Performance Specification for Automotive ... - yth-test.com

1 SAE/USCAR-2 Revision 6 Performance Specification for AutomotiveElectrical Connector SystemsFebruary 2013 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS--`,,```,,,,````-`-`,,`,,`,`,,`--- ISBN: 978-0-7680-- 7998 2 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS--`,,```,,,,````-`-`,,`,,`,`,,`---___ __ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors.

2 Neither the SAE International (SAE) nor the United States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes. Copyright 2013 USCAR Printed in All rights reserved. QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 SAE/USCAR-2 REVISION 6 Issued August 1997 Revised 2013-02 Performance Specification FOR Automotive ELECTRICAL CONNECTOR SYSTEMS TABLE OF CONTENTS 1.

3 SCOPE .. 3 2. TEST SEQUENCE .. 3 3. REFERENCED DOCUMENTS .. 3 Document 3 Part Drawing .. 4 Product Design Specification .. 4 Test Request/Order .. 4 Samples, Test Type, and Special tests .. 4 Test Request/Order Instructions .. 4 Performance and Durability Test Instructions .. 4 Documents MENTIONED IN THIS Specification .. 4 4. GENERAL REQUIREMENTS .. 5 Record Retention .. 5 Sample Documentation .. 5 Sample Size .. 5 Default Test Tolerances .. 5 Equipment .. 6 Measurement Resolution.

4 6 Test Repeatability & Calibration .. 6 Conformance Determination .. 7 Disposition of Samples .. 7 Part Endurance .. 7 5. TEST AND ACCEPTANCE REQUIREMENTS .. 7 General .. 7 Performance Requirements .. 7 Dimensional Characteristics .. 7 Material Characteristics .. 7 Classifications .. 8 Testing Headers & Direct Connect Components .. 9 Terminal Sample Preparation .. 10 Connector and/or Terminal Cycling .. 10 Visual Inspection .. 11 Circuit Continuity 12 Multi-cavity (mat) Conductor Seals Sample Preparation.

5 14 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS--`,,```,,,,````-`-`,,`,,`,`,,`---SAE /USCAR-2 REVISION 6 Revised 2013-02 Performance Specification FOR Automotive ELECTRICAL CONNECTOR SYSTEMS - 2 - Terminal Mechanical tests .. 14 Terminal to Terminal Engage/Disengage Force .. 14 Terminal Bend Resistance .. 15 Terminal - Electrical 17 Dry Circuit Resistance .. 17 Voltage Drop .. 19 Maximum Test Current Capability.

6 21 Current Cycling .. 24 Connector - Mechanical tests .. 25 Terminal - Connector Insertion/Retention and Forward Stop Force .. 25 Connector-Connector Mating/Unmating/Retention/Lock Deflection Forces (non-assist) .. 29 Connector to Connector Mate/Unmate Forces (mechanical assist) .. 31 Polarization Feature Effectiveness .. 34 Miscellaneous Component Engage/Disengage Force .. 35 Vibration/Mechanical Shock .. 37 Connector-to-Connector Audible Click .. 44 Connector Drop Test .. 44 Cavity Damage Susceptibility.

7 45 Terminal/Cavity Polarization Test .. 46 Connector Mounting Feature Mechanical Strength .. 47 Mechanical Assist Integrity (Connectors with Mechanical Assist Only) .. 49 Connector Seal Retention - Unmated Connector .. 50 Connector Seal Retention - Mated Connector .. 52 Connector - Electrical tests .. 52 Insulation Resistance .. 52 Connector Environmental tests .. 53 Thermal Shock .. 53 Temperature/Humidity Cycling .. 54 High Temperature Exposure .. 55 Fluid Resistance .. 56 Submersion.

8 57 Pressure/Vacuum Leak .. 58 High Pressure Spray .. 60 tests for Headers .. 61 Header Pin Retention .. 61 Severe Duty tests .. 63 Test Sequence .. 63 General Notes .. 63 Test Flow Chart .. 63 Terminal Mechanical Test Sequence .. 64 Terminal Electrical Test Sequence .. 64 Connector System Mechanical Test Sequence .. 64 Connector System Electrical Test Sequence .. 65 Sealed Connector System Environmental Test Sequence .. 66 Unsealed Connection System Environmental Test Sequence .. 67 Stand-Alone Sealing Performance Test Sequence.

9 67 6. APPENDICES .. 68 APPENDIX A: DEFINITIONS .. 68 APPENDIX B: ABBREVIATIONS USED .. 70 APPENDIX C: tests FOR NEW OR MOVED TOOLS AND MATERIAL CHANGES .. 72 APPENDIX D: tests FOR NEW/EXISTING TERMINAL OR CONNECTOR DESIGNS .. 73 APPENDIX E: SOURCE LIST .. 74 APPENDIX F: DESIGN NOTES: TEMPERATURE AND CURRENT RATING .. 75 APPENDIX G: REVISIONS .. 76 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS--`,,```,,,,````-`-`,,`,,`,`,,`---SAE /USCAR-2 REVISION 6 Revised 2013-02 Performance Specification FOR Automotive ELECTRICAL CONNECTOR SYSTEMS - 3 - 1.

10 SCOPE 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, twist lock connector systems, > 20 VAC or DC, or to eyelet-type terminals.