SAE_USCAR2_Rev3_2001 汽車電子連接器性能標準

1、PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS車用電子連接器系統(tǒng)性能標準*WARNING警告*No electrical connector, terminal, or related component may be represented as having met USCAR /EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and

2、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 par

3、ts . 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.如果沒有完全符合所有USCAR/EWCAP的要求并作驗證確認和文文件記錄，任何電子連接器、端子或相關(guān)零件都不能宣稱已經(jīng)符合USCAR/EWCA

4、P的規(guī)格。至少要達到最少樣品數(shù)量要求并且其中所有樣品都必須通過該測試所對應(yīng)的“接受標準”。所有要求的確認和文書記錄必須由零件供貨商完成。如果測試由其它單位完成，供貨商并不能豁免記錄所有零件測試結(jié)果并符合相應(yīng)“接受標準”的責任。1.0 SCOPE適用范圍Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals,

5、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 VA

6、C or DC, or to eyelet type terminals. 本規(guī)范中的程序意在包括端子、連接器及其部件（這些端子、連接器及其部件構(gòu)成路面交通工具直流0-20伏低壓電子連接系統(tǒng)）的在所有研發(fā)、生產(chǎn)和現(xiàn)場分析中的性能測試標準。這些規(guī)程只適用于線路中連接器系統(tǒng)中、針類連接器系統(tǒng)中和設(shè)備連接器系統(tǒng)中的端子，但不適用于“邊板連接器系統(tǒng)”（Edge Board connector systems），交/直流20伏，或針孔（eyelet）型的端子。Note that this specification does not cover the mechanical assist portion

7、s 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。注意本規(guī)范并沒有包含連接器的輔助機械部份。負責人必須提供相關(guān)額外測試的信息以滿足這些機械作為測試一部分的要求。IMPORTANT NOTICE: In any intended vehicle application, if the

8、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, thi

9、s 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

10、 specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested.重要提示：如果被測試零件是用于一些超過本規(guī)范所規(guī)定范圍的車輛，這些零件必須通過和實際情況的相一致的模擬測試才能投入正式使用。例如，這些包括在圖5.1.4中顯示的超過4級的極端溫度、非扭轉(zhuǎn)（unsprung）部分例如輪軸（hub）的振動及搖擺。已通過本規(guī)范測試標準的零件不應(yīng)在超過其測試條件的條件下使用。The Authoriz

11、ed 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 pr

12、ocedures contained in this specification. Any such deviation must be documented and included in the final test report.負責人最終決定對零件進行何種測試及測試目的，他/她亦解決任何有關(guān)測試的問題并允許設(shè)備及程序的偏差。所有這類偏差都必須有所記錄并包括在最終測試報告中。Guidance as to the recommended tests for selected purposes is given in the charts in Appendix C and D. In th

13、e 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.推薦測試的指導可以在附錄C和D的圖表中找到。如果負責人沒有相反的指示，所有電子連接器及其相

14、關(guān)端子和部件都需要符合本文的規(guī)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. 沒有明確要求的測試或在第三部分各層次中規(guī)定了額外測試要求的。2.0 OUTLINE & GLOSSARY OF TERMS大綱和術(shù)語表2.1 GENERAL通則Diagrams are provided where necessary to clarify the details

15、 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.在有必要協(xié)助明確各測試程序的細節(jié)的地方，本文提供圖表。除了特別指出之外，所有測試都必須按照給定的順序執(zhí)行。

16、本規(guī)則提供測試設(shè)備和裝置的安裝信息。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.附錄B提供術(shù)語表。術(shù)語單詞都用大寫開頭（如：Room Temperature, Steady State, PLR 等）。 附錄A提供定義表。For t

17、he purposes of this specification there are only two types of electrical connector: sealed and unsealed.為了說明的目的，本規(guī)范只有兩種連接器：密封型和不密封型。3.0 REFERENCED DOCUMENTS REQUIRED要求參考文獻3.1 DOCUMENT HIERARCHY文件等級層次In the event there is a conflict between performance standards, part drawings, and other related stan

18、dards or specifications, the requirements shall be prioritized as follows:當性能標準、零件圖紙和其它相關(guān)標準及規(guī)則發(fā)生不一致時，優(yōu)先級順序如下：1st - Applicable FMVSS requirements and other applicable state and Federal requirements .2nd - Applicable part drawings3rd - Applicable product design specification(s) .4th - Automotive Indus

19、try Action Group (AIAG) Production Part Approval Process (PPAP)5th - Applicable USCAR/EWCAP performance standards6th - Other applicable standards and specifications1 適用的FMVSS和其它的州及美國聯(lián)邦規(guī)定2 適用的零件圖紙3 適用的產(chǎn)品設(shè)計規(guī)范4 汽車行業(yè)工作組 (AIAG) 的生產(chǎn)零件批準過程 (PPAP)5 適用的 USCAR/EWCAP 性能標準6 其它適用的標準和規(guī)范3.2 PART DRAWING零件圖紙The par

20、t drawing for each connection system component should contain or reference:每個連接系統(tǒng)的零件圖紙都應(yīng)該包含或指定以下內(nèi)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 nu

21、mber 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. 所有規(guī)定尺寸（必須用GD&T格式）B. 性能要求C. 部件號D. 適合本規(guī)范部分的參考。E. 使用端子的數(shù)量及零件號F. 典型的連接器和端子的裝配。G. 零件計劃使用或已經(jīng)成功測試的最大允許溫度等級 (根據(jù)圖5

22、.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:為了便于控制及標準化起見，每個包含有符合USCAR/ EWCAP footprint

23、的電容器的圖紙也必須在圖紙說明或其它顯著位置標明以下聲明：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 Corporation, Ford Motor Company and Genera

24、l 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

25、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 ente

26、red in this drawings control column.該圖紙由美國汽車研究協(xié)會(USCAR)所屬的電子線路零件應(yīng)用協(xié)會(EWCAP)控制。USCAR是戴姆勒-克賴斯勒集團、福特汽車公司和通用汽車集團之間的合伙機構(gòu)。對于一個EWCAP圖紙的任何一個改動，包括一個“記錄變化”，都必須得到來自各個USCAR公司EWCAP相關(guān)成員的書面許可。每個被授權(quán)的EWCAP成員在代表其公司簽字前都必須得到其公司內(nèi)部各相關(guān)方的批準。EWCAP明確禁止任何一方在得到所有EWCAP成員認可之前擅自改動EWCAP控制圖紙或任何對應(yīng)模具。在該圖紙的控制欄中必須填寫同意改動簽字的相關(guān)證明內(nèi)容。3.3 PR

27、ODUCT DESIGN SPECIFICATION產(chǎn)品設(shè)計規(guī)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 spe

28、cifications and requirements in this document.產(chǎn)品設(shè)計規(guī)范可能是也可能不是零件圖紙中獨立的部分。如要求相關(guān)零件進行特別測試，或?qū)Ρ緳n中的普通規(guī)范及要求做改動或，在產(chǎn)品設(shè)計規(guī)范中必須說明。3.4 TEST REQUEST/ORDER測試要求/順序3.4.1 Samples, Test Type and Special Tests樣品、測試類型和特殊測試The laboratory test request/order shall provide location and documentation of test samples, identify

29、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.實驗室測試要求/順序應(yīng)該提供

30、測試樣品的地點和檔、明確將要進行的測試的種類（研發(fā)、確認、特別目的等）并描述所有不屬于本規(guī)范的特殊測試。任何對于本規(guī)范中測試的改動或偏離都必須有詳細說明。3.4.2 Test Request/Order Instructions測試要求/順序指示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 speci

31、fication.如果測試要求/順序和本規(guī)范的內(nèi)容有所不同，必須加以說明。3.4.3 Performance and Durability Test Instructions性能和持久性測試說明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 t

32、han outlined in this specification.如果對于性能和持久性測試的測試要求/順序（包括極限環(huán)境條件的定義）和本規(guī)范不同，必須加以說明。3.4.4 Development Tests研發(fā)測試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 determ

33、ining root causes of field problems.為評估設(shè)計的特定領(lǐng)域會經(jīng)常使用研發(fā)測試，它們是評估其它可能設(shè)計方案或改進方案、降低成本和發(fā)現(xiàn)實際使用中出現(xiàn)問題的根本原因的有效工具。3.4.5 Validation Tests確認測試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

34、this specification before designating it as a validation or compliance test.確認測試或樣品認可測試都屬于接受型測試。在把本規(guī)范的一些測試作為確認或應(yīng)用測試前必須考慮其內(nèi)在的可重復(fù)性或主觀性。3.4.6 Special Purpose Tests特定目的測試Portions of this specification may be useful for special purpose testing. For example, verifying a process or material change may, in

35、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 o

36、ther testing, described outside this specification, in any phase of product development, production testing, or analysis of parts from the field.本規(guī)范的部分內(nèi)容可以用于特定目的測試。例如：為了證實步驟或物料的改變并不會產(chǎn)生不良影響，經(jīng)負責人判斷，只需要一兩個特定測試或一個測試的一部分。在產(chǎn)品開發(fā)、生產(chǎn)測試或使用現(xiàn)場的零件分析的任何階段都可以單獨使用本規(guī)范中的一個測試的任何一部分，或組合使用本規(guī)范之外的多個測試。3.5 MATERIALS AND PR

37、OCESSES STANDARDS材料和步驟標準 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.供貨商應(yīng)該遵照本規(guī)范所用得適當?shù)牟牧虾筒襟E標準、對應(yīng)制圖及參考文獻。Unless otherwise specified or required by law, suppliers are ex

38、pected to use the most recent versions of any applicable drawings, reference documents, and standards.除非特別指出，否則供貨商應(yīng)該使用所有制圖、參考文獻和標準的最新版本。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

39、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 Autho

40、rized Person and the applicable supplier quality representative at least ninety (90) days prior to start of production validation testing.在選擇來源（source selection）90天內(nèi)，基于當前設(shè)計理念，供貨商向負責設(shè)計工程師提供一份FMEA樣本。經(jīng)過修訂的FMEA必須在模具計劃公布(program tooling release)10周之前發(fā)布，并且在模具（TOOLING）發(fā)布之前由負責人全面批準。在正式生產(chǎn)確認之前90天之前供貨商必須完成流程FM

41、EA并提交到負責人及相關(guān)質(zhì)量代表人處。3.7 OTHER REFERENCED DOCUMENTS其它參考文獻 SAE J1127: Battery Cable（電池線） SAE J1128: Low Tension Primary Cable（低張力總線） AIAG: Measurement Systems Analysis Reference Manual（測量系統(tǒng)分析參考手冊）4.0 GENERAL REQUIREMENTS一般要求4.1 RECORD RETENTION檔保管The supplier shall maintain a central file for the stora

42、ge of laboratory reports and calibration records. Such record storage must be in accordance with established QS-9000 and AIAG policies and practices.供貨商應(yīng)該為實驗室報告和校準記錄保持一份主文件。此記錄的存儲必須符合QS-9000和AIAG的政策和做法。4.2 SAMPLE DOCUMENTATION樣本記錄存盤All test samples shall be identified in accordance with the requirem

43、ents of QS-9000 and the AIAG PPAP.所有測試樣本都應(yīng)該按照QS-9000和AIAG PPAP的要求確定。4.3 DEFAULT SAMPLE SIZE默認樣本數(shù)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

44、 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 speci

45、fication has been met.本規(guī)范給出每個測試所要求的最少樣本樣品數(shù)量，而測試要求/規(guī)定可能要求更多的樣本。除非使用了要求的最少樣品數(shù)量并且其中所有樣品都符合接受準則，否則不能宣稱被測零件已符合本規(guī)范。決不允許選用很多的樣本數(shù)量做測試，然后合格的樣品數(shù)量恰好達到或超過最少試驗樣品數(shù)量要求，并且測試結(jié)果滿足接受準則，就認為被測零件已符合本規(guī)范。A minimum of 10 connector assemblies (male and female halves or female half plus a header or device connector) are requi

46、red 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.每次測試需要至少10個連接器總成（陰陽連接器或陰連接器和針類連接器（如：又電路板、

47、針和塑件組成的連接器）或設(shè)備連接器）。每次測試也需要至少30對端子(扁針或p針和陰性端子)。如果連接器塑件和端子一同測試的話，需要準備滿足這兩個條件的樣品。4.4 DEFAULT TEST TOLERANCES默認測試公差Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated:默認公差，除非另行規(guī)定，以百分比形式標示。A. Temperature溫度= 3 B. Voltage電壓= 2%C. Current電流= 1%D. Resistance電阻= 1%E.

48、Length長度= 1%F. Time時間= 5%G. Force力= 5%H. Frequency頻率= 5%I. Distance距離= 1%J. Flow Rate流速= 5%K. Relative Humidity相對濕度= 5%4.5 TEST DEFAULT CONDITIONS默認測試條件When specific test conditions are not given either in the product design specification, the test request/ order or elsewhere in this specification,

49、the following basic conditions shall apply:如果在產(chǎn)品設(shè)計規(guī)范、測試要求/順序或本規(guī)范的其它方面沒有指明，應(yīng)該滿足以下基本條件：Room Temperature = 235室溫=235Relative Humidity= Ambient相對濕度=環(huán)境濕度Voltage = 14.0 0.1 VDC電壓=14.0 0.1 VDC 4.6 EQUIPMENT設(shè)備Neither this list nor the list in each test section is all-inclusive. It is meant to highlight spec

50、ialized equipment or devices with particular accuracy requirements. Many other items of customary laboratory equipment and supplies will also be required.以下清單和本文各章節(jié)中提到的指示所需設(shè)備的一部分，主要用于強調(diào)一些專用設(shè)備或有特殊精確要求的裝置。很多其它常規(guī)的實驗室設(shè)備和供給也是需要的。ITEM項目DESCRIPTION描 述REQUIREMENTS*要 求 *1DC Power Supply (Regulated)直流電源（可調(diào)）0-

51、20V 0-10A2DC Power Supply (Regulated)直流電源（可調(diào)）0-20V0-100A3Micro-ohmmeter微型歐姆計0-20mV 0-100mA4Digital Multimeter (DMM)數(shù)字萬用表Capable of measuring the following at an accuracy of *0.5% of full scale:可以在以下精度范圍內(nèi)測量0.5%全程：0-50Volts DC0-10兆歐Me ohms5Current Shunts分路器100mA or as required with accuracy of 1% of n

52、ominal10毫安或者要求值的1%6Mill volt Meter毫伏表Capable of measuring 0-100mVDC at *0.5% full scale全程精度0.5%并可測量0-100直流毫伏7Thermocouples熱電偶Type “J” or “T” and as required“T”或“J”型和測試特定要求的型號8Insertion/Extraction Force Tester插入/抽取式測力計Capable of1.0% accuracy , full scale全程精度1.0%9Data Logger數(shù)據(jù)記錄器As required根據(jù)要求10Tempe

53、rature Chamber恒溫腔-40 to 1750%to 95% RH11Vibration Controller振動控制器As required根據(jù)要求12Vibration Table振動臺2640N(600 Lbs.) Sine Force2200N(500 Lbs.) RMS Force13Vacuum真空As required根據(jù)要求14Megohmeter兆歐姆計Capable of measuring100 Megohms at 500 Volts DC能在500直流伏條件下測量100兆歐以上電阻TABLE 4.6.1: Equipment*Note on requirem

54、ents: 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

55、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：如測試允許，可以使用量程比表中要求更小的儀器；也可以使用更大量程的儀器，但精度必須符合規(guī)定要

56、求。例如：表中規(guī)定應(yīng)使用全程測量范圍50伏、精度0.5%或0.25伏的數(shù)字萬用表（DIMM）；如果用全程測量范圍100伏的DIMM代替，精度應(yīng)該是0.25伏，而不是100伏的0.5%。4.7 MEASUREMENT RESOLUTION測量精度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 specifie

57、d 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.除非另有說明，用于測量的儀表和器

58、具都應(yīng)該有比所標示值優(yōu)一個小數(shù)點的精度。例如： 雖然線徑標示為0.1毫米和0.10毫米實際上可能是一樣的，但對于0.1毫米用0.01毫米精度的測徑器，而對于后者要0.001毫米精度的測徑器。4.8 TEST REPEATABILITY & CALIBRATION測試重復(fù)性和校準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 obtain