都用大写开头(如:Room Temperature, Steady State, PLR 等) 。 附录 A 提供定义表。 For the purposes of this specification there are only two types of electrical connector: sealed and unsealed. 为了说明的目的,本规范只有两种连接器:密封型和不密封型。 3.0 REFERENCED DOCUMENTS REQUIRED 要求参考文献 3.1 DOCUMENT HIERARCHY 文件等级层次 In the event there is a conflict between performance standards, part drawings, and other related standards or specifications, the requirements shall be prioritized as follows: 当性能标准、零件图纸和其它相关标准及规则发生不一致时,优先级顺序如下: 1st - Applicable FMVSS requirements and other applicable state and Federal requirements . 2nd - Applicable part drawings 3rd - Applicable product design specification(s) .

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
4th - Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) 5th - Applicable USCAR/EWCAP performance standards 6th - Other applicable standards and specifications 1 – 适用的 FMVSS 和其它的州及美国联邦规定 2 – 适用的零件图纸 3 – 适用的产品设计规范 4 – 汽车行业工作组 (AIAG) 的生产零件批准过程 (PPAP) 5 – 适用的 USCAR/EWCAP 性能标准 6 – 其它适用的标准和规范 3.2 PART DRAWING 零件图纸 The part drawing for each connection system component should contain or reference: 每个连接系统的零件图纸都应该包含或指定以下内容: A. All dimensional requirements (which must be in GD&T format). B. Performance requirements. C. Component part number. D. Reference to applicable portions of this specification. E. The quantity and part number of terminals used. F. The typical mating connector and terminals. G. Maximum permissible Temperature Class (per Figure 5.1.4) for which the part is intended or has been successfully tested. A. 所有规定尺寸(必须用 GD&T 格式) B. 性能要求 C. 部件号 D. 适合本规范部分的参考。 E. 使用端子的数量及零件号 F. 典型的连接器和端子的装配。 G. 零件计划使用或已经成功测试的最大允许温度等级 (根据图 5.1.4) For purposes of control and standardization, each drawing that contains a part or a device that includes an electrical receptacle conforming to a USCAR/ EWCAP "footprint," must contain the following statement in the drawing notes or other prominent place: 为了便于控制及标准化起见,每个包含有符合 USCAR/ EWCAP "footprint"的电容器的图纸也必须在图纸说明或其它 显著位置标明以下声明: NOTICE 注意 This drawing, is controlled by the Electrical Wiring Components Application Partnership (EWCAP) , a subgroup of the United States Consortium for Automotive Research (USCAR). USCAR is a partnership between DaimlerChrysler

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

Corporation, Ford Motor Company and General Motors Corporation. Any change to a EWCAP drawing, including a "record change," must be approved, in writing, by the responsible EWCAP member from each USCAR Company. Each EWCAP member authorized to sign for his or her Company is responsible for obtaining all necessary approvals within that Company prior to signing for approval of the change. EWCAP expressly prohibits any party from changing either any EWCAP controlled drawing or any associated tooling before receiving an approval signed by an authorized representative from each EWCAP partner. Reference to the signed approval form must be entered in this drawing's control column. 该图纸由美国汽车研究协会(USCAR)所属的电子线路零件应用协会(EWCAP)控制。 USCAR 是戴姆勒-克赖斯勒集团、 福特汽车公司和通用汽车集团之间的合伙机构。对于一个 EWCAP 图纸的任何一个改动,包括一个“记录变化” ,都 必须得到来自各个 USCAR 公司 EWCAP 相关成员的书面许可。每个被授权的 EWCAP 成员在代表其公司签字前都 必须得到其公司内部各相关方的批准。 EWCAP 明确禁止任何一方在得到所有 EWCAP 成员认可之前擅自改动 EWCAP 控制图纸或任何对应模具。在该图纸的控制栏中必须填写同意改动签字的相关证明内容。 3.3 PRODUCT DESIGN SPECIFICATION 产品设计规范 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 modifications to the general specifications and requirements in this document. 产品设计规范可能是也可能不是零件图纸中独立的部分。如要求相关零件进行特别测试,或对本档中的普通规范及 要求做改动或,在产品设计规范中必须说明。 3.4 TEST REQUEST/ORDER 测试要求/顺序 3.4.1 Samples, Test Type and Special Tests 样品、测试类型和特殊测试 The laboratory test request/order 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 revisions to, or deviations from, any tests in this specification must include detailed instructions for each change. 实验室测试要求/顺序应该提供测试样品的地点和档、明确将要进行的测试的种类(研发、确认、特别目的等)并描 述所有不属于本规范的特殊测试。任何对于本规范中测试的改动或偏离都必须有详细说明。 3.4.2 Test Request/Order Instructions 测试要求/顺序指示 Instructions must be included in the test request/order concerning applicable tests and the order in which the tests are to be performed if different than outlined by this specification. 如果测试要求/顺序和本规范的内容有所不同,必须加以说明。 3.4.3 Performance and Durability Test Instructions 性能和持久性测试说明 Instructions must be given in the test request/order concerning limits for performance and durability tests, including definition of the conditions under which those limits apply, if they are different than outlined in this specification. 如果对于性能和持久性测试的测试要求/顺序(包括极限环境条件的定义)和本规范不同,必须加以说明。 3.4.4 Development Tests 研发测试 Development tests are frequently used to evaluate specific areas of the design. They are a tool for evaluating design alternatives, proposed improvements, cost reduction proposals , or determining root causes of field problems.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
为评估设计的特定领域会经常使用研发测试,它们是评估其它可能设计方案或改进方案、降低成本和发现实际使用 中出现问题的根本原因的有效工具。 3.4.5 Validation Tests 确认测试 Validation tests or sample approval tests are acceptance type tests. Consideration must be given to the inherent repeatability or subjectivity of certain tests outlined by this specification before designating it as a validation or compliance test. 确认测试或样品认可测试都属于接受型测试。在把本规范的一些测试作为确认或应用测试前必须考虑其内在的可重 复性或主观性。 3.4.6 Special Purpose Tests 特定目的测试 Portions of this specification may be useful for special purpose testing. For example, verifying a process or material change may, in the judgement of the Authorized Person, require only one or two specific tests, or a portion of a test, to verify that no adverse consequence resulted from the change. Any portion of a test or any combination of tests contained in this specification may be used individually or may be combined with other testing, described outside this specification, in any phase of product development, production testing, or analysis of parts from the field. 本规范的部分内容可以用于特定目的测试。例如:为了证实步骤或物料的改变并不会产生不良影响,经负责人判断, 只需要一两个特定测试或一个测试的一部分。在产品开发、生产测试或使用现场的零件分析的任何阶段都可以单独 使用本规范中的一个测试的任何一部分,或组合使用本规范之外的多个测试。 3.5 MATERIALS AND PROCESSES STANDARDS 材料和步骤标准 Suppliers are expected to adhere to the appropriate Materials and Process Standards that are referenced in this specification and any associated drawings and reference documents. 供货商应该遵照本规范所用得适当的材料和步骤标准、对应制图及参考文献。 Unless otherwise specified or required by law, suppliers are expected to use the most recent versions of any applicable drawings, reference documents, and standards. 除非特别指出,否则供货商应该使用所有制图、参考文献和标准的最新版本。 3.6 FAILURE MODE and EFFECT ANALYSIS (FMEA) 失效模式和效果分析(FMEA) Within ninety (90) days of source selection the supplier must submit a preliminary design FMEA, based on the current design concept, to the responsible design engineer for review. A revised FMEA must be submitted ten (10) weeks prior to program tooling release and must be fully approved by the Authorized Person before tooling release. The supplier must complete a process FMEA and submit it to the Authorized Person and the applicable supplier quality representative at least ninety (90) days prior to start of production validation testing. 在选择来源(source selection)90 天内,基于当前设计理念,供货商向负责设计工程师提供一份 FMEA 样本。经过 修订的 FMEA 必须在模具计划公布(program tooling release)10 周之前发布,并且在模具(TOOLING)发布之前由负 责人全面批准。在正式生产确认之前 90 天之前供货商必须完成流程 FMEA 并提交到负责人及相关质量代表人处。 3.7 OTHER REFERENCED DOCUMENTS 其它参考文献 ?? SAE J1127: Battery Cable (电池线)

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

?? SAE J1128: Low Tension Primary Cable(低张力总线) ?? AIAG: Measurement Systems Analysis Reference Manual(测量系统分析参考手册) 4.0 GENERAL REQUIREMENTS 一般要求 4.1 RECORD RETENTION 檔保管 The supplier shall maintain a central file for the storage of laboratory reports and calibration records. Such record storage must be in accordance with established QS-9000 and AIAG policies and practices. 供货商应该为实验室报告和校准记录保持一份主文件。此记录的存储必须符合 QS-9000 和 AIAG 的政策和做法。 4.2 SAMPLE DOCUMENTATION 样本记录存盘 All test samples shall be identified in accordance with the requirements of QS-9000 and the AIAG PPAP. 所有测试样本都应该按照 QS-9000 和 AIAG PPAP 的要求确定。 4.3 DEFAULT SAMPLE SIZE 默认样本数量 Minimum sample sizes are given for each test in this specification. A greater number of samples may be required by the test request/order. However, no part or device may be represented as having met this specification unless the minimum sample size has been tested, and all samples of the group tested have met the applicable Acceptance Criteria for that test. It is never permissible to test a larger group, then select the minimum sample size from among those that passed and represent that this specification has been met. 本规范给出每个测试所要求的最少样本样品数量,而测试要求/规定可能要求更多的样本。除非使用了要求的最少样 品数量并且其中所有样品都符合接受准则,否则不能宣称被测零件已符合本规范。决不允许选用很多的样本数量做 测试,然后合格的样品数量恰好达到或超过最少试验样品数量要求,并且测试结果满足接受准则,就认为被测零件 已符合本规范。 A minimum of 10 connector assemblies (male and female halves or female half plus a header or device connector) are required for each test . Also, a minimum of 30 terminal pairs (male blade or pin and female receptacle) are required for each test . Samples are to be prepared so that both these requirements are met when terminals and connector housings are to be tested together. 每次测试需要至少 10 个连接器总成 (阴阳连接器或阴连接器和针类连接器 (如: 又电路板、 针和塑件组成的连接器) 或设备连接器) 。每次测试也需要至少 30 对端子(扁针或 p 针和阴性端子)。如果连接器塑件和端子一同测试的话,需 要准备满足这两个条件的样品。 4.4 DEFAULT TEST TOLERANCES 默认测试公差 Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated: 默认公差,除非另行规定,以百分比形式标示。 A. Temperature 温度= ±3 ℃ B. Voltage 电压= ±2% C. Current 电流= ±1% D. Resistance 电阻= ±1% E. Length 长度= ±1%

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准 F. Time 时间= ±5%
G. Force 力= ±5% H. Frequency 频率= ±5% I. Distance 距离= ±1% J. Flow Rate 流速= ±5% K. Relative Humidity 相对湿度= ±5% 4.5 TEST DEFAULT CONDITIONS 默认测试条件 When specific test conditions are not given either in the product design specification, the test request/ order or elsewhere in this specification, the following basic conditions shall apply: 如果在产品设计规范、测试要求/顺序或本规范的其它方面没有指明,应该满足以下基本条件: Room Temperature = 23± 5℃

室温=23± 5℃
Relative Humidity= Ambient 相对湿度=环境湿度 Voltage = 14.0 ±0.1 VDC

电压=14.0 ±0.1 VDC
4.6 EQUIPMENT 设备 Neither this list nor the list in each test section is all-inclusive. It is meant to highlight specialized equipment or devices with particular accuracy requirements. Many other items of customary laboratory equipment and supplies will also be required. 以下清单和本文各章节中提到的指示所需设备的一部分,主要用于强调一些专用设备或有特殊精确要求的装置。很 多其它常规的实验室设备和供给也是需要的。 ITEM 项目 1 DESCRIPTION 描 述 DC Power Supply (Regulated) 直流电源(可调) 2 DC Power Supply (Regulated) 直流电源(可调) 3 Micro-ohmmeter 微型欧姆计 4 Digital Multimeter (DMM) 数字万用表 REQUIREMENTS* 要 求 *

?0-20V ? 0-10A ?0-20V ?0-100A ?0-20mV ? 0-100mA Capable of measuring the following at an accuracy of *0.5% of full scale: 可以在以下精度范围内测量 0.5%全程:

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

?0-50Volts DC ?0-10 兆欧 Me ohms 5 Current Shunts 分路器 6 Mill volt Meter 毫伏表 7 Thermocouples 热电偶 8 Insertion/Extraction Force Tester 插入/抽取式测力计 9 Data Logger 数据记录器 10 Temperature Chamber 恒温腔 11 Vibration Controller 振动控制器 12 Vibration Table 振动台 13 Vacuum 真空 14 Megohmeter 兆欧姆计 TABLE 4.6.1: Equipment *Note on requirements: Use of equipment with a lesser range is acceptable for specific tests where the required range for that test can be met. The equipment range specified does not preclude use of equipment with a larger range, but the accuracy must remain within the specified tolerance. For example, a DMM with a range of 0-100 volts could be substituted for one specified as 0-50 volts, with the provision that the accuracy could be maintained as +/-0.5% of the 50 volts full scale, or 0.25 volts, not 0.5% of the 100 volt full scale of the substituted equipment. *注:如测试允许,可以使用量程比表中要求更小的仪器;也可以使用更大量程的仪器,但精度必须符合规定要求。 例如:表中规定应使用全程测量范围 50 伏、精度 0.5%或 0.25 伏的数字万用表(DIMM) ;如果用全程测量范围 100 伏的 DIMM 代替,精度应该是 0.25 伏,而不是 100 伏的 0.5%。 4.7 MEASUREMENT RESOLUTION 测量精度 Unless otherwise specified, meters and gages used in measurements of the test sample(s) shall be capable of measuring with a resolution one decimal place better than the specified value. For example, even though a wire diameter specified as 0.1 mm might actually be the same as one specified as 0.10 mm, calipers capable of 0.01 mm resolution may be used to measure the first wire but a micrometer with 0.001 mm resolution is required to measure the second wire. 100mA or as required with accuracy of ±1% of nominal 10 毫安或者要求值的±1% Capable of measuring 0-100mVDC at *0.5% full scale 全程精度 0.5%并可测量 0-100 直流毫伏 Type “J” or “T” and as required “T”或“J”型和测试特定要求的型号 Capable of≤1.0% accuracy , full scale 全程精度≤1.0% As required 根据要求 ?-40℃ to 175℃ ?0%to 95% RH As required 根据要求 ?2640N(600 Lbs.) Sine Force ?2200N(500 Lbs.) RMS Force As required 根据要求 Capable of measuring≥100 Megohms at 500 Volts DC 能在 500 直流伏条件下测量 100 兆欧以上电阻

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
除非另有说明,用于测量的仪表和器具都应该有比所标示值优一个小数点的精度。例如: 虽然线径标示为 0.1 毫米 和 0.10 毫米实际上可能是一样的,但对于 0.1 毫米用 0.01 毫米精度的测径器,而对于后者要 0.001 毫米精度的测径 器。 4.8 TEST REPEATABILITY & CALIBRATION 测试重复性和校准 All equipment used for test sample evaluation shall be calibrated and maintained according to the applicable standards and requirements set forth by QS9000 and the AIAG publication Measurement Systems Analysis Reference Manual. Copies of this Manual can be obtained from the AIAG by calling (248) 358-3570 or writing to AIAG, Dept. 77839, Post Office Box 77000, Detroit, MI 48277-0839, Attn: Customer Service. Documentation is to be recorded and retained in accordance with Section 4.1 of this USCAR/EWCAP specification. 所有用于测试的设备都必须依据 QS9000 和 AIAG(美国汽车行业工作组)出版的《测量系统分析参考手册》校准和 维护。可以拨打(美国)248 358-3570 或者写信至:(美国) AIAG, Dept.77839, Post Office Box 77000, Detroit, MI 48277-0839, Attn: Customer Service 索取该手册。文件应该根据本规范 4.1 节中的内容记录和保管。 4.9 CONFORMANCE DETERMINATION 符合性判断 Test conformance shall be determined by the performance requirements of the test being conducted. All samples must satisfy the performance requirements regardless of sample age, test cycles, or test temperature, except where a test to failure is specified. 测试一致性应该由所进行的测试的性能要求决定。除了失效性是测试之外,无论测试样品的新旧、测试周期或测试 温度如何,所有的样品都必须符合规定的性能要求。 4.10 DISPOSITION OF SAMPLES 样品的处理 Should a premature non-conformance occur during a test, contact the requesting party to determine if the test is to be continued to gain additional product experience or if testing is to be suspended or terminated. When contact cannot be immediately made, the type of test shall determine the disposition of the samples. If the test order indicates that the test is investigative in nature, continue until the requesting party or parties are available. If the test order is for sample approval or validation, stop the test until the requesting party can be contacted. If the test must be stopped or terminated for any other reason (safety, equipment failure, etc.) the Authorized Person must be contacted for concurrence before the test is restarted. The test request/order should always specify desired sample disposition at the conclusion of the applicable testing. 当在测试中发生非一致性现象时,应当联系委托测试方由其决定是否应该继续进行测试以取得更多产品经验、暂停 或终止测试。当不能及时联系到委托测试方,应由该测试的种类决定如何处理样品。如果测试是研究性的,继续测 试——除非委托测试方提出相左要求。如果测试是批准或确认性的,在联系到委托测试方之前终止测试。如果因为 其它原因(安全、设备失效等)测试不得不终止,在重新开始前,必须有测试负责人在场。测试要求/顺序应该总是 在测试结论部分中标明样品处理的计划方案。 4.11 PART ENDURANCE 零件耐久性 Successful completion of all requirements of this specification is intended to demonstrate that the design and construction of the components and connector systems tested are capable of operating in their intended vehicle environment and application.

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

符合本规范中所有要求被认为是表示被测零件和连接器系统可以在计划中的汽车和使用环境中使用。 5.0 TEST & ACCEPTANCE REQUIREMENTS 测试和接受必备条件 5.1 GENERAL 通则 The tests detailed in this specification are qualitative in nature and are not expected to stress any part beyond its anticipated application limit, except where tests to failure are specified. 本规范中的测试原则上都是定性的,除了失效性测试之外,所有测试都是基于假设合理的使用条件而不会超过预期 使用极限。 All parts to be tested are intended to be in their "as furnished for vehicle assembly" condition when testing begins, unless specific instructions as to any pre-test "conditioning" are contained in the test request/order. For example, electrical terminals typically have residual die lubricant on them when finally assembled into a vehicle. This same condition must prevail for test samples unless part cleaning is specified in the Test Request/Order. 除非测试要求/顺序中有特定说明如测是前“条件” ,所有零件都应该是“车辆组装”的状态下被测试。例如:端子 在组装上车的时候往往残留有冲压油,所以,除非在测试要求/顺序中有专门的清洗要求,测试中用的端子也应该有 同样的条件。 The test procedures that follow were written as stand-alone tests and may be used as such. However, they are normally used in a sequential test format and common sense is required to overcome any redundancies in sample preparation or in procedures. For example, if samples have already been prepared for the preceding test in a sequence, it should be obvious that the sample preparation step for that individual test (included so that test can be used as a stand alone test) should be skipped. Should any conflicts or questions arise concerning procedures and/or requirements, contact the Authorized Person. 各个测试的步骤可以被独立使用,但是通常它们是一个连续的过程。而且,在样品准备和操作的步骤中需要常识以 避免过于冗长的内容。例如:如果样品在前一个测试之前做好准备了,显然如果需要独立操作下一个测试,该包括 该准备步骤。如对测试的条件要求有矛盾或疑问,需要联系测试负责人。 5.1.1 Performance Requirements 性能要求 All connection systems must meet all performance test requirements for the appropriate Temperature Class listed in Figure 5.1.4. 所有连接器系统都必须符合图 5.1.4 中列出的适用温度等级的性能要求。 5.1.2 Dimensional Characteristics 尺寸特性 Part construction shall conform to the dimensions, shape, and detail attributes specified on the latest revision of the applicable part drawing(s). 零件结构应该符合最新版本图纸规定的尺寸、形状和细节特征。 5.1.3 Material Characteristics 材料特征 All material used in each test sample shall conform to the material standards specified on the latest revision of the applicable part drawing(s). 测试零件中所用的所有材料都应该符合最新版本图纸规定材料标准。 The material hardness specified for electrical terminals refers to the blank strip material and not the finished product because the terminal manufacturing process can modify the hardness values.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
端子的硬度是指胚料(blank strip)而不是成品的硬度,因为端子加工过程会改变硬度值。 5.1.4 Temperature Classifications 温度等级划分 Components to be tested must be assigned a class from the table below according to the expected environment in their intended vehicle application. "Rise" is defined as the temperature rise due to electrical heating caused by the maximum steady state current flow expected for the component under test. Care must be taken to ensure that the conductor and insulation selected for the application or any test will itself withstand the maximum temperature for the class selected without exceeding the conductor manufacturer's maximum temperature recommendations. 根据在车辆中的使用温度条件,必须给零件从下表中指定一个等级。 “上升”的定义是指由于稳定的电流流过所测的 样品而引起的温升(I2R) 。必需确认导体和绝缘体本身都能经受住最大温度(从图 5.1.4 选取合适的温度等级) ,并 且不能超过导线制造商所推荐的最高温度。 Note that the total expected vehicle environment, including the maximum steady state current flow expected in each circuit of the connector, must be considered when selecting a Temperature Classification. 注意:选择温度等级时,所有车辆运行环境因素都必须考虑进去,包括连接器由于稳定电流而产生的温升(I2R) 。 Note also that terminals packaged such that they are surrounded by other terminals will dissipate heat more slowly, and thus experience a higher temperature "rise" with the same current flow, than terminals located on the periphery of a connector. 另外请注意:若一个端子被其它端子所围绕,其散热比较慢,因此比在连接器边缘的端子在相同电流情况下产生更 高“温升” 。 It is important to consider how the "Potential Peak Temperature (Ambient + Rise)" is reached. If the ambient temperature is low and the "rise" due to current flow is high, the effect on the material of the terminal and the connector housing may not be the same as if the same temperature is reached by a higher ambient and a lower "rise". 考虑“潜在温度峰值(环境温度 + 温升) ”是很重要的。例如:即使两者的总温度是一样,但低环境温度和高的电 流“温升”对于材料和连接器的影响效果和高环境温度及低的“温升”可能是不同的。 When "Maximum Temperature" is mentioned with respect to Figure 5.1.4, the highest ambient temperature in the middle column, "Ambient Temperature Range" is to be used unless otherwise specified. 除非另外说明, “最高温度”是指环境温度范围的最高值,请见图 5.1.4 中栏。 If not specified in the Test Request/Order, the Authorized Person is expected to select the appropriate Temperature Classification. Considering the cost of testing and the time it takes, it generally will be best to qualify a given terminal and connector system to the highest possible Temperature Classification. 如果没有在测试要求/规则中说明,由测试负责人选择温度等级。考虑测试所需的费用和时间,通常给予端子和连接 器可能的最高温度等级。 Class 等级 1 Ambient Temperature Range 环境温度范围 -40℃ to +85℃ Potential Peak Temperature(Ambient + Rise) 潜在温度峰值(环境温度+温升) +105℃

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

2 3 4

-40℃ to +100℃ -40℃ to +125℃ -40℃ to +155℃

+120℃ +145℃ +175℃

FIGURE 5.1.4: Component Temperature Classes 零件温度等级 5.1.5 Testing Headers & Direct Connect Components 插头和直接连接部件的测试 Cases frequently arise where only one half of a connector, usually the female half, is available and it mates directly to a Header or to a receptacle in an electrical component or device. This presents special problems for testing. In order to completely test the electrical connection, access must be gained to the terminals in the device or header. Great care must be taken in these cases so as not to introduce leak paths that are not present in the vehicle application. Where this risk is unacceptable, or making the necessary electrical connections is not feasible, the tests normally required to verify connection integrity must be modified. 经常会出现只有一半连接器的情况,通常是阴连接器。它直接装配到电子部件或装置的插头或插座上。这样测试会 产生特殊问题。为了完成电连接试验,必须有与设备或插头里的端子接触的通道。在这种情况下必须注意防止引入 在汽车实际运行中不存在的漏电通路。当此类危险不允许出现或制作必要的电连接是不可行,必须改进通常需要验 证连接完整性的测试。 Another problem sometimes arises due to the length of the terminals or buss bars in the device or header. The general rule is to connect one of the millivolt test leads at the point where the Header or device terminal attaches to the circuit board or similar point in the device. The bulk resistance of the terminal "tail" is measured and subtracted during the connection resistance calculation. 另外一个问题来自于在装置或柱头中端子或针类接触件(bruss bars)的长度。一个常用的方法是把毫伏计的触点和 柱头或设备端子和电路板交界的地方相接。测量端子“尾”的阻抗,然后在计算连接阻抗的时候减去。 However, if there is more than one "tail" length involved, but the bulk resistance per unit length is common, it may be more convenient to attach the millivolt leads at a common distance from the connection to be measured. 然而,如果有超过一个“尾”长,但每单位长度的体积电阻相同,则把毫伏计的测量点置于测试连接点的相同距离 处较为方便。 Therefore, in situations where there is more than 50 mm from the point of contact in the connection nearest to the Header or device to the point where the terminal "tail" or buss bar connects to the device, these two options are available. (1) Attach the millivolt lead at a convenient common distance 30 to 50 mm from the contact to be measured. Then subtract the bulk resistance of the selected common length when calculating the resistance of the associated Header or device connection. (2) Measure bulk resistance of each individual Header terminal or component buss bar from the connection to be measured to the point of millivolt lead attachment and subtract this resistance when calculating the resistance of the associated Header or device connection. 因此,如果从距柱头或设备(device)最近的连接接触点到端子“尾部”或 buss bar 和装置的连接点的距离超过 50 毫米, 可以: (1) 毫伏计探针连接与和被测点相同距离(30-50 毫米)处, 然后在计算相应柱头或设备 (device) connection 电阻的时候减去这段相同距离的总电阻(bulk resistance) 。(2) 单独测量从被测点到毫伏计触点各个柱头型端子(接 线盒类连接器的插针)或 component buss bar 的总电阻,然后在计算相应柱头 或设备(device)连接的电阻的时候减

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
去该值。 When attaching millivolt leads, take care that the heat applied does not damage platings or cause stress relaxation in any connection component. Application of an appropriate heat sink may be advisable. Refer to Figure 5.1.5. 当毫伏计接触的时候,注意不要碰掉涂层或碰松接触部件,可以考虑采用一个适当的吸热设备(heat sink) 。参见图 5.1.5。

FIGURE 5.1.5: Header Millivolt Lead Placement 柱头 毫伏计安放位置 It may be that the electrical component or device being connected is not itself capable of withstanding the tests to which the connector is usually subjected. In these cases samples of just the connector receptacle portion of the device must be obtained. Then the required connections for testing can be made and sealed. As stated in the first paragraph of this section, great care must be taken to ensure no leak paths are introduced in the course of making and sealing test connections to the device side of the electrical connection being tested. 有时连接的电子部件或装置本身不能承受连接器的测试,这种情况下只是必须获取该装置的连接插孔部分。然后测 试的连接部分就可以封装起来了。如本段开头所讲的那样,在封装的时候一定要小心避免产生漏电并检查被测电路 连接装置部分。 In any case, the Authorized Person must be consulted and must approve any deviation from the normal tests of this performance specification. 在任何情况下对本规范测试标准的变动都要征得负责人的批准。 5.1.6 Visual Inspection 外观测试 5.1.6.1 Purpose 目的 This test is used to document (证明) the physical appearance of test samples. A comparison can then be made with other test

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

samples. Examinations in most cases can be accomplished by a person with normal or corrected vision, and normal color sensitivity, under cool white fluorescent lighting. Photographs and/or videos are encouraged as a more complete means of documentation. An appropriately identified untested sample from each test group must be retained for post-test physical comparisons. 该测试目的在于记录样品的物理外观,可以和其它测试样品做比较。在白色荧光灯冷光源下,大部分情况下试验可 以由一个具有正常或正常校正视力和具备正常颜色辨别力的人来完成。鼓励使用照片和/或录像作为文件记录方式。 每个测试样品组中必须保留一个样品以便以后外观对比用。 5.1.6.2 Equipment 设备 ?Camera 照相机 ?Video Recorder 录像机 ?Magnification Apparatus (as required)?放大设备 (如果有要求的话) 5.1.6.3 Procedure 步骤 1. Visually examine each test specimen prior to testing and/or conditioning, noting in detail any manufacturing or material defects such as cracks, tarnishing, flash, etc. When specified in the test request/order, take photographs and/or video recordings of representative samples to be tested and keep a properly labeled control sample. 测试和/或处理之前目视检查每个测试样品,详细记录有没有制造或物料上的缺陷,如裂纹、印花、飞边等。如测试 要求/顺序中有规定,需要对代表样品拍照和/或摄像,并保存一份正确标了签的控制样品。 2. After testing and/or conditioning, re-examine each test sample and note in detail any observable changes, such as swelling, corrosion, discoloration, contact plating wear, physical distortions, cracks, etc. Compare the tested and/or conditioned samples to the control samples, the videos, and/or the photographs, recording any differences in the test report. The Authorized Person will need to provide an additional sample for this purpose. 测试和/或处理之后,重新检查每个测试样品并仔细观察有无变化,如腐蚀、鼓起变色、变形、接触面镀层磨损、物 理变形、 裂纹等。 把这些试验过和/或处理过的样品和控制样品、 录像和/或照片比对, 在测试报告中记录下所有差异。 负责人需要为此提供额外样品。 3. Return test samples to requestor after all tests are completed and all necessary data has been obtained. 在完成测试、记录所有必要数据后交还样品给测试委托人。 5.1.6.4 Acceptance Criteria 接受标准 All samples must be free of defects that could affect the electrical or mechanical performance of the part or degrade the long term performance of the part. If there is a questionable condition or defect, the Authorized Person must be notified. 所有样品都不应有影响电子或机械性能或导致零件长期性能不良的缺陷。如存在疑问的情况或缺陷,必须通知负责 人。 5.2 TERMINAL - MECHANICAL TESTS 端子-机械测试 5.2.1 Terminal to Terminal Engage/Disengage Force 端子对端子插拔力 5.2.1.1 Purpose 目的 This test determines the engagement and disengaging forces associated with compatible male and female terminal pairs.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
Determination of the number of terminals that can be packaged in a given connector design without exceeding allowable mating force limits is largely dependent on this information. 本测试用于测定对应阴阳连接部分的插拔力。在设计连接器确定端子数量时要考虑所允许的最大插拔力,而相关参 考数据就来自于本测试。 Note that this test is written so that only the first engagement and the last (10th) disengagement are recorded and used to verify compliance with the Acceptance Criteria. 注意只记录第一次插入力和最后 1 次(即第 10 次)拔出力并且确认是否符合接收标准。 5.2.1.2 Equipment 设备 ?Insertion/Extraction Force Tester with peak reading feature 带有最大值记录功能的插拔力测试计 ?Polished Steel Gage(s) (optional)?标准插针(可选) 5.2.1.3 Procedure 步骤 1. Completely identify and number each terminal to be tested. A minimum of 20 samples (10 male and 10 female) is required. If the optional Step 8 is to be used, at least an additional 10 female terminal samples will be required. 完全识别并编号每个被测试端子。至少需要 20 个样品(10 个阴接触件和 10 个阳接触件) 。如果还选择了步骤 8 的 话,另外还需要 10 个阴接触件样品。 2. Fixture one male and one female terminal so that proper alignment is achieved during testing. 利用工装将阳接触件和阴接触件固定好,使得在试验时能够对正插拔。 3. Engage the mating terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied parallel to the centerlines of the terminals. Proper alignment of the terminals is critical to avoid side loads and binding which can adversely affect the force measurement. 两个需对配的端子以不超过 50 mm/min 的均匀速度对插。外界施加力应该和端子的中心线平行。正确对齐端子是避 免产生附加负荷影响测试结果的关键。 4. Record the peak force required to completely engage the terminal to its mating part and use this value to verify conformance to the Acceptance Criteria of Figure 5.2.1.4. 记录在端子对配过程中测力计显示的最大值,该值与图 5.2.1.4 中接受标准的内容相比较,判定是否符合。 5. Disengage the mated terminals at a uniform rate not to exceed 50 mm/min. The force shall be applied parallel to the centerlines of the terminals. 以不超过 50 mm/min 的恒定速度分离成对的端子,外界力应该和端子中心线平行。 6. Repeat Steps 3 & 5 nine (9) more times and record the 10th disengage force reading. Use this value to verify conformance to the Acceptance Criteria of Figure 5.2.1.4. 再重复步骤 3 和 5 九次然后记录第 10 次的拔出力,用该值与图 5.2.1.4 中接受标准的内容比较,判定是否符合。 7. Repeat Steps 2-6 for each pair (one male and one female) of sample terminals. 对每一对(一个阴性端子和一个阳接触件)端子重复步骤 2 到 6。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

8. (Optional) Repeat Steps 2-7 except use the applicable gage in place of the male terminals. Use new female terminals. The applicable gage is to be of polished steel made to within .01 mm of nominal. Surface finish must be at least .076-.305 micro meters (3-12 micro inches). Polish direction must be parallel to the blade/pin length. Test the additional 10 production female terminal samples to determine the force correlation between polished gage and actual samples. (可选) 重复步骤 2 到 7,用可适用的标准插针取代阳接触件。使用新阴接触件。对应可适用的标准插针应该是抛光 钢制产品而且公差在 0.01 毫米内。表面光洁度至少 0.076 – 0.305 微米(3-12 微英寸) 。抛光方向必须和扁针/方针的 长度方向相同。测试额外 10 个阴接触件样品用来决定在可适用的标准插针和实际样品间力的相关性。 5.2.1.4 Acceptance Criteria 接收标准 Terminal 端子 GAGE(optlonal) 可 适 用 的 标 准 插 针 Actual Part 实际零件

(可选)
Size(mm) 尺寸(mm) 0.64 1.50 2.80 6.35 8.0 TBD NOTE:A”*” denotes values to be inserted by the authorized person pending design completion and prototype evaluation. 注: “*”所指示的值由负责人在设计过程中和原型样件评估时填入。 FIGURE 5.2.1.4: Engage/Disengage Forces 图 5.2.1.4:插拔力 5.2.2 Terminal Bend Resistance 端子抗弯性 5.2.2.1 Purpose 目的 This test checks for at least a minimum level of terminal strength so as to resist bending or breakage during crimping, assembly, or service. Since terminal material thickness varies so widely, and the bending force can be applied in any direction, only minimum values have been assigned to this test. Actual bending force values in each of three directions are recorded and it is then up to the Authorized Person to evaluate the results and determine the suitability of the tested terminal for its intended application. 本测试至少要检查端子在压接、组装或使用时抗弯曲或破坏强度的最小值。因为端子材料的厚度可能变化很大,而 外界弯曲力可能来自于任何方向,只有最小值应用于本测试。记录下三个不同方向的实际弯曲力后由测试负责人根 据结果来评估被测试端子在实际环境中的可用性。 5.2.2.2 Equipment 设备 ?Special steel mounting fixture(s) appropriate to the terminal(s) under test.?和被测端子相适应的特别钢制夹具 ?Linear Force Tester with peak reading feature.?具有最大值读取功能的线性测力计。 Type 类型 Square Post 方针 Blade 扁针 Blade 扁针 Blade 扁针 Round Pin 圆针 Engage Max.(N) 插入最大力 * * * * * Disengage Min.(N) 拔出最小力 * * * * * Engage Max.(N) 最大插入力 * * * * * Disengage Min.(N) 最小拔出力 * * * * *

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
5.2.2.3 Procedure 步骤 1. From Figure 5.2.2.3.1, determine which design style most closely resembles the terminal under test 根据图 5.2.2.3.1 图判 定被测端子(TUT)与哪种设计类型最接近。第 1 种端子只对 location“1”做试验,而第 2 种端子需要做 2 次试验: location“1”和 location“2” 。

FIGURE 5.2.2.3.1: Terminal Design Style 端子设计类型 2. Use the smallest gage size conductor with the thinnest insulation applicable to the design of the terminal to be tested. Machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the terminal maker. Then, for Style "A" terminals, machine crimp a total of at least 15 samples at that crimp setting. For Style "B" terminals, machine crimp a minimum of 30 terminals at that crimp setting, in order to test both bend locations. 对被测端子用最小尺寸导体(线芯)和最薄绝缘体(线皮) 。用机器压接样品直到符合规范或符合制造商要求的压接 宽度、高度和抗张强度的端子。对于 A 型端子,压接至少 15 个样品;对于 B 型端子,因为要测试两个位置,所以 至少需要压接 30 个端子。 3. Repeat Step 2 except use the largest conductor gage size with the thickest insulation applicable to the design. 重复步骤 2,但使用最大导体和最厚绝缘体压接端子。 4. Number each terminal. Then record crimp height and width of a representative group of samples of each terminal(except for insulation displacement type terminals). 给每个端子标号, 然后记录每个端子样品代表组的高度和宽度 (除了绝缘置换类型端子外 (insulation displacement type terminals) ) 。 5. Use at least 5 new samples for each test sequence (Steps 6 - 9). 每组至少使用 5 个新样品(步骤 6 – 9) 。 6. Mount the TUT in a fixture taking care that location "1" is positioned as shown in Figure 5.2.2.3.2. 把被测端子(TUT)装配到工装中,注意位置 1(Location “1” )应该如图 5.2.2.3.2 中所示定位。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

FIGURE 5.2.2.3.2: Terminal Bend Test 端子弯曲测试 7. Gradually apply a force to the TUT in the direction indicated in Figure 5.2.3. This force is to be applied at a speed no greater than 50mm/min. Record the peak force necessary to bend the terminal 300 + 50 from its centerline. Inspect the area around the bend using at least 10X magnification. Note in the test report any signs of metal cracking or tearing. 按如图 5.2.3 所示方向逐步给被测端子(TUT)施加力,速度不大于 50mm/min。当弯到离中心线 30°±5°过程中 记录下最大力。用 10 倍或 10 倍以上放大镜观察弯曲部分,在试验报告中记录端子弯曲处有没有出现裂缝或撕裂现 象。 8. Select a new batch of at least 5 samples and mount them in the test fixture with the terminal rotated 180o from the position shown in Figure 5.2.2.3.2. Repeat Steps 6 - 9. 选择一批新的至少 5 个样品并把它们安装到测试夹具上,端子从图 5.2.2.3.2 的位置旋转 180°(绕端子的中心线旋 转) 。重复步骤 6-9。 9. Select a new batch of at least 5 samples and mount them in the test fixture with the terminal rotated 90o from the position shown in Figure 5.2.2.3.2. Repeat Steps 6 - 9. Since terminals are typically symmetrical in this "side to side'' direction, it is not necessary to test both directions. If the TUT is not symmetrical in this direction, it may be necessary to test both ways. Consult the Authorized Person for guidance in this regard. 选择一批新的至少 5 个样品并把它们安装到测试夹具上,端子从图 5.2.2.3.2 的位置旋转 90°。重复步骤 6-9。因为 端子通常是从两边对称的, 所以没有必要两边都测试 (即不需要从图 5.2.2.3.2 的位置旋转-90°) 。 如果被测端子 (TUT) 在这个方向不对称,就可能有必要两个方向都测试。可向测试负责人征询意见。 10. For terminal style "B" designs (Figure 5.2.2.3.1), repeat Steps 5 - 11 with each TUT mounted such that location "2" is firmly retained at the edge of the fixture. 对于 B 类型的端子设计(图 5.2.2.3.1) ,重复步骤 5-11,每个被测端子位置 2(TUT Location "2")应稳固地固定在夹 具的边缘。 11. Verify that the bending force in any of the directions tested meets the applicable minimum force specified in the Acceptance Criteria of Section 5.2.2.4. 检查各个方向的弯曲力并判断与第 5.2.2.4 节有关最小弯曲力接收标准的符合性。 5.2.2.4 Acceptance Criteria 接受标准 Terminal Material Thickness 端子材料厚度 ≤0.20mm Minimum Bending Force Requiremen 最小弯曲力要求 4.0N

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
≤0.30mm ≤0.40mm >0.40mm FIGURE 5.2.2.4: Material Thickness vs.Bending Force 图 5.2.2.4:材料厚度和弯曲力要求 The Authorized Person must review the test data and determine if the results demonstrate that the terminal design tested has sufficient bend strength for its intended application. Note that insufficient bend strength for the conductor size selected can lead to a high incidence of terminal damage during the assembly process. 测试负责人必须评估测试得到的数据并根据结果判定被测端子是否在实际应用中具有足够的弯曲强度。注意所选取 的芯线弯曲强度不足会对装配过程中的端子损坏有很大得影响(即导线的导体抗弯性强一些,会减轻端子装配过程 中弯曲损伤) 。 5.3 TERMINAL - ELECTRICAL TESTS 端子– 电性能测试 5.3.1 Dry Circuit Resistance 干电路电阻 5.3.1.1 Purpose 目的 This test determines the combined resistance of the two conductor crimps (or single crimp in the case of a Header connector) and the contact interface of a mated terminal pair under low energy (dry circuit: 20mV open circuit voltage and 100 mA current limit) conditions. Since it tests for the presence of thin insulating films that may have developed on the contact surfaces during field service or environmental type stress tests, it is important that no other electrical test be performed on the samples prior to this test. 这个试验是在低功率条件下进行(干电路:开路电压是 20mV,最大电流是 100 mA) 。 干电路电阻是指:两个芯线压线脚的压接电阻(对于接线盒类连接器(Header connector) ,只有一个压线脚)和两个 相配端子的连接界面的电阻。因为在实际应用或环境试验过程中会在端子的表面产生很薄的绝缘膜层影响接触电阻 值,所以该干电路电阻试验前不应该进行其它电性能试验。 5.3.1.2 Equipment 设备 ?Micro-ohmeter which limits the open circuit voltage to 20 mV and limits the current applied to 100 mA. The micro-ohmeter must also use either offset compensation or current reversal methods to measure resistance 微欧计(开路电压最大 20mV,最大电流是 100 mA) ,同时它必须带有偏移补偿或反向电流方法测量电阻。 5.3.1.3 Procedure 步骤 ***NOTE 注意*** Take care to avoid any mechanical disturbance of mated terminal samples submitted for this test. Such disturbance could rupture any insulating film which may have developed on the contact surfaces. 在测试过程中,要注意避免对配合好的样品端子机械干扰,因为这些机械干扰可能破坏已在接触面上产生的绝缘膜 层(不导电氧化薄膜) 。 10.0N 15.0N 20.0N

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

***NOTE 注意*** If for any reason the terminals, when submitted for this test, are already contained in their mated connector housings, do not disconnect them unless otherwise directed by the Authorized Person. For terminals in mated connector housings, omit steps 1 and 6 - 9. 如果端子在交付测试时已经在连接器的孔座里了,除非测试负责人提出,不要擅自把它们取出。对于已和连接器孔 座相连的端子,省去步骤 1 和 6 – 9。 ***NOTE 注意*** If the samples submitted for this test have already been subjected to any other electrical test, the purpose of this test has likely been defeated and the Authorized Person must be contacted for approval before proceeding. 如果样品在这试验之前已被用于其它电气性能的测试,样品很可能已被破坏、不能达到本测试目的,因此要联系负 责人征得其同意才能继续测试。 1. Using a conductor of the largest applicable gage size, and insulation thickness appropriate to the application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the terminal maker. Then machine crimp a minimum of 20 samples (at least 10 male & 10 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. 用一个与实际相适应的最大尺寸导体和绝缘厚度来压接端子直到符合实际规范或端子制造商要求的压接宽度、高度 和强度,再用相同设置机器压接至少 20 个样品(阴阳端子至少各 10 个) 。前后角都压接。对于绝缘置换型端子按制 造商推荐的装配标准装配。对于针类连接器(Header type connectors)只是为了装配端子而准备样品。 2. Number each terminal. For virgin terminals, record the crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals). Do NOT mate the terminal pairs until after the millivolt leads have been attached, as directed in Step 5. For terminals that have been subjected to prior testing, do not disconnect their connector housings or remove any terminal from its housing. 给每个端子编号。对于没用过的端子,记录每种端子样品代表组的压接高度和宽度(除了绝缘置换型端子之外) 。在 毫伏计探针接触之前不要把端子成对装配起来,如步骤 5 所示。 对于已经装到连接器中的端子,不要把已经对配好的连接器分开或将它们从连接器孔座中取出。 3. Measure and record the resistance across 150? ? 1mm of the conductor to be used for the test. For tests using a Header terminal as one half of the test connection, refer to Section 5.1.5 and measure only 75? ? 1mm of the conductor. Record the conductor resistance. 测量并记录试验的导线 150 ? ? 1毫米长的电阻。对于接线盒类连接器,请参见 5.1.5 节,并只测量导线 75 ? ? 1毫 米长的电阻,记下电阻值。 4. Attach the millivolt leads in positions T1 and T2 as shown in Figure 5.3.1.3. For Header type connectors, T2 is attached to the Header terminal per Section 5.1.5. All millivolt leads must be no larger than 0.060 mm2 (30 AWG). 把毫伏计探针接到位置 T1 和 T2,如图 5.3.1.3。对于接线盒类连接器,位置 T2 是和柱头型端子(接线盒类连接器的 插针)相接的,如 5.1.5 节所述。所有毫伏计探针都不能大于 0.060 平方毫米(30 AWG) 。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准

FIGURE 5.3.1.3: Connection Resistance Millivolt Lead Locations 图 5.3.1.3:毫伏计探针接点位置 5. For purposes of this test, the male terminal must be inserted to a precise depth into the female. Standard practice is that, in the worst case, there must be at least 1mm of excess insertion between the rearmost contact point with the female terminal and the start of any lead-in taper on the male terminal, as illustrated in Figure 5.3.1.4. This dimension is to be calculated from the terminal drawings by the Authorized Person, taking into account the worst case tolerances. Each male terminal is to be suitably marked so test personnel can make the one and only mating of the test terminal pairs to the correct depth. Score marks or any other marking that might introduce contaminants or alter the strength or conductivity of the male terminal or the interface is not permitted. 为了得到准确的干电路电阻,阳接触件与阴接触件对插深度要满足如下要求(见下面 5.3.1.4 两个图) 。标准做法是, 在最差的情况下,在两个阴阳端子接触点(距离 Entry End 最近处)和阳接触件锥形结构(如倒角)的开始处之间至 少要有 1 毫米间距,如图 5.3.1.4 所示。这个尺寸是由相关人员根据端子图纸计算出来,考虑了最差情况下的公差。 为了使测试人员能在正确的深度配合每对端子,每个阳接触件都要作上适当的标记。但不允许使用刻标记的方法和 其他任何可能引入污染物或改变强度或改变端子传导率或改变连接界面的标记方法。

FIGURE 5.3.1.4: Terminal Insertion 图 5.3.1.4:端子装配图 6. Prior to mating the test terminal pairs, provision must be made for mounting them on an electrically non-conductive surface in such a manner that the mechanical stability of the male to female interface can be maintained. 在两个端子插合之前,先把它们装到不导电的工装上。通过这种方式把连接界面固定住,防止改变物理的接触表面 或不导电的氧化薄膜。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

7. Carefully mate the test terminal pair to the appropriate depth, as specified in Step 6 above. Use caution to assure that mating is done along terminal centerlines to prevent side pressure that may distort either terminal. Secure the TUT to the mounting surface so that the correct insertion depth is maintained throughout the test. 根据步骤 6 所述,仔细配对阴阳端子到适当深度。要小心沿着中心线施力以防止产生附加负荷破坏两个端子的接触 面。安置被测端子于工装上,使得在整个测试过程中插入深度得到保证。 8. Using the appropriate equipment, measure and record the resistance between T1 and T2, as shown in Figure 5.3.1.3. Then deduct the conductor resistance to find the total connection dry circuit resistance. 使用适当设备测量并记录 T1 和 T2 点间的电阻值,如图 5.3.1.3 所示,再减去导体电阻值求出连接部分的总干电路电 阻。 9. Verify conformance to the Acceptance Criteria of Section 5.3.1.4. 确认是否符合接受条件 5.3.1.4 5.3.1.4 Acceptance Criteria 接受条件 The Total Connection Resistance calculated in Step 8 must not exceed the values listed in section 5.3.2.4. 步骤 8 中间的总连接电阻不得超过 5.3.2.4.节规定值。 5.3.2 Voltage Drop 电压降测试 5.3.2.1 Purpose 目的 This test determines the voltage drop associated with the electrical resistance of the conductor crimp(s) and contact interface regions at nominal current conditions. This voltage drop is then used to calculate the total connection resistance. 该测试是用来测定在一定电流条件下由于端子导体和接触部分电阻而引起的压降, 再用该压降计算连接部分总电阻。 5.3.2.2 Equipment 设备 ?Digital Multimeter (DMM)?数字万用表 ?DC Power Supply (0-20 VDC @ 0-150 A)?直流电源 ?Current shunts 电流分路器 5.3.2.3 Procedure 步骤 1. Using a conductor of the largest gage size and insulation thickness appropriate to the TUT, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the terminal manufacturer. Then machine crimp a minimum of 20 samples (at least 10 male and 10 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. 使用一个最大尺寸导体和与被测端子相适应的绝缘厚度,机器压接样品是长、宽和强度符合使用要求或端子制造商 的要求。再用该设置压接至少 20 个样品(阴阳端子各 10 个) 。压接导体和绝缘体边. 根据制造商推荐装配标准装配 绝缘置换型端子。对于接线盒类连接器,只准备用于连接地端子 2. Number each terminal. Then record crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals) . 给每个端子编号,再记录每个端子代表组压接部分的高度和宽度(除了绝缘置换型端子外)。 3. Completely mate and unmate each terminal pair a total of 10 times and then mate them again for testing. Use caution to

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
assure that mating and unmating is done along terminal centerlines to prevent side pressure that may distort either terminal. 完整地装配并拆卸每组端子 10 次,然后再装配起来准备测试。注意装和拆时要沿着端子中心线以免测向力造成端子 变形。 4. For purposes of this test, the male terminal must be inserted to a precise depth into the female. Standard practice is that, in the worst case, there must be at least 1mm of excess insertion between the rearmost contact point with the female terminal and the start of any lead-in taper on the male terminal, as illustrated in Figure 5.3.1.4. This dimension is to be calculated from the terminal drawings by the Authorized Person, taking into account the worst case tolerances. Each male terminal is to be suitably marked so test personnel can make the final mating of the test terminal pairs to the correct depth. Score marks or any other marking that might introduce contaminants or alter the strength or conductivity of either terminal or the interface are not permitted. Do not use the connector housings, even unsealed, to control terminal insertion since the housings will alter heat dissipation during testing. This will compromise test repeatability and will invalidate comparisons of data collected for various terminals. 为了实现本测试目的,阳接触件必须精确地插入阴接触件一定深度。标准做法是,在最差的情况下,在两个端 子接触的末端和阳型端子的导入锥之间至少要有 1 毫米间距,如图 5.3.1.4 所示。对应尺寸应该由负责人根据端子图 纸计算,要考虑使用情况的最差情况下的公差。为了使测试人员能在正确的深度配合每对端子,每个阳接触件都要 作上适当的标记。但不允许任何可能污染或改变阳连接器强度和导电性记号或标记。 压降试验不要使用连接器塑件(与干电路电阻试验不同是:干电路电阻试验对于已经装到连接器中的端子,不要将 已经对配好的连接器分开或将它们从连接器孔座中取出)哪怕是未密封的,来控制端子插入,因为孔座会影响测试 时的热量散发。这会降低测试的可重复性并且使不同端子的数据比对失效。 5. Prior to mating the test terminal pairs, provision must be made for mounting them on an electrically non-conductive surface in such a manner that the mechanical stability of the male to female interface can be maintained. 用于测试的成对端子应该装在绝缘台面上以便成对装配,而且要保证阴阳端子的接触面都完好无损。 6. Carefully mate the test terminal pair to the appropriate depth, as specified in Step 4 above. Use caution to assure that mating is done along terminal centerlines to prevent side pressure that may distort either terminal. Secure the TUT to the mounting surface so that the correct insertion depth is maintained throughout the test. 根据步骤 4 所述,仔细配对阴阳端子到适当深度。要小心沿着中心线施力以防止破坏两个端子的接触面。安置被测 端子于试验平台上, 因此在整个测试过程中插入深度得到保证。 7. Assemble the test circuit shown in Figure 5.3.2.3, Current Resistance Test Set-Up. Adjust the power supply to provide the required test current of 5A per square millimeter of conductor cross section for the conductor selected in Step 1. Refer to SAE Standards J1127 and J1128 for the cross sectional area of the conductor selected. More than one terminal pair may be tested in series. Refer to Figure 5.3.1.3: Connection Resistance Millivolt Lead Locations, for placement of the millivolt test leads. Record the test current used. 如图 5.3.2.3”电流电阻测试装置”所示连接测试电路。 调节电源提供给步骤 1 中所选导体每平方毫米 5 安培电流。 (与干电路电阻试验不同点:干电路电阻试验是在低功

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

率条件下进行,开路电压是 20mV,最大电流是 100 mA。 ) 关于所选导体截面请参考 SAE 标准 J1127 及 J1128。一个系列可测试超过一对端子。参考图 5.3.1.3 以确定毫伏表探 针位置。如下测试电流。

FIGURE 5.3.2.3: Current Resistance Test Set-Up 电流电阻测试装置 8. Measure and record the millivolt drop across 150 ± 1 mm of the conductor size and insulation type to be used during the test, using the test current determined in Step 7. For testing Header type connectors, refer to Section 5.1.5 and measure the millivolt drop across only 75 ± 1 mm of the conductor used. NOTE: For attachment points exceeding 75mm per side, the extra wire resistance shall be measured and subtracted per step 11. 用步骤 7 中的电流数据, 测量并记录导体尺寸 150 ± 1 毫米的压降和测试中使用的绝缘体类型。 对于接线盒类连接器, 参考 5.1.5 节并测量毫伏计使用导体 75 ± 1 毫米压降。注意:对于每边超过 75 毫米处的接触点进行测量,应该根据 步骤 11 测量并减去额外的导线电阻。 9. Attach the millivolt leads as shown in Figure 5.3.1.3. All millivolt lead wire must be 0.060 mm2 (30AWG) or smaller. Attach the circuit to a non-conductive surface, such as wood or high temperature plastic, leaving a minimum of 50 mm between test samples. 如图 5.3.1.3 接上毫伏计探针,所有的毫伏计探针导线都不得超过 0.060 平方毫米(30 AWG)。把回路置于绝缘表面, 如木头或高温塑料(high temperature plastic) ,在样品之间留至少 50 毫米间距。 10. Set the power supply for the current determined in Step 7 and wait 30 minutes minimum to ensure that the test current stabilizes at the appropriate value. Allow sufficient time for all other test equipment to warm and stabilize per the manufacturer's recommendations. 如步骤 7 规定设置电源电流,再至少等待 30 分钟直到电流稳定到一个适当值。根据制造商的建议给其它测试仪器留 出足够时间以预热及稳定。 11. Using the test current determined in Step 7, measure and record the millivolt drop (mVD) readings between test points T1 and T2. Use these values in the equation below to calculate the voltage drop across the entire connection, including the crimp(s) and terminal interface. In the case of Header type connectors, T2 is attached to the "tail" of the Header connector per Section 5.1.5. 根据步骤 7 中设置的测试电流,测量并记录在测试点 T1 和 T2 间的电压降。 利用下面等式中的数值计算整个连接——包括压接处和端子接触面——的压降。关于接线盒类连接器,根据 5.1.5 节 T2 连接到接线盒类连接器的“尾”部。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
mVD Entire Connection = mVD(T1 - T2) - [mVD Conductor (Step 8)] 整个连接的压降 mVD = mVD(T1 - T2) - [mVD 导体(Conductor) (步骤 8)] Total Connection Resistance = mVD Entire Connection ÷Test Current 整个连接电阻 = 整个连接的 mVD ÷ 测试电流 Use these results to verify conformance to the Acceptance Criteria of Section 5.3.2.4. 使用这些结果来确认是否符合 5.3.2.4 节中的接受标准。 ***NOTE 注意*** Use the "After Test" values of Section 5.3.2.4 when this test is done following a stress test, such as Thermal Shock, Temperature/Humidity Cycling, etc. or on field samples. 如果该测试是在应力试验(热冲击、温度/湿度循环试验)之后进行,也使用 5.3.2.4 节中的规定值进行判定。 5.3.2.4 Acceptance Criteria 接受标准 Terminal Size Total Connection Resistance After Test(mΩ ) Maximum 试验后总连接电阻(允许的最大值) 20.0 10.0 5.0 1.5

端子规格
0.64mm 1.5mm 2.8mm 6.35mm *

FIGURE 5.3.2.4: After Test Values 测试后值 NOTE: The "After Test" values are for "crimp - to - crimp" measurements (T1 to T2 in Figure 5.3.2.3 less the appropriate conductor resistance). 注意: “测试后” ("After Test")值是“压接到压接” ("crimp - to - crimp")的测量。 (如图 5.3.2.3 中 T1 到 T2 减去适 当的导体电阻) 。 *Values for other terminal sizes may be calculated by interpolation. In no case may the total connection resistance exceed 20 mΩ .

其它规格端子的总电阻值可以通过插补计算。
不管什么情况,总连接电阻不得超过 20 mΩ 。 5.3.3 Maximum Test Current Capability 最大承载电流试验 5.3.3.1 Purpose 目的 This test is used to determine the maximum test current at which a terminal system can operate in a room temperature environment before excessive thermal degradation and/or resistance begins to occur. Temperature Rise (Y axis) vs. Current (X axis) shall be plotted for each applicable conductor size. These graphs are NOT to be used for actual terminal application in a vehicle. This test is conducted on terminals alone, thus eliminating the variation that may be introduced by variations in the heat dissipating characteristics of differing connector housing designs and sizes.

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

该测试用来测定由于过热,端子退化和阻抗出现前,一个端子系统在室温条件下工作所能承载的最大测试电流。对 于每一导线规格都绘制了温度上升(Y 轴)和电流(X 轴)的关系图,但这些图并不反映车辆中端子的实际情况。该测 试只用于端子,因此消除了由于不同连接器孔座设计和尺寸散热性能引起的差异。 NOTE: A draft free environment is necessary to get accurate measurements. 注意:测试环境应该没有空气流动以免影响测量精度。 5.3.3.2 Equipment 设备 ?Digital Multimeter (DMM)?数字万用表 ?DC Power Supply (0-20 VDC @ 0-150 A)?直流电源 ?Current shunts (Size as required, ±1%)分流器 ?Thermocouples (Type "J" or "T")热电偶("J"或"T"型) ?Data Logger (As required) 数据记录器(根据要求) 5.3.3.3 Procedure 步骤 1. Using a conductor of one of the gage sizes and insulation thicknesses appropriate to the TUT, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the manufacturer of the terminal. Then machine crimp a minimum of 20 samples (at least 10 male and 10 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. 使用某一规格的导体和被测端子相适应的绝缘厚度, 机器压接样品使其宽、高及强度符合实际使用或制造商的要求。 再用该设置机器压接至少 20 个样品(阴阳型端子至少各 10 个) 。压接导体和绝缘部分。根据制造商的建议标准装配 绝缘置换类型端子。对于接线盒类连接器,只需准备用于装配的样品。 2. Number each terminal. Then record crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals). 给每个端子编号,除了绝缘置换型端子外,记录下每种端子代表组的宽度和高度值。 3. Completely mate and unmate each terminal pair a total of 10 times and then mate them again for testing. Use caution to assure that mating and unmating is done along terminal centerlines to prevent side pressure that may distort either terminal. 完整地装配和拆卸每对端子各 10 次,再装配起来准备测试。注意装配和拆卸时要沿着端子中心线,否则侧应力可 能造成端子变形或损坏。 4. Measure and record the voltage drop across 150 ± 1mm of the conductor to be used for the test, using the expected maximum current capability of the TUT in combination with that conductor size and insulation type. For testing Header type connectors, refer to Section 5.1.5 and measure the millivolt drop across only 75 ± 1 mm of the conductor used. 在测试的端子、导体及绝缘类型(线皮)通被测端子预最大电流承载能力的电流,测量并记录该导体 150 ± 1mm 的 压降。对于接线盒类连接器测试,参见 5.1.5 节,只测量导体 75 ± 1 mm 的压降。 5. Assemble the circuit shown in Figure 5.3.3.3 in a draft free enclosure. Use at least 10 terminal pairs. Attach the millivolt leads as shown in Figure 5.3.1.3. All millivolt leads and thermocouple leads must be no larger than 0.060 mm2 (30 AWG) wire. Attach conductor ends of the terminal pairs to form one continuous series circuit and attach the thermocouples to each

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
mated pair as shown in Figure5.3.3.3. Attach the circuit to a non-conductive surface, such as wood or high temperature plastic, leaving a minimum of 50 mm between test samples. 在一个没有空气流动的空间中,根据图 5.3.3.3 装配电路,要使用至少 10 对端子。根据图 5.3.1.3 所示连接毫伏计探 针。所有毫伏计和热电偶(thermocouple)探针或连接仪器用的导线不得大于 0.060 平方毫米(30 AWG 美国线规)。 将每对端子用导线串联起来,再如图 5.3.3.3 所示将热电偶和每对装配好的端子相连。置电路于绝缘平面上,如木头 或耐高温塑料,测试样品间至少要留 50 毫米间距。

FIGURE 5.3.3.3: Set-Up for Maximum Test Current 最大测试电流安装设置 6. Determine the Temperature Class of the terminal design and application intent from Figure 5.1.4. Test the sample terminal pairs at 23oC (room temperature). The ambient temperature sensor must be placed on the same plane as the test samples, 30 to 60 cm from the nearest sample. 从图 5.1.4 选定端子的设计温度等级和使用环境,在 23℃室温下进行测试。环境温度传感器必须置于距测试样品 30 到 60 厘米的同一平面上。 7. Adjust the power supply to zero amps output and then turn on the supply and the DMM's. 电源调节至零安培输出,再打开电源和数字万用表。 8. Slowly increase the power supply output until it is providing 50% of the expected maximum current capability of the TUT. 慢慢提高电源输出至被测端子最大承载电流的 50%。 9. Wait at least 15 minutes for the circuit temperature to reach Steady State. Then record the ambient temperature, the temperature of each terminal pair interface, and the millivolt drop across each terminal pair (T1 to T2 in Figure 5.3.1.3, less the millivolt drop of the conductor as determined in Step 4). Then calculate the resistance of the terminal pair interface. 等待 15 分钟直到电路温度达到稳定状态, 记录环境温度、 每对端子的接触面温度及每对端子的毫伏压降 (用图 5.3.1.3 中的 T1-T2 减去步骤 4 中描述的导体的毫伏压降) ,再计算每对端子接触面的电阻。 10. Increase the current by 10% of the expected maximum current capability of the TUT and repeat Step 9. 再增加被测端子最大承载电流的 10%,重复步骤 9。 11. Repeat Step 10 until 80% of the expected maximum current capability of the TUT is met. 重复步骤 10 直到达到被测端子最大承载电流的 80%。 12. Continue to increase the current in increments of 5% of the expected maximum current capability of the TUT, repeating

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

Step 9 after each incremental increase. 继续增加电流,增加量为被测端子最大承载电流的 5%,每次增加后重复步骤 9。 13. For samples to be used in subsequent tests, repeat Step 12 until one of the following conditions occurs: 对于样品接下来的试验,重复步骤 12 直到发生下列情形之一: A. The temperature of any terminal interface exceeds a 55 oC rise, or the maximum temperature recommended by the terminal manufacturer, whichever is lower. 任何一个端子连接面的温升超过 55℃,或者端子制造商建议的最大温度;两者中取低值。 B. The Total Connection Resistance of any terminal interface exceeds the "After Test" Acceptance Criteria listed in Section 5.3.2.4. 任何一个端子连接面的总连接电阻超过 5.3.2.4 节中“测试后”的接受标准所规定的值。 (电流增大,导致温度上升, 所以总连接电阻增大) 14. The maximum test current capability of the specific combination of the terminal and the conductor gage and insulation type used is then determined to be the current in the first increment in which either the condition described in A. or B. of Step 13 above was achieved, less 10% of that value. 该对端子和标准导体、绝缘体特定组合的最大承载电流为:第 1 次出现上述步骤 13 的情况 A 或 B 时的电流, 再减去该值的 10%。 15. As an optional step, at the discretion of the Authorized Person for samples that will not be used in subsequent tests, continue to increase the current in steps of 5% of the expected maximum current capability of the TUT until the thermal stability of any one or more samples can no longer be achieved. Data from this test to failure step may be useful for statistical purposes or for estimating safety margins. 作为一个可选步骤, 由负责人判断不继续做试验的样品, 否则继续按照被测端子最大承载电流的 5%增加电流直到任 何一个或更多的端子的热稳定性不能实现为止,继续以 5%幅度增加电流,该测试数据用作统计目的,或者用于评估 安全界线是很有用的。 16. Repeat Steps 1 – 14 or 15 for each conductor size and insulation type applicable to the TUT. 对于每个导体尺寸和绝缘体类型重复步骤 1 – 14 或 15。 17. Graph the data with temperature on the Y-axis and current (in amps) on the X-axis for all conductor sizes and insulation types tested. Note that this data is NOT to be used as guidance for any actual application of the TUT. 对于每个端子导体尺寸和绝缘体类型作出 XY 图,温度在 Y 轴,电流 X 轴。注意该图不用于端子在任何实际情况下 的指导作用。 5.3.3.4 Acceptance Criteria 接受标准 For the current determined to be the "Maximum Test Current":对于“最大测试电流” : 1. The measured temperature of the terminal must not exceed a 55 oC rise over ambient, or the maximum temperature recommended by the terminal manufacturer, whichever is lower. 测出的端子温度不得超过室温 55℃或端子制造商的推荐温度,以低者为准。 2. The calculated Total Connection Resistance of any sample must not exceed the "After Test" Acceptance Criteria of Section 5.3.2.4. 任何样品计算得到的总连接电阻值不得超过 5.3.2.4 节的“测试后”接受标准。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准 5.3.4 1008 Hour Current Cycling 1008 小时电流循环
5.3.4.1 Purpose 目的 This test simulates the main function of the terminal over the expected life of the vehicle. Current cycling is an accelerated aging test which electrically heats terminal interfaces and core conductor crimps, then allows them to cool under no current conditions, causing expansion and contraction that may affect connection resistance due to wear, oxidation, intermetallic growth and stress relaxation. 该测试模拟端子在汽车预计寿命过程中的主要功能。电流循环是一个加速老化测试。用电加热端子接口和中心导体 压接部分,然后切断电流冷却,导致膨胀和收缩,这样可能会引起磨损、氧化、生成金属化合物及应力释放从而影 响连接电阻。 5.3.4.2 Equipment 设备 ?Digital Multimeter (DMM) 数字万用表 ?DC Power Supply (0-20 VDC @ 0-150 A, timer controlled 可控定时器) 直流电源 ?Current shunts (Size as required, ±1%)分流器 ?Thermocouples (Type "J" or "T")热电偶 ("J" 或 "T" 型) ?Data Logger (As required) 数据记录器 (根据要求) 5.3.4.3 Procedure 步骤 1. Using a conductor of one of the gage sizes and insulation types appropriate to the TUT, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the manufacturer of the TUT. Then machine crimp a minimum of 60 samples (at least 30 male & 30 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. 使用和被测端子尺寸相适应的导体和绝缘类型(线皮) ,压接样品直到符合实际运用或制造商的宽、高和强度要求, 再按该设置压接至少 60 个样品(阴阳端子至少各 30 个) 。压接导体和绝缘体边。按制造商要求装配绝缘置换类型端 子。对于柱头类型连接器,只准备用于装配的样品。 2. Number each terminal and record crimp height and width of a representative group of samples if applicable. 如果合适,给每个端子代表组中的端子编号并测量高和宽。 3. Attach the millivolt leads in positions T1 and T2 as shown in Figure 5.3.1.3. For Header type connectors, T2 is attached to the Header terminal per Section 5.1.5. All millivolt leads must be no larger than 0.060 mm2 (30 AWG). 连接毫伏计探针到位置 T1、 T2 如图 5.3.1.3 所示。对于接线盒类连接器,根据节 5.1.5,连接 T2 和端子。所有毫伏 计探针都不得大于 0.060 平方毫米(30 AWG)。 4. Completely mate and unmate each terminal pair a total of 10 times and then mate them again for testing. Use caution to assure that mating and unmating is done along terminal centerlines to prevent side pressure that may distort either terminal. 完全装配并拆卸每对端子 10 次,并再次装配以准备测试。注意装配和拆卸时要沿着端子中心线,否则侧应力可能造

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

成端子变形或损坏。 5. Measure and record the voltage drop across 150 ± 1mm of the conductor to be used for the test, using the maximum test current previously determined (Section 5.3.3.3, Step 14) for the combination of that conductor size, insulation type and the TUT. For testing Header type connectors, refer to Section 5.1.5 and measure the millivolt drop across only 75 ± 1 mm of the conductor used. 测量并记录测试导体 150±1 毫米压降。对于特定导体尺寸、绝缘类型(线皮)和端子,电路中通最大测试电流(上 述节 5.3.3.3 步骤 4 中规定) 。 对于柱头类型连接器 (接线盒类) , 参见节 5.1.5 并测量所用导体 75 ± 1 毫米的毫伏压降。 NOTE: For attachment points exceeding 75 mm per side, the extra wire resistance shall be measured and subtracted per step 11. 注意:对于接触点放置在每边 75 毫米处,应该测量额外的导线电阻,再根据步骤 11 减去此电阻值。 6. Assemble the circuit shown in Figure 5.3.3.3 in a draft free enclosure, except use a timer controlled power supply. Set the power supply to provide 45 minutes 'ON' and 15 minutes 'OFF' at the maximum test current previously determined (Section 5.3.3.3, Step 14) for the combination of that conductor size, insulation type and the TUT. Also connect a data logger to the voltage drop and thermocouple leads. 在无空气流动的室内根据图 5.3.3.3 连接电路,但要用配有时间控制装置的电源。对应于特定的导体尺寸、绝缘类型 (线皮)和端子,设定定时器 45 分钟开、15 分钟关,电流设置为规定的最大测试电流(节 5.3.3.3 步骤 14) 。并连 接数据记录器到压降和热电偶探针上。 7. Test the set of sample terminal pairs at 23o C. (room temperature). The ambient temperature sensor must be placed on the same plane as the test samples, 30 to 60 cm from the nearest sample. 在 23℃室温下做测试。环境温度传感器必须置于距测试样品 30 到 60 厘米的同一平面上。 8. Turn 'ON' the power supply, DMM's, and data logger. 开启电源、数字万用表和数据记录器。 9. After 30 minutes into the first 'ON' cycle, record terminal crimp and interface millivolt drop readings (T1 to T2 in Figure 5.3.2.3) as well as thermocouple readings for each terminal pair. “开启”后 30 分钟,记录每对端子压接部分和接触面的毫伏压降(图 5.3.2.3 中 T1 到 T2)和热电偶的读数。 10. Cycle for 1008 hours taking readings at least once daily or as specified by the test request/order, 30 minutes into the 'ON' cycle, and at the conclusion of the test, 30 minutes into the final "on'' cycle. Mv drop readings are taken at maximum test current. 进行 1008 小时电流循环,每日至少一次或按规定读取试验结果,测试时间为: “开启”30 分钟后和测试结束时最后 一个“开启”30 分钟(因为电流通 45min,关断 15min) 。在最大测试电流时读取毫伏压降。 11. For each set of data, calculate and record the Total Connection Resistance by subtracting the conductor millivolt drop reading (Step. 5) from the T1 to T2 millivolt drop reading (Step 9) and dividing the result by the test current (Step 6). 对于每组数据,从 T1 到 T2 间毫伏压降(步骤 9)减去导体毫伏压降(步骤 5)并除以测试电流(步骤 6) ,从而计 算出总连接电阻。 12. Allow the samples to cool to ambient, then complete the voltage drop test section 5.3.2. 允许样品自然冷却到环境温度,再完成 5.3.2 节中压降测试。 13. Verify conformance to the Acceptance Criteria of Section 5.3.4.4.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
确认是否符合 5.3.4.4 节中的接受标准。 5.3.4.4 Acceptance Criteria 接受标准 1. The measured temperature of any mated terminal pair must not exceed a 55 oC rise over ambient for any reading during the test. 在测试的任何时候被测的端子对的读数不得高于环境温度 55℃。 2. The calculated Total Connection Resistance must not exceed the "After Test" Acceptance Criteria in the table in Section 5.3.2.4 for any data set. 对于任何数据,总连接电阻的计算值不得超过 5.3.2.4 节表格中的“测试后”接受标准。 5.4 CONNECTOR - MECHANICAL TESTS 连接器 – 机械性能试验 5.4.1 Terminal - Connector Insertion/Extraction Force 端子 – 连接器固定力(插入、拔出) 5.4.1.1 Purpose 目的 This test is to ensure that the insertion force of a terminal into its connector cavity is not greater than the column strength of its associated conductor and is also low enough to allow easy and consistent production assembly. Extraction testing is to ensure that the terminal is retained in its housing with sufficient strength to withstand the rigors of the wiring harness and vehicle assembly processes. 该测试保证端子进入连接器的插入力不大于导体抗弯强度,并且易于生产装配(即涉及到能不能装,好不好装的问 题) 。拔出力测试用于确保端子能以一定保持力留在孔座内以抵挡线束和汽车装配时的苛刻条件。 5.4.1.2 Equipment 设备 ?Insertion/Extraction Force Tester with Peak Reading Feature 带有最大值读数功能的插拔力测量仪 ?Temperature/Humidity Chamber capable of 95 to 98% RH at 40° C 能达到相对湿度 95%到 98%,温度 40° C 的温度/湿度试验箱。 5.4.1.3 Procedure 步骤 A. INSERTION FORCE : 插入力 1. Using the largest conductor size and insulation type applicable to the design, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the manufacturer of the terminal being used for the test. Then machine crimp a minimum of 20 samples (at least 10 male & 10 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. For connectors with more than 10 terminal cavities, prepare at least one additional male and one additional female sample for each terminal cavity in excess of 10, so that each terminal cavity in the connector can be tested at least once. If the connector being tested uses a multi-cavity (mat) type seal, prepare at least one complete additional set of samples. 使用符合设计的最大的导体尺寸和绝缘类型(线皮) ,机器压接样品直到符合特定要求或制造商规定的高、宽和抗张

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

强度。 再按照该设置压接至少 20 个样品 (阴阳各至少 10 个) , 压接导体和绝缘体边根据制造商要求装配置换式端子。 对于柱头类型连接器,只准备用于装配的端子。对于具有超过 10 个端子腔的,每个腔至少准备阴阳端子各 1 个,所 以每个端子腔至少能被测试一次。如果被测连接器使用多腔型密封,要多准备至少一组样品。 2. Repeat Step 1 using the smallest conductor size and insulation type applicable to the design. Use a fresh connector sample. 使用与设计相符的最小导体尺寸及绝缘类型(线皮)重复步骤 1,要用新的连接器样品。 3. Number each terminal and record crimp height and width of a representative group of samples if applicable. Number each connector terminal cavity and, if applicable, each connector. 给每个样品代表组中的端子编号并记录压接端的高度和宽度,给每个连接器端子腔和(如果可行的话)每个连接器 编号。 4. Secure the connector shell in an appropriate fixture. If the connector being tested uses conductor seals, assemble the connector with all appropriate conductor seals. 固定连接器外壳在适当的工装上。如果被测连接器使用导体密封物,装配连接器和导体密封物。 5. Secure the terminal sample in the force tester by gripping the conductor 2 cm behind the back edge of the terminal. For terminals requiring a gripping distance other than 2 cm, obtain approval from the Authorized Person. 在测试仪上通过固定端子后部导体 2 厘米处来固定端子样品。对于需要超过 2 厘米的端子,请示负责人。 6. Adjust the force tester to insert the terminal straight into the connector at a uniform rate not to exceed 50 mm per minute. Use a fresh terminal sample for each insertion and test each terminal cavity in the connector at least once. For connectors with multi-cavity (mat) seals, each test sample must be removed after its cavity is tested. This is to prevent possible seal distortion or compression that might affect test results if neighboring seal holes remain filled. For connectors with less than 10 cavities, use a new connector after each terminal cavity in the first connector has been tested and continue until at least 10 terminal samples have been used. 调节测试仪,使端子以不大于 50 毫米每分钟的均匀速度对正插入连接器中。每次都用新的端子,连接器的每个型腔 至少测试一次。对于具有多腔密封物的连接器,它的型腔测试之后必须移除测试的样品(即把端子插入连接器型腔 测出插入力,然后把端子拔出来) 。这是为了防止由于相邻封孔装满而导致密封变形或挤压进而影响测试结果。对于 少于 10 个型腔的连接器,在测试完第一个连接器每个型腔后使用一个新的连接器直到至少 10 个端子样品被测试。 7. As a special test only for connectors using multi-cavity (mat) seals, use the extra set of samples prepared in Step 1 above. Using the force tester as in Step 5 above, load each terminal into a separate cavity without removing samples previously inserted. Perform the test in such a sequence that the last cavity to be tested is as centrally located as possible. In addition to the data required in Step 8 below, record the cavity number, the insertion force and the order in which the cavities were tested. 这是一个特殊测试,只针对使用多个型腔密封物的连接器,使用步骤 1 准备的另一组样品。使用步骤 5 中的力测量 仪,安装每个端子到不同型腔,不要移除原先插入的样品(即把端子插入连接器型腔测出插入力,测试后不把端子 拔出来) 。正确的测试顺序应该是使最后一个被测的型腔尽量位于中部。除了步骤 8 得到的数据之外,还要记录型腔 号、插入力和每个型腔的测试顺序。 8. Record the force required to insert the terminal into the connector for each terminal sample to be tested and verify conformance to the Acceptance Criteria of Section 5.4.1.4. 记录每个端子样品插入连接器的插入力,与第 5.4.1.4 节中的接受标准进行比较。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
9. Repeat Steps 4 - 8 using the set of samples with the smallest conductor size and insulation type. 使用一组适用的最小导体尺寸和绝缘体类型压接的端子,重复步骤 4 – 8。 B. EXTRACTION FORCE: 拔出力 1. Using the largest conductor size and insulation type applicable to the design, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the manufacturer of the terminal being used for the test. Then machine crimp a minimum of 20 samples (at least 10 male & 10 female terminals) at that crimp setting. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating terminals. For connectors with more than 10 terminal cavities, prepare at least one additional male and one additional female sample for each terminal cavity in excess of 10, so that each terminal cavity in the connector can be tested at least once. At least 3 connector housings must be used in the test. Each terminal cavity location in the connector must be tested, but these tests may be distributed among the connector housings used. Connectors are to be tested in “dry as molded” condition and should be protected from high humidity and heat levels between the time they are molded and the time they are tested. 使用符合设计最大的导体尺寸和绝缘类型(线皮) ,机器压接样品直到符合特定要求或制造商规定的高、宽和抗张强 度。再按照该设置压接至少 20 个样品(阴阳各至少 10 个) ,压接导体和绝缘体边(前角和后角)根据制造商要求装 配置换式端子。对于柱头类型连接器,只准备用于装配的端子。对于具有超过 10 个端子腔的,每个腔至少准备阴阳 端子各 1 个,每个端子腔至少能被测试一次。必须使用至少 3 个连接器孔座用于测试,每个连接器端子腔都要测试, 但是这些测试可以分布于使用的连接器孔座。连接器要在“干燥出模”的状态下测试,要避免从出模到测试之间受 潮和温度变化的影响。 2. Number each terminal and record crimp height and width of a representative group of samples if applicable. Number each connector terminal cavity in each connector housing so there are no duplicate cavity numbers among the housings used. 如果可行,给每个样品代表组编号并记录下压接部分的高度和宽度。给每个连接器的每个腔编号,使得在被用的孔 座中没有重复的型腔编号。 3. Secure the connector shell in an appropriate fixture. If the connector being tested uses conductor seals, assemble the connector with all appropriate seals。. 固定连接器外壳。如果被测连接器使用导体封套,所有合适的密封物装配到连接器中。 4. Install a terminal sample into each cavity in the connector being tested. For connectors with less than 10 cavities, use a new connector after each terminal cavity has been tested and continue until all 10 terminal samples have been used. Do not install the terminal lock (PLR, TPA, Wedge, etc.). 在测试连接器的每个腔中装入端子样品。对于少于 10 个型腔的连接器,在每一个腔测试之后使用一个新的连接器, 直到使用了 10 个端子。不要安装端子锁定装置,如 PLR, TPA, Wedge 等。 5. Secure the terminal sample in the force tester by gripping the conductor 2 cm behind the back edge of the terminal. For terminals requiring a gripping distance other than 2 cm, obtain approval from the Authorized Person.

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

在测试仪上通过固定端子后部导体 2 厘米处来固定端子样品。对于需要超过 2 厘米的端子,请示负责人。 6. Adjust the force tester to pull the terminal straight back from the connector. Straight back extraction is critical to avoid side loads and binding which can affect force measurements. Increase the pullout force at a uniform rate not to exceed 50mm/min. until pullout occurs. 调节测力仪,从连接器对正拔出端子。要对正拔出以避免侧力等附加的载荷影响测量精度。匀速增加拉力,不要超 过 50mm/min,直到全部拔出。 7. Record the force required to pull the terminal out of each terminal cavity along with the cavity number and the connector number. If the conductor breaks or pulls out of the terminal grip before the terminal is pulled from the connector, record this force together with a note as to what happened. 一起记录下连接器编号、端子腔编号和每个端子所需拉拔力。如果导体断裂,或导线从端子中拔出,记录下拔出力 和所发生的现象。 8. Verify that the forces obtained in Step 6 above conform to the Acceptance Criteria of Section 5.4.1.4 for each cavity tested. 确认步骤 6 中得出的每个腔对应的拔出力符合 5.4.1.4 节中的接受标准。 9. Using new connectors, repeat Steps 1-8 above except install the terminal lock (PLR, TPA, Wedge, etc.). 使用新连接器,重复步骤 1 – 8,但要安装端子锁定装置(PLR, TPA, Wedge 等)。 10. Repeat Step 9 using moisture conditioned parts. Parts are brought to their practical limit of moisture content by exposing “dry as molded parts” to 95-98% Relative Humidity at 40° C for 6 hours, then immediately completing the extraction test. 使用加湿处理的零件重复步骤 9。通过把“出模干燥”状态下零件置于相对湿度 95-98%温度 40° C 的环境中 6 个小时,使零件受潮至实际使用环境的上限,随后立即做拔出力测试。 5.4.1.4 Acceptance Criteria 接受标准 Insertion: 插入(端子插入塑件) 1. The maximum insertion force for a terminal with a≤1 mm2 conductor core is 15 N. 对于导体截面积≤1 平方毫米的端子组件,最大插入力 15N。 2. The maximum insertion force for a terminal with a >1 mm2 conductor core is 30 N. 对于导体截面积>1 平方毫米的端子组件,最大插入力是 30N。 3. Neither the conductor nor the terminal may buckle during the test. 无论是导体还是端子都不得出现变形弯曲。 4. The forward stop must withstand a push-through force of 50N or the column strength of the largest applicable conductor size , whichever is smallest. 连接器必须能承受向前的推力 50N 或最大规格导线的抗弯强度,两者取小者。 Extraction: 拔出(端子从塑件中拔出) : Minimum extraction force of a terminal from its cavity shall meet the values shown in the table below: 端子最小拔出力必须符合下表中的值。 Terminal Size 端子规格 Primary Lock(N) 主锁(即 Primary and Secondary Lock(N) Before and After Moisture Conditioning per step 5.4.1.3-B10 Primary and Secondary Lock(N) after High Temp Exposure(para.5.6.3) and/or, Temp/Humidity(para.5.6.2)

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
有 倒 钩 等) ≤0.64 ≤1.5 ≤2.8 >2.8 30 50 60 70 主锁和副锁(有倒钩,还有其它锁定装置) 在高温(5.6.3 节)和/或温度/湿度(5.6.2 节) 按照步骤 5.4.1.3.-B 10. 吸湿处理前后 75 90 90 90 环境后主锁和副锁 48 48 48 48

FIGURE 5.4.1.4: Terminal-Connector Minimum Extraction force 端子-连接器最小拔出力 5.4.2 Connector-Connector Mating/Unmating Force 连接器-连接器装配/拆卸力 5.4.2.1 Purpose 目的 This test determines the mating/unmating forces associated with manual mating and unmating of complete connector assemblies. Note that this test can also be used for connectors with manually operated mating assist devices such as slides or cam locks. In this case, the force measured is that required to manually operate the mechanical assist in mating and unmating the fully populated connector. Mating forces are an important consideration in determining the suitability of a given connector design for use in production. Unmating forces are important in determining serviceability of the design and ensuring the connection will stay mated for the service life of the vehicle. 该测试测定完整连接器的人工装配/拆卸力。 注意该测试也适用于带有辅助装置的手工装配操作, 如滑块或凸轮锁等。 在这种情况下,被测量的是装配和拆卸完整的连接器所要求的人工操作机械所需的力。在连接器生产设计时,装配 力是一个重要的考虑因素。拆卸力是决定连接器在服务期限内是否可靠并易于维修的重要因素。 5.4.2.2 Equipment 设备 ?Insertion/Extraction Force Tester with Peak Reading Feature 带有最大值读数功能的插拔力测量仪 5.4.2.3 Procedure 步骤 A. MATING FORCE 装配力 1. Using any conductor size and insulation type applicable to the design, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable specification or as required by the manufacturer of the terminal being used for the test. Using that crimp setting, machine crimp enough samples of male and female terminals to assemble a minimum of 10 fully populated (a terminal in every available cavity) connector assemblies (at least 10 male and 10 female halves). Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1.利用任何规格的线芯和线皮压接样品,样品需满足规范或厂家要求的压接高度,压接宽度和抗张强度。保持上述 压接工艺参数不变,压接足够的数量的样品。至少 10 个连接器组件(要求塑件上的每个型腔都要装上端子,并且至 少 10 阳连接器半成品和 10 个阴连接器半成品) 。 端子前后角都必须压接。 按照厂家装配标准装配绝缘体和端子导线。 对于 Header 类型的连接器,只是为了装配连接器而准备样品。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

2. Completely assemble (but do not mate) all connector halves (both male and female) using all applicable components such as terminals, wedges, and seals. 2. 用所需的零件,如端子,楔和密封物装配好形成半成品(但是阴阳连接器不能装配好) 。 3. Number each connector assembly. 3. 标记每个连接器组件。 4. Secure the connector halves (one male and one female) in the appropriate fixtures of the force tester. Adjust the force tester to insert the male connector straight into the female connector. Straight-in engagement is critical to avoid side loads and binding which can affect force measurements. 4. 确保连接器半成品恰当地装在测力计工装上。调整测力计使阳连接器对正装入阴连接器。一定要使阳连接器对正 装入阴连接器否则产生附加的负荷影响测量的准确度。 ***NOTE***注意 If appropriate equipment is available, a continuous graph of applied mating force vs. Insertion distance is highly recommended. A properly designed connector (and sealing system where applicable) should produce a graph showing a smooth rise to a single peak force, then a fall off until the connector is fully mated. If the graph shows more than one force peak, the potential for a false lock condition exists. 如果有恰当的设备,就能产生一个装配力与插入深度的曲线图。一个设计恰当的连接器(如果有,包括密封系统。 ) 应该产生一个合理的曲线图。曲线图是先升后降的抛物线形状。只有一个峰值,如果有两个峰值,则说明存在潜在 的锁错情况。 5. Increase the mating force at a uniform rate not to exceed 50mm/min. until complete mating occurs. Test all samples. 5. 以小于等于 50mm/min 的均匀速度装配阴阳连接器,直到装配完成。测试所有的样品。 6. Record the force required to completely mate each set of connector halves into their locked position and use these values to verify conformance of each connector pair to the Acceptance Criteria of Section 5.4.2.4. 6. 阴阳连接器装配到位并记录过程中产生的装配力,该装配力与第 5.4.2.4 段的接收标准作比较,看是否满足标准中 的要求。 B. UNMATING FORCE 拆卸力 1. This test uses the same samples as in Section 5.4.2.3 Step A above. If the test equipment permits, each sample may be mated and then unmated without removing it from the force tester. 1. 该项测试使用与第 5.4.2.3 段相同的样品。假如测试设备允许,做完装配力测试后不需要将样品从测力计上拆卸

下来就可以接下去做拆卸力测试。
2. Half of the samples (at least 5) are to be tested with the connector primary locking mechanism fully engaged. For this group, completely unmate the connector halves by applying a uniform force parallel to the centerlines of the fully mated connector halves. The force tester must be configured to apply the unmating force directly to the connector halves, not through the conductor(s). Straight-out unmating is critical to avoid side loads and binding which can affect force measurements. 2. 用一半的样品(至少 5 只)在装有锁扣的情况下测试。对于这组样品,通过施加沿连接器轴线方向的拆卸力来测 量。测力计的配置要求能直接施力于连接器半成品上,而不是施力于导线上。对正地拆卸出来是关键的,这样能避 免产生附加的负荷影响测量的准确度。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
*** CAUTION ***警告 The following step will result in sample breakage. Adequate shielding and personnel safeguards must be employed to ensure the safety of persons and property in the vicinity of the test. 下面的步骤可能会导致样品的破裂。所以必须采取相应的安全措施,保护做试验时人身和财产的安全。 3. Increase the unmating force at a uniform rate not to exceed 50mm/min. until complete separation occurs. Test all samples (at least 5) in the first group. 3. 以不大于 50mm/min 的均匀速度施加拆卸力直到完全拆卸开两个对配的连接器。测试第一组的所有样品(至少 5 只) 4. Record the force required to completely separate the connector halves and verify conformance to the Acceptance Criteria of Section 5.4.2.4. 4. 记录测试过程中产生的拆卸力, 要求完全拆卸开两个对配的连接器并且验证与第 5.4.2.4.段的标准的符合性。 5. For the remaining samples (at least 5) measure the force required to disengage the primary connector lock. This is the force a person would apply to the appropriate point such that the mated connector halves (or a connector mated to a device), could be unmated in the intended manner with no damage to any component. Apply the force perpendicular to the appropriate unlocking surface at a rate not to exceed 50mm/min. Record the force required to displace the lock so it just clears its mating feature. Verify conformance to the appropriate Acceptance Criteria of Section 5.4.2.4. 5. 对于剩余的样品(至少 5 只)需要在去除锁扣的情况下测量拆卸力。试验者需要在恰当的施力点施加拆卸力使得 两个配合的连接器(或连接器与设备配合)能够在没有损坏任何零部件的情况下拆卸开。垂直于锁扣面并且以不大 于 50mm/min 的速度施加力。这种在去除锁钩的情况下测量得到的拆卸力纯粹显示了两个阴阳连接器的配合特性。 验证与第 5.4.2.4.段的标准的符合性。 6. Repeat Steps 2, 3 and 4 above using the samples (at least 5) from Step 5 above except completely remove/disable the primary connector locking mechanism(s). 5.4.2.4 Acceptance Criteria 6. 从第 5 步去除锁扣装置或使锁扣装置失去应有的功能开始,重复第 2、3、4 步骤。至少做 5 只样品。 ***NOTE***注意 The maximum mating effort is meant to simulate assembly in a vehicle when the assembler's body position and access to the connector being mated is not physically restricted. This specification will cover most operations, but not all conditions of vehicle assembly and connector location can be anticipated. 最大装配力测试试验是有意模拟在汽车上的连接器的装配情况。装配者的位置和装配情况没有受限制。这份规范覆 盖了大部分的操作,但不是所有的在汽车上的装配情况和位置都已经预料到了。 ***NOTE***注意 The forces specified in the Acceptance Criteria must be met regardless of the moisture content of the connector housing material. Consult the test request/order to determine if any "conditioning'' of the test samples is required prior to testing. 不管连接器塑件中水份含量如何, 标准中要求的力都必须满足。 试验要求/规则中是否要求在试验前样品需要预处理,

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

可以经过商量确定。 1. Mating force must be 75 N. 1. 装配力必须 75N。 2. Unmating force must be 75 N with the primary connector lock completely disengaged /disabled. 2. 去除锁钩或使之失去作用的情况,要求拆卸力 75N。 3. Unmating force must be 110 N with the primary connector lock fully engaged. A CPA device, if provided for, must NOT be engaged during this test. 3. 有锁钩的情况,要求拆卸力 110N。如果有 CPA 锁定装置,在测试时必须不能用 CPA 锁定装置。 4. The force to completely disengage the primary connector lock must be > 20N and < 70N. 4. 分开锁钩的力必须大于 20N 小于 70N。 5.4.3 Polarization Feature Effectiveness 防配错能力试验 5.4.3.1 Purpose 目地 This test ensures that the polarization feature(s) is adequate to meet its intended purpose of preventing incorrect mating of a connector housing with its intended mate, and preventing mating of a connector housing with any unintended mate. It also tests the adequacy of the polarization feature(s) in preventing terminal damage during incorrect assembly attempts. In addition to this objective force test, it is recommended that a jury evaluation be conducted among knowledgeable individuals trying "hands-on'' mis-mating. 这项测试检验防配对配错的能力。可以检验正确的阴阳连接器沿错误的装配方向装配的情况,也可以检验两个本身 不配对的连接器的装配情况,还可以检验在不正确的装配时对端子的保护能力。对于该项试验,推荐组成多方论证 小组来讨论该防配错能力试验。 5.4.3.2 Equipment ?Insertion/Extraction Force Tester with Peak Reading Feature ?带有最大值读数功能的插拔力测力计 5.4.3.3 Procedure 步骤 1. Two factors must be considered: attempting to incorrectly mate two connector halves, or a connector half and a header, that are supposed to mate if properly oriented, and attempting to mate a connector with an incorrect mate. 1. 两个因素必须考虑:以错误的装配方式装配对插件或装配两个错误的对插件。 2. No terminals are required for this test of the polarizing feature(s). However, a suitable mechanical or electrical means must be devised to detect penetration of one half of the CUT into the other to a depth sufficient to contact any male terminal in any position if that male terminal was installed. 2. 在这个试验中不需要装上端子。但是必须按照机械或电子的原理,设计出一套方案,能检测出对配的深度。以便 知道在正常使用时对配件装配到位,端子接触良好。 3. Orient the CUT with any possible mate in the same family in one or more incorrect orientations chosen by the Authorized Person as most likely to defeat the polarization. The parts should be tested as follows, using a fresh sample of each half for each orientation: ? ? The correct orientation, but with the wrong index ? ? The incorrect orientation

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
3. 以尽可能多的装配方向且经权威人士认可装配对插件来检测防配错的能力。零件需按照如下要求试验,每一个方 向地装配都用新样品来做。 正确的方向对配,但用错误的对配件 错误的方向对配。 4. Secure the connector halves (or connector and header) (one male and one female) in the appropriate fixtures of the force tester. Adjust the force tester to attempt insertion of the male connector into the female connector in the orientation selected in Step 3. 4. 把需要对配的阴阳连接器恰当地安装在测力计上。调整测力计按照第 3 步选取的装配方向把阳连接器装入阴连接 器中。 5. Engage the connector halves at a uniform rate not to exceed 50mm/min. until the maximum force specified in the part drawing is applied. If no value is specified, apply a maximum force of 220 N. Note the indication of the penetration detection device installed in Step 2. 5.以不大于 50mm/min 的均匀速度装配连接器,直到达到图纸上要求的力,如果图纸上没有相应力的要求, 就施加最大为 220N 的力。注意在第 2 步安装的仪器上显示的装配深度值。 5.4.3.4 Acceptance Criteria 接收标准 The minimum mismating force that must be resisted by the polarizing feature(s) is the value given on the part drawing. If no value is specified, the minimum value is 220N. If sufficient mismating is achieved to allow contact with any male terminal if it were properly installed in any position in its connector housing, the polarizing feature(s) is considered to be inadequate. 防配错最小的力必须符合图纸上的要求。如果图纸上没有具体规定,最小的力是 220N。如果装配后阴连接器接 触到任何一只阳接触件(如果连接器装上端子)则表明防配错能力不充分。 5.4.4 Miscellaneous Component Engage/Disengage Force 连接器上锁定装置的装配/拆卸力 5.4.4.1 Purpose 目的 This test is to ensure that connector assembly components such as TPAs, PLRs, CPAs, Locator Clips, etc. will be sufficiently retained, yet allow easy and consistent assembly as well as removal for service where necessary. 这项试验是检测各种锁扣保持有效的能力。如 TPAs, PLRs, CPAs,夹子等是否充分地保持住。但是当需要装配或拆卸 时又可以很容易完成,便于后期服务。 5.4.4.2 Equipment ?Insertion/Extraction Force Tester with Peak Reading Feature ?带有最大值读数功能的插拔力测力计 5.4.4.3 Procedure 步骤 A. ENGAGEMENT FORCE 装配力 1. Completely identify and number each component to be tested. A minimum of 10 samples is required. 1. 标记每一个需要做试验的零部件。至少需要 10 只样品。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

2. All components to be tested and their mating parts must be fixtured so that proper alignment is maintained during testing. Straight-in engagement and extraction is critical to avoid side loads and binding which can affect force measurements. 2. 所有需试验的零部件及其配合的零件要恰当的安装在工装上以便在整个试验过程中两个需配合的零件能够保持 对正。对正地装配是关键点,这样能避免附加的载荷影响测量准确性。 3. Engage each component to be tested, with its retaining mechanism(s) in place, at a uniform rate not to exceed 50 mm/min. 3. 在每个零部件上附属装置不去除的情况下,以不大于 50 mm/min 的均匀速度装配需要试验的零部件。 4. Record the force required to completely engage the component with its mating part and use this value to verify conformance to the Acceptance Criteria of Section 5.4.4.4. 把两个需要装配的零部件装配到位后,记录测试得到的力,并用它与第 5.4.4.4 段的接收标准进行比较,看是否符合 接受标准。 B. DISENGAGING FORCE 拆卸力 *** CAUTION ***警告 The following step will result in sample breakage. Adequate shielding and personnel safeguards must be employed to ensure the safety of persons and property in the vicinity of the test. 下面的步骤会导致样品地破坏。必须采取相应的保护措施,防止人身受到伤害和财产受到损坏。 1. With the component fully installed and properly fixtured, disengage the component at a uniform rate not to exceed 50mm/min. The force must be applied parallel to the centerline of the component being tested to avoid side loads and binding which can affect force measurements. The direction must be opposite to the direction of normal insertion of the component part. 1. 零部件必须充分和适当地安装在工装上。 然后以不大于 50mm/min 的均匀速度沿零部件的中心线方向拆卸装配件。 必须对正拆卸装配件,否则会产生附加载荷影响测量的准确性。 2. Record the force required to completely disengage the component from its mating part and use this value to verify conformance to the Acceptance Criteria of Section 5.4.4.4. 2.装配件完全拆卸后,记录测试得到的结果,并用测得的值与第 5.4.4.4 段的接收标准进行比较,看是否符合接受标 准。 3. For locator clips only, repeat Step 1 above in each of the three directions 90° , 180° , and 270°from the initial insertion direction. Then repeat Step 1 in a direction orthogonal to the plane of the first four tests. Do not exceed a force of 110N for any of these subsequent tests. 3. 对于定位夹,通过翻转零件 90° , 180° ,和 270° ,重复上面的步骤 1。然后按照与前面 4 个试验方向垂直的方向进行 试验。对于上述几个拆卸力测试试验都要求力不大于 110N。 5.4.4.4 Acceptance Criteria 接收标准 For Insertion:插入力 Device (TPA, PLR, CPAs, Locator Clip, etc.) insertion force must conform to the value(s) specified on the part drawing. If no value is specified, insertion force must be greater than 15 Newtons and less than or equal to 30 Newtons. 设备(TPA, PLR, CPAs, Locator Clip 等各种锁定装置)插入力要符合图纸的要求。如果图纸上没有具体的规定,则 插入力要求大于 15N 小于等于 30N。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
For Extraction:拔出力 For devices with a positive retaining feature, such as locator clips, the disengaging force with the retainer engaged must not be less than 110 Newtons. For devices such as a TPA, CPA or PLR meant for manual removal for service, the disengaging force must conform to the value(s) specified on the part drawing. If no value is specified, disengaging force must be > 15N and < 30N. 如有产品本身有锁定特征,则拆卸力必须不小于 110N。对于 TPA, PLR, CPAs, Locator Clip, 等各种锁定装置,若用 手工的方法拆卸,则拆卸力要求符合图纸上的要求。如果图纸上没有具体的规定,则拆卸力要求大于 15N 小于 30N。 5.4.5 Vibration/Mechanical Shock 振动/机械冲击 5.4.5.1 Purpose 目的 This test subjects a connector system to variable vibration simulating accelerated exposure to actual vehicle conditions. Vibration and shock can cause wear of the terminal interfaces, intermittent electrical contact and failure of mechanical components of the connector system. Note that two vibration "profiles" are available. One is for components actually mounted on the engine/transmission or on brackets, components, etc. that are directly attached to the engine /transmission and vibrate with it. The other is for components mounted everywhere else on the sprung portion of the vehicle. Unless a special vibration "profile" is specified in the test request/order, the appropriate profile must be used according to the intended location of the CUT on the vehicle. 这个试验是模拟汽车在实际环境条件中可变振动应用于连接器系统中。振动和冲击会导致端子磨损,从而出现间歇 导通和连接器系统机械零件失效。这里有两种振动波形。一种是零部件实际安装在引擎/变速器或支架上。直接连在 引擎/变速器和振源上。另一种是安装在汽车弹簧上。对于振动波形,除非有另外要求/说明,否则必须根据在汽车上 的实际安装位置采用恰当的振动波形。 Since unsealed connectors are not suitable for use outside the passenger and luggage compartments, they would normally be tested only to the non-engine/transmission profile. Sealed connectors may be used in applications requiring direct attachment to the engine/transmission, so they should normally be qualified to the harsher vibration profile. 因为不密封的连接器不适合用在乘客,行李箱,车厢外面。所以通常没有用引擎/变速器振动波形测试。密封的连接 器可能用在引擎/变速器上,所以通常用苛刻的振动波来测试。 ***NOTE***注意 This section does not apply to components mounted on unsprung portions of the vehicle, such as the wheel hub. Components mounted on unsprung portions of the vehicle require special testing to ensure they can survive and properly function in the intended application. 本部分不应用于如下零部件,该零部件安装在汽车上没有弹簧的地方,如轮毂。安装在汽车上没有弹簧地方的零部 件要求进行特殊的测试来确保能按预定的功能运行而不失效。 5.4.5.2 Equipment 设备 ?DC Power Supply (0-20 VDC) ?Vibration Table

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

?Vibration Controller ?Continuity Analyzer/Totalizer (CT/A) (or equivalent) ?Accelerometers ?直流电源(0-20 VDC) ?振动台 ?振动控制器 ?连续性分析仪/累加器(或等效仪器) ?加速计 5.4.5.3 Procedure 步骤 1. Prepare each sample by assembling all applicable parts and bundling (with tape, convolute, scroll, etc.) the conductors according to the intended application of the parts being tested. Consult the Authorized Person for details on intended bundling. Refer to Fig. 5.4.5.3 for examples of test mounting arrangements. Mounting position A is for in-line type connectors. Positions B and C are for connectors that will mate to an electrical device. At least 10 samples are required unless otherwise specified in the test request/order. 1. 把需试验的零件装配好并且按照预定的方式捆扎好(可以用胶带捆扎,可以螺旋绕制,可以盘绕等) 。对于捆扎 可以向权威人士询问。对于安装方式可以参考图 5.4.5.3。A 安装方式是用于在线路中连接的连接器类型。B 和 C 安 装方式是用于装配到电子设备上的连接器类型。除非另外说明,否则准备不少于 10 只样品。

FIGURE 5.4.5.3: Mounting Positions 图 5.4.5.3:安装位置 ***NOTE***注意 It is vital to secure the conductors to their respective connector housings. Terminals "float" in their cavities and will wear rapidly if the associated conductors are allowed unrestrained movement relative to the connector housing. 把导线限制住是非常关键的。假如与塑件相配的导线没有限制好而能移动,则端子容易在塑件孔中摇摆并且也加速 端子的磨损。 2. Construct a suitable mounting apparatus using the following design criteria: 2. 根据如下的设计标准制造合适的装配工装 A. The mounting apparatus must be constructed and secured to minimize added effects (harmonics, dampening, resonance, etc.). A. 装配工装必须尽量减少附加的影响(谐波,阻尼,共振等) B. For in-line connectors, mount the mated connector pair directly to the Mounting Bracket using the connector feature

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
provided for mounting. Refer to Figure 5.4.5.3-A. Do not use a "Christmas Tree'' or any other type of mounting device. Instead, the Mounting Bracket itself must be constructed so as to include a direct mounting feature to mate with the mounting feature on the mated connector pair. B. 用于在线路中连接的连接器类型。把两个配合好的连接器通过其上面的连接结构直接安装在装配支架上。参考图 5.4.5.3-A.不允许使用树形网络或其他任何类型的装配设备。必须建造装配支架以便能够直接装配连接器。 For device connectors, mount the device directly to the Mounting Bracket. Refer to Figure 5.4.5.3-B or C. Use the normal device mounting feature(s) used to secure the device in its intended vehicle location. Do not use any intervening bracket or mounting device. Instead, the Mounting Bracket must be fabricated to include any cooperating features necessary to mount the device directly to it. 用于装配到电子设备上的连接器类型,直接把连接器装配到装配支架上。参考图 5.4.5.3-B or C。使用标准设备装配 结构以便设备在汽车上预定的位置。不允许使用介入的支架和装配设备。必须制作装配支架并且包含协同操作的结 构,该设备(产品)能够直接安装在装配支架上。 Should an application arise that does not lend itself to either situation described above, consult the Authorized Person. It is his or her responsibility to devise a suitable method for attaching the CUT as directly and firmly as possible to the Mounting Bracket consistent with the intended vehicle mounting. 假如出现与上述描述不一样的情形,请向权威人士询问。这是他或她的责任设计出合适的方法来把待测样品直接并 且牢固的安装在与它配合的汽车上的装配件中。 C. The distance between conductor attachment points to the fixture must not exceed 750 mm in overall length. The conductor attachment points must both be within 100 mm of the centerline of the CUT. C. 导线安装到工装上的两个安装点距离不超过 750 mm。导线安装点必须在待测零件中心线两边 100mm 范围内。 D. When only one conductor attachment point is specified, as when testing the connection to a device, the distance between the vertical centerline of the electrical receptacle portion of the device and the attachment point must not exceed 100 mm。 D. 当只指定一个导线安装点时,并且连接器连接到设备上,则设备上的接插部分(如插座)与导线安装点之间的垂 直距离不超过 100mm。 3. Securely attach the conductor bundle ends to the mounting fixture such that there is a 10 ± 5 mm sag relative to the bisecting plane of the attachment points. See Figure 5.4.5.4. 3. 要求导线的终端安全可靠地安装在工装上,允许距离安装点 10 ±5 mm 的下垂。

FIGURE 5.4.5.4: Typical Connector Vibration Test Set-Up

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

图 5.4.5.4:典型连接器振动试验设置 4. Solder the conductors from each terminal in the CUT in series to form one continuous current path with only two free ends. Solder one of the free conductor ends to a 2 watt, 120 ±1.2 ohm resistor. Solder the " ? ? " (negative) lead to the free end o f the resistor and the " + " (positive) lead to the remaining free conductor end of the CUT. Connect the Continuity Totalizer/Analyzer (CT/A) across the resistor, making sure that the negative lead of the CT/A is connected to the negative side of the resistor. Adjust the power supply to provide 100 mADC to the circuit. Set the CT/A to monitor the current through the resistor and record any instance where that current falls below 95 mA. As an option, the CT/A may be used to monitor one or more terminal pairs instead of the resistor. A reference illustration of the test set-up is shown in Figure 5.4.5.5. Other suitable continuity monitoring equipment may be used. 4. 把来自每一对端子的导线焊接在一起形成一个只有两个自由端点的通路。把一个自由端点焊接到一只 2W,120 ± 1.2Ω 的电阻器上。 把负极连接到电阻器上, 待测零件 CUT 余下的另一个自由端点是正极。 连续性分析仪/累加器 (或 等效仪器)CT/A 连接到电阻器的两边,确保连续性分析仪/累加器(或等效仪器)CT/A 的负极连接到电阻器的负极。 调整电源使之给电路提供 100 mADC 的电流。 同过 CT/A 监视流过电阻器的电流并且记录当电流小于 95 mA 的情况。 建议 CT/A 可以用于监视一对或一对以上的端子来取代监视电阻器。图 5.4.5.5 是参考图。其他连续性监视的仪器也 可以用。

FIGURE 5.4.5.5: Test Set-Up 图 5.4.5.5:试验设置 The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing. 试验工装,系统布局,试验设置在试验前都必须得到权威人士的批准。 ***NOTE***注意 Voltage on the power supply must be limited, so that a high resistance or open circuit will not result in increasingly higher voltage being applied to the circuit in an attempt to maintain the 100 mA current. This would obscure detection of any current interruption and might invalidate subsequent Dry Circuit Resistance measurements. 电源电压必须受到限制,以便高电阻或开路不会导致更高的电压应用于电路上试图维持 100 mA 电流。这样使得电 流中断检测变得模糊一些,并且使得电阻测试得到的结果不准确。 5. Following Mechanical Shock, proceed with the vibration schedule.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
5. 按照振动时间进度表进行机械冲击。 6. Subject the CUT to 10 half-sine wave impulses (10 millisecond duration at 35 Gs force) in each of the three mutually perpendicular axes. 6. 在待测零件三个互相垂直轴的每个方向上施加 10 个半正弦波脉冲(在 35 Gs 下持续 10ms) 7. Unless otherwise specified in the test request/order all CUTs mounted directly to the engine or transmission shall be vibrated for 8 hours in each of the three mutually perpendicular axes (X,Y,Z). Vibrate the CUT using the vibration profile in Fig. 5.4.5.6. CUTs mounted anywhere else on the sprung portions of the vehicle, including the engine compartment (but not directly on or to the engine or transmission) use Figure 5.4.5.7. Vibration shall be 8 hours in each of the three mutually perpendicular axes (X,Y,Z) unless otherwise specified in the test request /order. 7. 除非另外说明,所有直接装配到引擎或变速器上的待测零件应在三个互相垂直轴的每个方向施加 8 小时的振动。 振动波形见图 5.4.5.6。装在汽车弹簧结构上的待测零件,包括机头车厢(但不直接装在引擎或变速器上)应在三个 互相垂直轴的每个方向施加 8 小时的振动。 8. Record the results, inspect the CUT, and verify conformance to the Acceptance Criteria of Section 5.4.5.4. 8. 记录结果,检查待测零件并且与第 5.4.5.4.段的接收标准比较,看是否符合标准。 All Sprung Portions of Vehicle Coupled to Engine 所有连接到引擎且支在汽车弹簧上的部分 Frequency(hz)频率 60.0 200.0 210.0 1000.0 1200.0 Grms=12.1 Power Spectral Density(g2/hz) 功率谱密度 0.00100 1.50000 0.10000 0.10000 0.10000

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

FIGURE 5.4.5.6: For Components Coupled to Engine 图 5.4.5.6:连接到引擎的零件 All Sprung Portions of Vehicle Not Coupled to Engine 所有不连接到引擎上的汽车弹簧部分 Frequency(hz) 频率 5.0 12.5 77.5 145.0 200.0 230.0 1000.0 Grms=1.81 Power Spectral Density(g2/hz) 功率谱密度 0.00200 0.24800 0.00320 0.00200 0.01180 0.00032 0.00002

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准

FIGURE 5.4.5.7: For Components Not Coupled to Engine 图 5.4.5.7:不连接到引擎的零件 5.4.5.4 Acceptance Criteria 接收标准 The following criteria must be verified during or after the Connector System Vibration/Mechanical Shock Test of this Section. 连接器系统的振动/机械冲击试验过程中或试验后以下的标准都必须符合。 1. There must be no loss of electrical continuity (any instance of the resistor current dropping below 95 mA), for more than 1 microsecond. If one or more terminal pairs are monitored, rather than the series resistor, there must be no instance in which the resistance of any terminal pair exceeds 7.0Ω for more than 1 microsecond. 1. 如果连续性分析仪接到电阻器上,则不允许出现以下情况:电路中的电流小于 95 mA 持续时间大于 1ms。如果

一对或一对以上的接触对接有连续性分析仪,则不允许出现以下情况:任何接触对的接触电阻超过 7.0Ω 持续时间大 于 1ms。 2. Each terminal pair of the connector assembly must meet the Acceptance Criteria of the Voltage Drop test of Section 5.3.2. 2. 连接器系统的每一对接触件都必须符合第 5.3.2.段压降试验的接收标准。 3. As an option, to verify the integrity of the connector housing after vibration, each terminal must meet the extraction requirements of the Terminal - Connector Insertion/Extraction Force test of Section 5.4.1. 3. 作为一个建议,振动试验后要验证塑件的完整性,端子要满足第 5.4.1 段端子与塑件的插入力/拔出力的要求。 4. The connector assembly must not show, with the aid of 10X magnification, any evidence of deterioration, cracks, deformities, etc. that could affect its functionality or severely degrade its appearance. 4. 可以用 10 倍的放大镜观察连接器系统(塑件)的外观,不允许出现明显的退化,裂缝,残缺等,因为这些会影

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

响功能和降低外观等级。 5. The terminals must not show, with the aid of 10X magnification, any evidence of deterioration, cracks, deformities, excessive plating wear, etc. that could affect their functionality. 5. 可以用 10 倍的放大镜观察端子的外观,不允许出现明显的退化,裂缝,残缺,镀层过度磨损等,因为这些可能 会影响功能。 5.5 CONNECTOR - ELECTRICAL TESTS 连接器电性能试验 5.5.1 Isolation Resistance 绝缘电阻 5.5.1.1 Purpose 目的 This test verifies that the electrical resistance between any two cavities in a connector system will be sufficient to prevent detrimental electrical conductivity between the various circuits passing through that connector system. This test is typically done on sealed connectors after other environmental stress tests to ensure that any contaminants that may have entered the connector during testing are not sufficient to create an unintended electrical path. 这个试验的目的是检验连接器任何两孔之间的绝缘电阻是否能充分阻止其他各种有害电流流过该连接器。这个试验 经常应用于经过环境试验后的密封型连接器。以便确保经过试验后不会有污染物进入该连接器形成不想要的电路。 5.5.1.2 Equipment 设备 ?Megohmeter (capable of detecting 25 microamperes or less of leakage current at 500 VDC) ?兆欧计(绝缘电阻测试仪) (能够检测在 500 VDC 下 25mA 或更小的泄漏电流) 5.5.1.3 Procedure 步骤 ***NOTE***注意 For connectors with more than 16 cavities, refer to the authorized person for location and quantity of the cavities to be checked. 对于大于 16 腔的连接器,参考权威人士确定的型腔号和型腔数量。 ***NOTE***注意 This test is typically used only in conjunction with another test that subjects the connector to the chance of some form of moisture or other contaminant intrusion. Test the same samples used for the related test. If this test is to be performed to check isolation resistance of a new connector housing, prepare samples as specified in Section 5.3.3.3, Step 1. All seals and all other components of the connector assembly must be installed and all cavities of the connector must be populated or plugged, as appropriate to the application of the CUT. 这个试验的典型应用是与其他试验联合起来做。比如连接器放入有湿气或污染物的环境中进行环境试验。经过这些 环境试验后在做绝缘电阻试验。假如是对新连接器做绝缘电阻试验,则按照第 5.3.3.3 段第 1 步的要求准备样品。所 有的密封零件和其他零件都必须装配上去,所有的型腔必须装上相应的导线组件,合乎待测零件的实际应用。 ***NOTE***注意 When samples are to be tested following exposure to moisture or other contaminants, it is important that this Isolation Resistance test be performed on each sample within one hour of concluding the associated test. Otherwise, particularly where samples are exposed to elevated temperatures in the preceding test, any contaminant that might invade the samples may dry to the point of being undetectable by this Isolation Resistance test.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
当试验样品经过有湿气和其他污染物的环境试验后必须在 1 个小时内进行绝缘电阻测试,否则,特别是前面的 试验是高温试验,进入样品中的污染物会干燥聚成点很难通过测绝缘电阻探测到。 1. Connect the Megohmeter, set to 500 VDC, to the bared conductor ends from any pair of adjacent terminals in the connector system. For special applications, the test voltage may be reduced or increased with the approval of the Authorized Person. 1. 连接兆欧计(绝缘电阻测试仪) ,设置 500 VDC,探头连接到导线的剥头终端,导线的另一端连在连接器中相应 端子上。对于特殊的场合,在权威人士批准下可以降低或增加试验电压。 2. Use the Megohmeter to measure the resistance between the adjacent terminals. Apply the test voltage continuously for at least 15 sec. 2. 使用兆欧计(绝缘电阻测试仪)测试相邻端子的绝缘电阻。所施加的电压至少持续 15s。 1. Record the minimum resistance measured and verify conformance to the Acceptance Criteria of Section 5.5.1.4. 1. 记录测量得到的最小电阻值并且与第 5.5.1.4 的标准进行比较,检查是否符合标准。 2. Repeat Steps 1 - 3 above so that each terminal in the connector system is measured against all adjacent terminals. Test both halves of the connector system (if applicable) for new connector housings. Test the mated connector assembly for those samples that have been subjected to prior stress testing. 2. 重复上述步骤 1-3 以便测量连接器中所有相邻端子间的绝缘电阻。对于新的连接器塑件测试连接器系统的半成品 (假如适用) 。对于进行环境试验等试验的样品,测试装配好的连接器组件。 5.5.1.4 Acceptance Criteria 接收标准 The resistance between every combination of two adjacent terminals in the CUT must exceed 20 MOhms at 500 VDC. This includes terminals that may be separated by one or more vacant terminal cavities. 在 500 VDC 下测得的两相邻端子绝缘电阻要求超过 20MΩ 。 这包括两个相隔一个或一个以上型腔的端子间的绝 缘电阻。 5.6 CONNECTOR - ENVIRONMENTAL TESTS 连接器环境试验 5.6.1 Thermal Shock 热冲击 5.6.1.1 Purpose 目的 This test subjects the connector assembly to extreme temperature cycles which cause expansion and contraction of the various materials used in the connector system. This is intended to produce accelerated wear at the terminal - to - terminal interface. 这项试验是把连接器组件进行极端温度循环试验。试验会使连接器系统中的各种材料膨胀和收缩。这项试验加速端 子连接处的磨损老化。 5.6.1.2 Equipment 设备 ?DC Power Supply (0-20 VDC at 0-150 A) 直流电源(0-20 VDC at 0-150 A) ?Continuity Totalizer/Analyzer (CT/A)

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

连续性累加器/分析仪 ?Data Logger 记录装置 ?Temp. Chamber(s) (-40o C to +155o C *) 温度计(-40o C to +155o C *) * As required by the Temperature Class selected from Figure 5.1.4. 要求按照温度等级从图 5.1.4.选取。 5.6.1.3 Procedure 步骤 1. Using the terminal type, conductor size, and insulation type for the intended application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable crimp specification or as required by the manufacturer of the terminal system being used for the test. Using that crimp setting, machine crimp enough samples of male and female terminals to assemble a minimum of 10 pairs (at least 10 male and 10 female) of connector assemblies. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1. 使用合适的端子类型,线芯规格和绝缘体类型压接符合压接规范或制造商自己的压接要求的端子。端子的压接高 度,压接宽度,抗张强度要符合相应的要求。按照同一压接设置,压接足够数量的阴阳接触件,至少 10 对(至少 10 只阴接触件和 10 只阳接触件) 。压接出前角和后角。按照制造商推荐的装配标准装配类型端子。对于 Header 类型 连接器只是为了装配连接器而准备样品。 2. Record the crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals). 2. 记录每一端子典型样品的压接高度和压接宽度 (除 insulation displacement 类型端子) 3. Assemble a minimum of 10 pairs of fully populated connectors (at least 10 male and 10 female connector halves) using the terminals prepared in Step 1 above. Assembly must include all applicable Wedges (TPAs, PLRs, etc.), Seals, etc. Number each mated connector pair. 3. 用上述步骤 1 准备的端子装配至少 10 个连接器(至少 10 只阴连接器和 10 只阳连接器) 。装配件必须包括所有的 零件,如楔(TPAs, PLRs 等锁定装置)密封物。标记每一对连接器。 1. Completely mate and unmate each connector pair a total of 10 times and then mate them again for testing. 1. 每一对连接器总共需要插拔 10 次,然后再插合连接器做试验。 2. Verify conformance of each sample connector assembly to the following Acceptance Criteria: A. First, the Dry Circuit Resistance test, Section 5.3.1.4. B. Second, the Voltage Drop test, Section 5.3.2.4. 2. 验证连接器样品是否符合如下接收标准: 第一,第 5.3.1.4.段的干电路电阻试验; 第二,第 5.3.2.4.段的压降试验。 3. Solder the conductors from each terminal in the CUT in series to form one continuous current path with only two free ends.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
Solder one of the free conductor ends to a 2 watt, 120 ohm ± 1% resistor. Preset the power supply to provide 100 mA to the circuit. Solder the "-" (negative) lead to the free end of the resistor and the " + " (positive) lead to the remaining free conductor end of the CUT. Connect the Continuity Totalizer/Analyzer (CT/A) across the resistor, making sure that the negative lead of the CT/A is connected to the negative side of the resistor. Set the CT/A to monitor the current through the resistor and record any instance where that current falls below 95 mA. As an option, the CT/A may be used to monitor one or more terminal pairs instead of the resistor. 3. 把来自每一对端子的导线焊接在一起形成一个只有两个自由端点的通路。把一个自由端点焊接到一只 2W,120 ± 1.2Ω 的电阻器上。 把负极连接到电阻器上, 待测零件 CUT 余下的另一个自由端点是正极。 连续性分析仪/累加器 (或 等效仪器)CT/A 连接到电阻器的两边,确保连续性分析仪/累加器(或等效仪器)CT/A 的负极连接到电阻器的负极。 调整电源使之给电路提供 100 mADC 的电流。 同过 CT/A 监视流过电阻器的电流并且记录当电流小于 95 mA 的情况。 建议 CT/A 可以用于监视一对或一对以上的端子来取代监视电阻器。 A reference illustration of the test set-up is shown in Figure 5.6.1.3. Other suitable continuity monitoring equipment may be substituted for this circuit. The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing. 图 5.6.1.3.是试验设置的说明图。其他合适的监视设备可以取代上述设备用于该电路。工装,布局,试验设置必须得 到权威人士批准。

FIGURE 5.6.1.3: Connector Environmental Test Set-Up 图 5.6.1.3:连接器环境试验的试验设置 7. Place the samples in the Chamber so that there is no substantial obstruction to air flow across and around the samples, and the samples are not touching each other. 7. 把样品放在试验箱中,并且所放位置不能影响气流在样品周围流动。样品不能相互接触。 8. Determine the Temperature Class for the intended application of the connector system from Figure 5.1.4. Then set the Temperature Chamber to the minimum ambient temperature for that class. Allow the Chamber to stabilize, then cold soak the

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

samples an additional 30 min. 8. 根据试验的连接器从图 5.1.4.中选取合适的温度等级。按照选定的温度等级把试验箱温度设置成最低温度。试验 箱温度稳定。样品在低温中存放 30min。 9. At the conclusion of the 30 minute cold soak, transfer the samples to another Chamber set to the maximum ambient temperature for the Temperature Class selected in Step 8. It is important to complete the transfer of all samples from the cold to hot Chamber (or, optionally, to transition one Chamber from the coldest to the hottest extreme) in less than 30 seconds. Allow the samples to heat soak for 30 minutes. 9. 30min 低温试验后,把样品放入高温试验箱中,按照选定的温度等级把试验箱温度设置成最高温度。 这是很重要得,把所有样品从低温箱中转移到高温箱中(或者,同一个试验箱从最低温度升到最高温度)少于 30s (压接确认试验中的热冲击试验转换时间是少于 5min) 。在高温箱中存放 30min。 10. At the conclusion of the 30 minute heat soak, transfer the samples to another set to the minimum ambient temperature for the Temperature Class selected in Step 8. It is important to complete the transfer of all samples from the hot to cold Chamber in less than 30 seconds. Allow the samples to cold soak for 30 minutes. 10. 30min 高温试验后,把样品放入低温试验箱中,按照选定的温度等级把试验箱温度设置成最低温度。这是很重要 得,把所有样品从高温箱中转移到低温箱中少于 30s。在低温箱中存放 30min。 11. Repeat Steps 9 and 10 ninety nine (99) more times. 11. 重复步骤 9 和 10 至少 99 次。 12. During the test, there must be no loss of electrical continuity (resistance≥7.0 ohms, which corresponds to a drop in current flow below 95 mA) for more than 1 microsecond. 12. 测试中, 则不允许出现以下情况: 接触对的电阻超过 7.0Ω(相当于电路中的电流小于 95 mA) 持续时间大于 1ms。 13. Verify conformance to the Acceptance Criteria of Section 5.6.1.4. 13. 验证与第 5.6.1.4.标准的符合性。 5.6.1.4 Acceptance Criteria 接收标准 At the conclusion of the test, verify conformance of each terminal pair and each sample connector assembly, as appropriate, to the Acceptance Criteria of the following tests: A. First, the Dry Circuit Resistance test, Section 5.3.1.4. B. Second, the Voltage Drop test, Section 5.3.2.4. 试验结束后,要验证每一对端子和每一只连接器组件与以下标准的符合性。 第一,第 5.3.1.4.段的干电路电阻试验; 第二,第 5.3.2.4.段的压降试验。 ***NOTE***注意 If samples are to be subjected to further testing (for example as part of the test sequence shown in Section 5.8.6) The following steps may be deferred until the sequence is complete. The connector assemblies must not show, with the aid of 10X magnification, any evidence of deterioration, cracks, deformities, etc. that could affect their fit or function, or distort their appearance. 如果样品还需进一步试验(如第 5.8.6 段的试验) ,则需这试验做完后才能做以下步骤。连接器没有外观缺陷。用 10 倍放大镜看,不能出现明显的退化,裂缝,残缺等这些会影响尺寸配合,功能或加速外观变形。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
5.6.2 Temperature/Humidity Cycling 温度/湿度循环试验 5.6.2.1 Purpose 目的 This test simulates actual operating conditions using temperature and humidity variations as aging mechanisms for evaluation of a connector system's electrical durability. High humidity and temperature can promote galvanic and electrolytic corrosion of the terminals which may cause electrical and mechanical degradation. Temperature cycling promotes relative movement of the contact surfaces that can cause wear and fretting corrosion. Note that, for a portion of this test only, the maximum temperature exceeds the maximum ambient temperature of the Temperature Class selected from Figure 5.1.4. 这个试验是模拟实际操作条件中温度和湿度变化使机械装置老化来评估连接器系统的电方面耐用性。高温度湿度能 加速端子的电流和电解腐蚀,这腐蚀可能会导致电气和机械降级。温度循环会加速接触件接触界面的相对移动,这 会导致磨损和摩擦腐蚀。 注意, 作为试验一部分, 该试验的最高温度超过按照图 5.1.4.选择的温度等级中的最高温度。 5.6.2.2 Equipment 设备 ?DC Power Supply (0-20 VDC at 0-150 A) 直流电源(0-20 VDC at 0-150 A) ?Continuity Analyzer/Totalizer (or equivalent) 连续性分析仪/累加器(或等效仪器) ?Data Logger 记录装置 ?Temperature Chamber(s) (-40°C to +155°C *, 0%-95% Relative Humidity) 温度计(-40°C to +155°C *, 相对湿度 0%-95%) * As required by the Temperature Class selected from Figure 5.1.4. 按照图 5.1.4.选择的温度等级的要求 5.6.2.3 Procedure 步骤 1. Using the terminal type, conductor size, and insulation type for the intended application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable crimp specification or as required by the manufacturer of the terminal system being used for the test. Using that crimp setting, machine crimp enough samples of male and female terminals to assemble a minimum of 10 pairs (at least 10 male and 10 female) of connector assemblies. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1. 使用合适的端子类型,线芯规格和绝缘体类型压接符合压接规范或制造商自己的压接要求的端子。端子的压接高 度,压接宽度,抗张强度要符合相应的要求。按照同一压接设置,压接足够数量的阴阳接触件,至少 10 对(至少 10 只阴接触件和 10 只阳接触件) 。压接出前角和后角。按照制造商推荐的装配标准装配 insulation displacement 类型 端子。对于 Header 类型连接器只是为了装配连接器而准备样品。 2. Record the crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals).

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

2. 记录每一端子典型样品的压接高度和压接宽度 (除 insulation displacement 类型端子) 3. Assemble a minimum of 10 pairs of fully populated connectors (at least 10 male and 10 female connector halves) using the terminals prepared in Step 1 above. Assembly must include all applicable Wedges (TPAs, PLRs, etc.), Seals, etc. Number each mated connector pair. 3. 用上述步骤 1 准备的端子装配至少 10 个连接器(至少 10 只阴连接器和 10 只阳连接器) 。装配件必须包括所有的 零件,如楔(TPAs, PLRs 等锁定装置)密封物。标记每一对连接器。 4. Completely mate and unmate each connector pair a total of 10 times and then mate them again for testing. 4. 每一对连接器总共需要插拔 10 次,然后再插合连接器做试验。 5. Verify conformance of each sample connector assembly to the following Acceptance Criteria: A. First, the Dry Circuit Resistance test, Section 5.3.1.4, when this test is performed stand-alone. B. Second, the Voltage Drop test, Section 5.3.2.4. C. Finally, the Isolation Resistance test, Section 5.5.1.4. 5. 验证连接器样品是否符合如下接收标准: 第一,第 5.3.1.4.段的干电路电阻试验; 第二,第 5.3.2.4.段的压降试验。 6. Solder the conductors from each terminal in every CUT in series to form one continuous current path with only two free ends. Solder one of the free conductor ends to a 2 watt, 120 ohm ± 1% resistor. Preset the power supply to provide 100 mA to the circuit. Solder the " ? ? " (negative) lead to the free end of the resistor and the " + " (positive) lead to the remaini ng free conductor end of the CUT. Connect the Continuity Totalizer/Analyzer (CT/A) across the resistor, making sure that the negative lead of the CT/A is connected to the negative side of the resistor. Set the CT/A to monitor the current through the resistor and record any instance where that current falls below 95 mA. As an option, the CT/A may be used to monitor one or more terminal pairs instead of the resistor. A reference illustration of the test set-up is shown in Figure 5.6.1.3. Other suitable continuity monitoring equipment may be used.The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing. 6. 把来自每一对端子的导线焊接在一起形成一个只有两个自由端点的通路。把一个自由端点焊接到一只 2W,120 ± 1.2Ω 的电阻器上。 把负极连接到电阻器上, 待测零件 CUT 余下的另一个自由端点是正极。 连续性分析仪/累加器 (或 等效仪器)CT/A 连接到电阻器的两边,确保连续性分析仪/累加器(或等效仪器)CT/A 的负极连接到电阻器的负极。 调整电源使之给电路提供 100 mADC 的电流。 同过 CT/A 监视流过电阻器的电流并且记录当电流小于 95 mA 的情况。 建议 CT/A 可以用于监视一对或一对以上的端子来取代监视电阻器。 图 5.6.1.3.是试验设置的说明图。其他合适的监视设备可以取代上述设备用于该电路。工装,布局,试验设置必须得 到权威人士批准。 7. Place the samples in the Chamber so that there is no substantial obstruction to air flow across and around the samples, and the samples are not touching each other. 7. 把样品放在试验箱中,并且所放位置不能影响气流在样品周围流动。样品不能相互接触。 8. Determine the Temperature Class for the intended application of the connector system from Figure 5.1.4. Then set the Temperature Chamber to the minimum temperature for that class. Allow the Chamber to stabilize before proceeding.

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
8. 根据连接器的要求从图表 5.1.4.选择相应的温度等级。然后按照选定的温度等级把试验箱设置成最低温度。允许 试验前保持稳定。 9. Cycle the test samples 40 times using the cycling schedule shown in Figure 5.6.2.3. Use the Maximum Ambient Temperature for hours 5 through 7 as determined from Figure 5.1.4 in Step 8 above. Figure 5.6.2.3 shows the temperature for Maximum Ambient Temperature for illustration only. 9. 按照图 5.6.2.3.要求循环 40 次。从第 5 小时到第 7 小时施加最高温度。最高温度按照图表 5.1.4 选取。图 5.6.2.3 只是作为最高温度的图示说明而已。

FIGURE 5.6.2.3: Temperature/Humidity Cycling Schedule 图 5.6.2.3:温度/湿度循环图 10. During the test, there must be no loss of electrical continuity ( Resistance ? ? 7.0 ohms, which corresponds to a drop in current flow below 95 mA) for more than 1 microsecond. 10. 测试中, 则不允许出现以下情况: 接触对的电阻超过 7.0Ω(相当于电路中的电流小于 95 mA) 持续时间大于 1ms。 11. Verify conformance to the Acceptance Criteria of Section 5.6.2.4. 11. 验证与第 5.6.2.4.段的标准的符合性。 5.6.2.4 Acceptance Criteria 接收标准

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

At the conclusion of the test, verify conformance of each terminal pair and each sample connector assembly, as appropriate, to the Acceptance Criteria of the following tests: A. First, the Dry Circuit Resistance test, Section 5.3.1.4. B. Second, Voltage Drop test, Section 5.3.2.4. C. Finally, the Isolation Resistance test, Section 5.5.1. 试验结束后,要验证每一对端子和每一只连接器组件与以下标准的符合性。 第一,第 5.3.1.4.段的干电路电阻试验; 第二,第 5.3.2.4.段的压降试验; 第三,第 5.5.1.段的绝缘电阻试验。 ***NOTE***注意 If samples are to be subjected to further testing (for example as part of the test sequence shown in Section 5.8.6) The following steps may be deferred until the sequence is complete. 如果样品还需进一步试验(如第 5.8.6 段的试验) ,则需这试验做完后才能做以下步骤。 D. The connector assemblies must not show, with the aid of 10X magnification, any evidence of deterioration, cracks, deformities, etc. that could affect their functionality or distort their appearance. D. 连接器没有外观缺陷。用 10 倍放大镜看,不能出现明显的退化,裂缝,残缺等这些会影响尺寸配合,功能或加 速外观变形。 E. Each terminal must meet the extraction requirements of Section 5.4.1.4 of the Terminal-Connector Insertion/Extraction Force test, except do NOT increase the force beyond 48N. E. 每一端子必须满足端子-连接器的插入力/拔出力中对拔出力的要求(既端子在塑件中的固定力)

5.6.3 High Temperature Exposure 高温暴露 5.6.3.1 Purpose 目的 This test evaluates the effects of long term exposure to elevated temperature on connector assembly components. Thermal aging may cause changes in metal and plastic materials, including stress relaxation in important flexing members of the terminal or its connector. These changes may be detrimental to electrical and physical performance. 这个试验是评估连接器长期暴露在高温环境后的影响程度。热老化可能会导致金属和塑料材料的变化。端子和塑件 弯曲后的应力释放。这些变化可能会使电性能和物理性能变差。 5.6.3.2 Equipment 设备 ?Temperature Chamber(s) (+155°C *) 温度计(+155°C *) * As required by the Temperature Class selected from Figure 5.1.4. 按图 5.1.4.温度等级要求。 5.6.3.3 Procedure 步骤 1. Using the terminal type, conductor size, and insulation type for the intended application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable crimp specification or as required by the manufacturer of the terminal system being used for the test. Using that crimp setting, machine crimp enough samples of

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
male and female terminals to assemble a minimum of 10 pairs (at least 10 male and 10 female) of connector assemblies. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1. 使用合适的端子类型,线芯规格和绝缘体类型压接符合压接规范或制造商自己的压接要求的端子。端子的压接高 度,压接宽度,抗张强度要符合相应的要求。按照同一压接设置,压接足够数量的阴阳接触件,至少 10 对(至少 10 只阴接触件和 10 只阳接触件) 。压接出前角和后角。按照制造商推荐的装配标准装配 insulation displacement 类型 端子。对于 Header 类型连接器只是为了装配连接器而准备样品。 2. Record the crimp height and width of a representative group of samples of each terminal (except for insulation displacement type terminals). 2. 记录每一端子典型样品的压接高度和压接宽度 (除 insulation displacement 类型端子) 3. Assemble a minimum of 10 pairs of fully populated connectors (at least 10 male and 10 female connector halves) using the terminals prepared in Step 1 above. Assembly must include all applicable Wedges (TPAs, PLRs, etc.), seals, etc. Number each mated connector pair. 3. 用上述步骤 1 准备的端子装配至少 10 个连接器(至少 10 只阴连接器和 10 只阳连接器) 。装配件必须包括所有的 零件,如楔(TPAs, PLRs 等锁定装置)密封物。标记每一对连接器。 4. Completely mate and unmate each connector pair a total of 10 times and then mate them again for testing. 4. 每一对连接器总共需要插拔 10 次,然后再插合连接器做试验。 5. Verify the performance of each sample connector assembly to the following Acceptance Criteria: A. First, the Dry Circuit Resistance test, Section 5.3.1.4. B. Second, the Voltage Drop test, Section 5.3.2.4. 5. 验证连接器样品是否符合如下接收标准: 第一,第 5.3.1.4.段的干电路电阻试验; B. 第二,第 5.3.2.4.段的压降试验。 6. The test fixtures, system layout, and test set-up must be approved by the Authorized Person prior to testing. 6. 工装,布局,试验设置试验前必须得到权威人士批准。 7. Determine the Temperature Class for the intended application of the connector system from Figure 5.1.4. Then set the temperature chamber to the maximum ambient temperature for that class. Allow the chamber to stabilize before proceeding. 7. 根据试验的连接器从图 5.1.4.中选取合适的温度等级。按照选定的温度等级把试验箱温度设置成最高温度。允许 试验箱温度稳定。 8. Place the samples in the chamber, set to the maximum ambient temperature, so that there is no substantial obstruction to air flow across and around the samples, and the samples are not touching each other. Leave the samples in the chamber for 1008 hours. 8. 把样品放在试验箱中,设置成最高温度,并且所放位置不能影响气流在样品周围流动。样品不能相互接触。

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

把样品放在试验箱中 1008 小时。 9. Sample evaluation is required only at the beginning and end of the test, but additional measurement intervals may be requested by the Authorized Person. 9. 样品评估只在试验开始前和试验后进行,但是如果权威人士要求也可以在试验过程中进行样品评估。 10. At the conclusion of the test, verify conformance to the Acceptance Criteria of Section 5.6.3.4. 10. 试验结束后,验证与第 5.6.3.4.段标准的符合性。 5.6.3.4 Acceptance Criteria 接收标准 At the conclusion of the test, verify conformance of each terminal pair and each sample connector assembly, as appropriate, to the Acceptance Criteria of the following tests, in the order shown: A. The Dry Circuit Resistance test, Section 5.3.1.4. B. Second, the Voltage Drop test, Section 5.3.2.4. 试验结束后,要验证每一对端子和每一只连接器组件与以下标准的符合性。 第一,第 5.3.1.4.段的干电路电阻试验; B. 第二,第 5.3.2.4.段的压降试验。

***NOTE***注意 If samples are to be subjected to further testing (for example as part of the test sequence shown in Section 5.8.6) do not perform any steps beyond this point. 如果样品还需进一步试验(如第 5.8.6 段的试验) ,则需这试验做完后才能做以下步骤。 C. The connector assemblies must not show, with the aid of 10X magnification, any evidence of deterioration, cracks, deformities, etc. that could affect their functionality or distort their appearance. Connector locking mechanisms must function without breakage. C. 连接器没有外观缺陷。用 10 倍放大镜看,不能出现明显的退化,裂缝,残缺等这些会影响尺寸配合,功能或加 速外观变形。连接器锁扣等装置不能有影响功能的破裂。 D. Each terminal must meet the extraction requirements of Section 5.4.1.4 of the Terminal-Connector Insertion/Extraction Force test, except do NOT increase the force beyond 48N. D. 每一端子必须满足端子-连接器的插入力/拔出力中对拔出力的要求(既端子在塑件中的固定力) 除非不增加力超过 48N。 5.6.4 Fluid Resistance 耐化学溶液能力试验 ***NOTE***注意 This test is to be used for sealed connector systems only. 这个试验只是用于密封型连接器系统。 5.6.4.1 Purpose 目的 This test evaluates the sealing capability and material compatibility of a sealed connector system when immersed in various fluids commonly found in and around road vehicles. 这个试验是评估密封型连接器系统在车用液体中的密封性和系统中各种零件材料的兼容性。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
5.6.4.2 Equipment 设备 ?Laboratory Fume Hood 实验室通风橱 ?Stainless steel tanks or Pyrex beakers 不锈钢桶或耐热玻璃杯 ?Explosion-proof Heat Chamber 防爆高温试验箱 5.6.4.3 Procedure 目的 1. Using the smallest conductor size and insulation type for the terminals to be used in the intended application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable crimp specification or as required by the manufacturer of the terminal system being used for the test. Using that crimp setting, machine crimp enough samples of male and female terminals to assemble a minimum of 9 pairs of connector assemblies. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1. 使用合适的端子类型,线芯规格和绝缘体类型压接符合压接规范或制造商自己的压接要求的端子。端子的压接高 度,压接宽度,抗张强度要符合相应的要求。按照同一压接设置,压接足够数量的阴阳接触件,至少 10 对(至少 10 只阴接触件和 10 只阳接触件) 。压接出前角和后角。按照制造商推荐的装配标准装配 insulation displacement 类型 端子。对于 Header 类型连接器只是为了装配连接器而准备样品。 2. Assemble a minimum of 9 pairs of fully populated connectors using the terminals prepared in Step 1 above. Assembly must include all applicable Wedges (TPAs, PLRs, etc.), Seals, etc. Number each mated connector pair. 2. 用上述步骤 1 准备的端子装配至少 10 个连接器(至少 10 只阴连接器和 10 只阳连接器) 。装配件必须包括所有的 零件,如楔(TPAs, PLRs 等锁定装置)密封物。标记每一对连接器。 3. Verify conformance of each mated sample connector assembly to the Isolation Resistance test, Section 5.5.1. This establishes a reference for the concluding Isolation Resistance test. 3. 验证该装配好的连接器组件与第 5.5.1.段绝缘电阻试验的符合性。做绝缘电阻试验总结时可以参考它。 4. Completely submerse at least 1 test sample in each fluid listed below for 30 minutes. Fluids are to be stabilized at the temperatures indicated. A fresh sample is to be used for each fluid and each sample is to be submersed in one fluid only, unless otherwise requested by the Authorized Person. 4. 至少有 1 个样品要放入以下表格中所列的液体 30min。在表中要求的温度下液体保持稳定。除非权威人士要求, 每一种液体需要用新样品并且每个样品只放入一种液体中。 CAUTION: Follow all Federal, state, and local safety regulations, standards, and procedures when performing this test. 警告:做该试验时要求有相应的安全规定,标准和步骤。 Fluid type 液体类型 Fluid description 液体描述 Stablization temperature 稳定

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

温度 Brake Fluid 制动液 Oil 石油 Gasoline 汽油 Engine Coolant 发动机冷却液 Automatic Transmission Fluid 变速器 上的液体 Windshield Washer Solvent 档风玻璃清洗液 Power Steering Fluid 转向装置处的液体 Diesel Fuel 柴油 E85 Ethanol Fuel E85 乙醇燃料 90%IRM903+10%T-Xylene 85% Ethanol+15%ASTM reference fuel C 25℃ 25℃ ASTM IRM-903 50℃ Commercial 25℃ SAE RM66-04 ASTM IRM-902 ASTM Ref. Fuel C ASTM Serv . Fluid 104 Citgo #33123 50℃ 50℃ 25℃ 100℃ 50℃

5. At the conclusion of the submersion period, remove the sample from the fluid. Do NOT shake off any excess fluid. Use care not to splash any fluid on unintended surfaces. Leave the samples "wet" and store them in a suitable container or area for one week. Do not allow samples submersed in different fluids to touch each other and do not allow any dissimilar fluid drippings to intermingle. 5. 完成规定时间的浸渍后,将样品从液体中取出来。不允许甩掉多余的液体。不允许液体溅到其他表面。保持样品 从液体中取出来时候的样子,并且把它放入一个适宜容器或表面上一个星期。不允许把样品放入另外一种液体中, 也不允许另外一种液体混入该液体中。 6. At the conclusion of the storage period, samples may be dried sufficiently to allow inspection and to avoid contamination of test apparatus. 6. 在存放规定时间后,样品就充分干燥,允许目测,避免试验样品的污染。 7. Verify conformance of each test sample to the Acceptance Criteria of Section 5.6.4.4. 7. 验证试验的样品与第 5.6.4.4.段标准的符合性。 5.6.4.4 Acceptance Criteria 接收标准 At the conclusion of this test: A. Each mated terminal pair in every test sample must meet the Acceptance Criteria of the Isolation Resistance test, Section 5.5.1.4. In the case of single cavity connectors, apply the test voltage between the ground plane and one of the conductors from the test sample. B. There must be no visible degradation, swelling, cracking, or loss of mechanical function evident on any test sample, examined with the aid of a 10X magnifying glass. 该试验结束后: 每个试验中的每一对接触件都必须符合第 5.5.1.4.段的绝缘电阻试验接收标准。假如是单腔的连接器,在试验样品中 的一根导线与地线之间施加规定的电压。 可以用 10 倍的放大镜观察,不能出现可见的退化,膨胀,裂缝或影响机械功能。

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
5.6.5 Submersion 浸渍试验 ***NOTE***注意 This test is to be used for sealed connector systems only. 这个试验只适用于密封型连接器系统。 5.6.5.1 Purpose 目的 This test is an accelerated simulation of the "breathing" that may occur in a sealed connector system when it is heated and suddenly cooled by submersion in a cooler liquid. Salt water is used as the liquid to facilitate detection of any leakage into the connector. As a further aid to detecting any leakage that may occur, it is recommended that a suitable ultraviolet dye be added to the salt water solution. 这个试验是把经过加热的样品突然放入冷溶液中,检测样品防止密封破坏的能力。用盐水检测连接器泄漏的情况。 按照步骤 8 的推荐在溶液中加入便于紫外线探测的染料,会益于探测。 5.6.5.2 Equipment 设备 ?Stainless steel tanks or Pyrex beakers 不锈钢桶或耐热玻璃杯 ?Megohmeter (0.5% accuracy Full Scale) 兆欧计(全刻度 0.5%的精度) ?Temperature Chamber (-40o C to +155o C*) 温度计(-40o C to +155o C*) *As required by the Temperature Class selected from Figure 5.1.4. 从图 5.1.4.选择温度等级要求。 5.6.5.3 Procedure 步骤 1. Using the smallest conductor size and insulation type for the terminals to be used in the intended application, machine crimp samples until one meets the crimp height, crimp width, and tensile strength requirements of the applicable crimp specification or as required by the manufacturer of the terminal system being used for the test. Using that crimp setting, machine crimp enough samples of male and female terminals to assemble a minimum of 10 pairs of connector assemblies. Crimp both the conductor and insulation grips. Assemble insulation displacement style terminals per their manufacturer's recommended assembly criteria. For Header type connectors, prepare samples only for the mating connector. 1. 使用合适的端子类型,线芯规格和绝缘体类型压接符合压接规范或制造商自己的压接要求的端子。端子的压接高 度,压接宽度,抗张强度要符合相应的要求。按照同一压接设置,压接足够数量的阴阳接触件,至少 10 对(至少 10 只阴接触件和 10 只阳接触件) 。压接出前角和后角。按照制造商推荐的装配标准装配 insulation displacement 类型 端子。对于 Header 类型连接器只是为了装配连接器而准备样品。 2. Assemble a minimum of 10 pairs of fully populated connectors using the terminals prepared in Step 1 above. Assembly must include all applicable Wedges (TPAs, PLRs, etc.), Seals, etc. Number each mated connector pair. For multiple conductor (mat) type seals only, insert and remove the terminal from its cavity twice, then re-insert for testing. The purpose

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

of this step is to ensure the terminal does not damage the seal during service operations. 2. 用上述步骤 1 准备的端子装配至少 10 个连接器(至少 10 只阴连接器和 10 只阳连接器) 。装配件必须包括所有的 零件,如楔(TPAs, PLRs 等锁定装置)密封物。标记每一对连接器。对于多导线类型连接器,端子插入型腔和拔出 型腔两次,然后重新插入型腔。这样做的目的是为了确保实际操作时不会破坏密封。 3. Completely mate and unmate each connector pair a total of 10 times and then mate them again for testing. 3. 每对连接器插拔 10 次,然后重新装上。 4. Verify conformance of each mated sample connector assembly to the Isolation Resistance test, Section 5.5.1.4. This establishes a reference for the concluding Isolation Resistance test. 4. 验证每一装配好的连接器样品与第 5.5.1.4.段绝缘电阻实验标准的符合性。做绝缘电阻试验总结时可以参考它。 5. Place the samples in the chamber such that there is no substantial obstruction to air flow across and around the samples, and the samples are not touching each other. 5. 把样品放在试验箱中,所放位置不能影响气流在样品周围流动。样品不能相互接触。 6. Determine the Temperature Class of the connector system from Figure 5.1.4 and set the chamber to the Maximum Ambient Temperature for that class. Allow the chamber to stabilize before proceeding. Heat soak the samples at the elevated temperature of the chamber for 2 hours. If the internal temperature of a representative sample of the parts to be tested can be shown to stabilize at oven temperature in less than two hours, the shorter time may be used. The demonstration sample may not be used as an actual test sample. 6. 按照图 5.1.4 决定相应的温度等级,并且按照这个温度等级中的最高温度把试验箱设置成最高温度。允许试验前 试验箱温度保持稳定。样品在最高温度环境中保持 2h。假如放在试验中的样品在 2 个小时之内使样品内部温度达到 稳定,则可以减少存放时间。不能用示范样品代替实际试验样品。 7. Prepare enough salt water solution to completely submerse all samples to a depth of 30-40 cm below the surface. Use tap water and add 15 to 16 grams of table salt per liter. Then add 10 ml of liquid dish washing soap per liter. Mix well before adding to test apparatus. This should result in a solution holding approximately 5% of the maximum weight of salt that each liter of water can dissolve at room temperature. Soap is added to approximate a 1% solution by volume. It is recommended that an appropriate ultraviolet dye be added to assist in visual inspection for any ingress of solution into the test samples. 7. 准备足够的盐水溶液使样品浸入到液面以下 30-40cm。 使用自来水并且每升添加 15-16g 精盐。 然后每升添加 10ml 肥皂水。在试验前将溶液混合好。这就是说,这份溶液包含大约 5%的盐(质量百分比) ,这也是一升水在室温时所 能溶解的食盐量。肥皂水大约含 1%(体积百分比) 。按照步骤 8 的推荐在溶液中加入便于紫外线探测的染料,会益 于探测。 8. Remove the samples from the chamber. Within 30 seconds, submerse them in the room temperature salt water solution to a depth of 30 - 40 cm.. The samples shall remain submersed at this depth for a period of 30 minutes. 8. 在 30s 内,将样品从试验箱中移去,并且浸入室温下的盐水溶液中,浸入深度是 30-40cm。样品在该深度下保持 30min。 9. At the end of the 30 minute submersion, remove the samples from the salt water solution, shake off the excess solution, then carefully dry the exterior surfaces of the samples. Immediately perform the Isolation Resistance test of Section 5.5.1 on each sample. 9. 30min 之后将样品从盐水溶液取出。甩掉多余的溶液,然后仔细弄干样品表面的液体。然后立即按照第 5.5.1 段的

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS 车用电子连接器系统性能标准
绝缘电阻试验测量其绝缘电阻。 10. Repeat Steps 6, 8, and 9 four (4) more times, except do not repeat when this test is done on samples that have completed the High Temperature Exposure Test of Section 5.6.3 or the Temperature/Humidity Cycling test of Section 5.6.2. 10. 重复 6,8,9 步骤 4 次以上,除非这个试验样品已经完成第 5.6.3 段的高温暴露试验或第 5.6.2.段的温度/湿度循 环试验。 11. Immediately upon concluding the test, verify conformance of each sample to the Acceptance Criteria of Section 5.6.5.4. 11. 立即评估样品,验证与第 5.6.5.4.段标准的符合性。 12. SPECIAL TEST for connectors with multi-cavity (mat) type conductor seals. This test is not applicable to single cavity connector designs. This is an additional test and requires use of new samples. Its purpose is to check for seal distortion from extremes of conductor size that may produce a leak. 12. 对于多腔密封型连接器需要做特殊试验。这个试验对于单腔连接器不适用。这是附加的一个试验并且需要新样 品。它的目的是检查由于导线尺寸变形引起密封处变形从而产生泄漏的情况。 A. Repeat Step 1, except prepare one male and one female terminal for each connector pair to be tested. B. Repeat Step 1 except use the largest conductor size and insulation type for the terminals to be used in the intended application. Prepare only enough terminal samples to fully populate all connector pairs, less one cavity for each connector half. 重复步骤 1,除非准备好 1 只阳接触件和 1 只阴接触件; 重复步骤 1,除非按照意图用最大的导线和绝缘类型(线皮)压接端子。准备足够的端子用于装配连接器,对于每 一连接器半成品(即阴连接器或阳连接器)留一个型腔不装配上端子。 C. Prepare a minimum of 10 connector pairs so that all but one randomly selected cavity in each connector half is populated with a terminal crimped to the largest conductor size, prepared in Step B above. Then fill the remaining cavity in each connector half with the appropriate terminal crimped to the smallest conductor size, prepared in Step A above. Number each connector pair. C. 准备 10 对连接器(阴连接器和阳连接器) ,在每一连接器半成品(即阴连接器或阳连接器)中任选一腔装上用最 大尺寸压接的端子(在 B 步骤准备的端子) 。剩余的型腔用最小尺寸压接的端子装上(在 A 步骤准备的端子) 。标记 每一对连接器。 D. Repeat Steps 3, 4, 5, 6, 8, 9, 10, and 11 using the samples prepared in Step C above. D. 利用步骤 C 准备的样品,重复步骤 3, 4, 5, 6, 8, 9, 10, and 11 的试验。 5.6.5.4 Acceptance Criteria 接收标准 At the conclusion of the test, disconnect each mated sample pair and perform the Visual Inspection test of Section 5.1.6. When disconnecting the samples, use care not to allow any residual solution to enter the interior of any connector half. Careful examination is required to detect any trace of fluid leakage that escaped detection by the Isolation Resistance test. Use of a dye in the solution, as recommended in Step 7 above, will aid in this inspection. There should be no trace of fluid ingress in any connector at the conclusion of this test.

SAE/USCAR-2 REVISION 3

Issued August 1997 Revised April 2001

试验结束后,分离装配好的样品,按照第 5.1.6.段的外观检验标准进行外观检验。当分离相配的连接器时,要注意防 止剩余的溶液进入任何一个半成品(即阴连接器或阳连接器) 。通过绝缘电阻试验检测泄漏情况。按照第 7 步的推荐 在溶液中加入染料,这样会有益于检测。试验结束后

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