SAE-USCAR-中英對(duì)照版課件

PERFORMANCESPECIFICATIONFORCABLE-TO-TERMINALELECTRICALCRIMPS

電線及端子壓著性能規(guī)格

SAE/USCAR-21Revision1TABLEOFCONTENTS

楊建均IssuedMay2002RevisedApril2004IMPORTANTNOTICE:Inanyintendedvehicleapplication,iftheproductscoveredbythisspecificationare,ormaybe,subjectedtoconditionsbeyondthosedescribedinthisdocument,theymustpassspecialtestssimulatingtheactualconditionstobeencounteredbeforetheycanbeconsideredacceptableforactualvehicleapplication.Productscertifiedbytheirsupplierashavingpassedspecificapplicableportionsofthisspecificationarenottobeusedinapplicationswhereconditionsmayexceedthoseforwhichtheproducthasbeensatisfactorilytested.重要的說明：在任何預(yù)期的車輛應(yīng)用，是否產(chǎn)品在此規(guī)格或，可能是本文件中所述的條件下作用之外，他們必須通過模擬實(shí)際情況，可將他們視為可以接受的實(shí)際車輛應(yīng)用過程前遇到的特殊測(cè)試。由其供應(yīng)商，通過這種規(guī)格的具體適用部分認(rèn)證產(chǎn)品不會(huì)在條件可能超過所為其產(chǎn)品已進(jìn)行了令人滿意地測(cè)試應(yīng)用過程中使用。有關(guān)的認(rèn)可人士是最終的權(quán)力，以測(cè)試執(zhí)行他或她的部分是什麼和什麼目的，這些測(cè)試所需。他或她也是最終的權(quán)力，以解決任何有關(guān)測(cè)試此規(guī)格，並授權(quán)任何設(shè)備或套裝過程含在本規(guī)範(fàn)中的偏差的問題。必須記錄並包含任何偏差在最終的測(cè)試報(bào)告中。1.SCOPE

Thisspecificationdefinesbasictestmethodsandrequirementsforsolder-lesscrimpedconnections.Somesectionsofthisdocumentmayalsobeapplicabletootherterminalattachmentmethodssuchassonicorelectricalweldingorsoldering.Inthesecases,applicabilityoftheproceduresinthisdocumentshallbedeterminedbytheResponsibleEngineer.1.本規(guī)範(fàn)定義了基本試驗(yàn)方法和要求的無焊錫壓接連接。此文件的某些部分可能也適用於其他端子附件方法如超音波或電氣焊或焊接。在這種情況下須由負(fù)責(zé)的工程師決定在此文件中過程的適用性。2.CrimpapplicationsvalidatedtothisspecificationsupercedeanycrimpinformationonFord,GM,orDaimlerChryslercomponentprints.Theterminalsupplierhastheprimaryresponsibilityfortestingandselectionofcrimptoolingandtosupplydetailedcrimpinformationormakecrimptoolingavailabletothewiringassemblysupplieractuallydoingtheproductioncrimping.Ifthewiringsupplierdeviatesfromthisinformationoritisnotavailable,thentheresponsibilityfortestingtothisspecificationorgettingapprovalfromthecustomerwithappropriatetestdatashowingthatthecrimpwillfunctioninit’sintendedcircuitlieswiththewiringharnesssupplier.2.壓接應(yīng)用過程驗(yàn)證用規(guī)格值特別分割任何壓接在福特，通用，戴姆勒-克萊斯勒資訊或元件列印。端子供應(yīng)商的責(zé)任對(duì)已用於測(cè)試和選擇的壓接工具，提供詳細(xì)的壓接資訊或使壓接工具可供做生產(chǎn)壓著佈線元件供應(yīng)商。如果偏離此資訊的佈線供應(yīng)商，或者它不可對(duì)該技術(shù)指標(biāo)測(cè)試批準(zhǔn)得到適當(dāng)?shù)臏y(cè)試資料顯示，會(huì)在壓接過程它運(yùn)行的客戶負(fù)責(zé)的擬電路佈線工具供應(yīng)商。3.Neworrevisedterminalsshallbedesignedtomeetthisspecification.4.Allnewcrimpapplicationsshallmeetthisspecification.Newcrimpapplicationsaredefinedasterminal/wirecrimpcombinationsnotpreviouslyspecifiedonFord,GM,orDaimlerChryslervehiclewiringharnessassemblies.Existingcrimpapplicationsmaybecarriedoverifapprovedbythecustomerengineeringdepartment.3.新的或修改的端子在設(shè)計(jì)上須符合此規(guī)格。4.所有新壓接申請(qǐng)須符合此規(guī)格。新壓接的應(yīng)用過程定義端子/線壓接組合以前沒有被福特、通用汽車公司或戴姆勒-克萊斯勒汽車規(guī)格的配線元件上。如果經(jīng)客戶工程部門批準(zhǔn)，可以持續(xù)保留壓接的現(xiàn)有應(yīng)用過程。5.ElectricaltestsinthisspecificationhavebeenprovenbypastexperiencetoensurethatcrimpswillmeettherequirementsinSAE/USCAR-2andSAE/USCAR-20byincludingThermalShock,TemperatureHumidity,andPowerCurrentCycling.Testingandelectricalacceptancecriteriawilldetectdefectsincrimptoolinggeometry,platingquality,inadequatestranddistributioninthegrip,orcablestranding.CrimpapplicationsthathavepassedSAE/USCAR-2andSAE/USCAR-20normallyhaveonlypassedthenominalcrimpheightandusuallyonlywiththelargestgaugesize.Therefore,crimpswithintheproductioncrimpheightrangemaynotnecessarilypassthistest.5.電氣測(cè)試本規(guī)範(fàn)中的已被證實(shí)過去的經(jīng)驗(yàn)，以確保金屬線是否壓接將通過包隔絕熱衝擊、溫濕度，和電源電流循環(huán)滿足SAE/USCAR-2和SAE/USCAR-20的規(guī)定的。測(cè)試和電氣驗(yàn)收標(biāo)準(zhǔn)將檢測(cè)中壓接幾何形狀的模具、電鍍品質(zhì)、抓地力，或電纜線束不足線束分佈的缺陷。壓接的應(yīng)用過程通常已通過SAE/USCAR-2和SAE/USCAR-20具有僅通過公稱壓接高度和通常只與最大衡量尺寸。因此，生產(chǎn)壓接高度範(fàn)圍內(nèi)的金屬線壓接可能不一定通過這個(gè)試驗(yàn)。6.Proceduresincludedwithinthisspecificationareintendedtocoverperformancetestinganddevelopmentofelectricalterminalcrimpsthatarepartoftheelectricalconnectionsystemsinlowvoltage(0-48VDC)roadvehicleapplicationsatambienttemperaturesof125°Cmaximum.TheOEMcustomermustapproveuseofthesetestproceduresforuseatvoltagesandtemperaturesbeyondtheselimits.7.Theseproceduresareapplicableonlytoterminalsusedforin-line,header,edgeboard,anddeviceconnectorsystems.6.此規(guī)範(fàn)中包括的過程是覆蓋性能測(cè)試及發(fā)展的電子端子壓接在低電壓(0-48VDC)道路車輛應(yīng)用的電子連接系統(tǒng)在環(huán)境溫度最大125°C下。OEM客戶必須被批準(zhǔn)使用這些測(cè)試於電壓及溫度超出這些限制的過程。7.這些過程只適用於在端子使用在同軸、座、邊緣板，和設(shè)備插頭系統(tǒng)。1.1CrimpingParameters1.1.1TheCrimpconnectionperformanceischaracterizedby:MechanicalperformanceismeasuredbyterminaltoconductorPull-OutForce.Electricalperformanceismeasuredbyterminal-to-conductorCrimpResistance.1.1.2Thegeometryofaconductorcrimpischaracterizedby:Conductorcrimpheight(CCH)Conductorcrimpwidth(CCW)Insulationcrimpheight(ICH)Insulationcrimpwidth(ICW)Cut-offEndofconductorEndofinsulationBellmouth(flare)Burr(anvilflash)dimensiononthebaseoftheconductorcrimpStepbetweenthecoreandinsulationtoolsCrimptoolinggeometry1.1壓接參數(shù)1.1.1壓接連線性能的特點(diǎn)是：機(jī)械性能是量測(cè)端子到插頭的拉出力。電氣性能測(cè)量通過端子到導(dǎo)體壓接電阻。1.1.2導(dǎo)體壓接幾何形狀的特點(diǎn)是：導(dǎo)體壓接高度(CCH)導(dǎo)體壓接寬度(CCW)絕緣壓接高度(ICH)絕緣壓接寬度(ICW)斷端導(dǎo)體的結(jié)束絕緣喇叭口(呈喇叭形展開)毛邊(鐵屑)尺寸導(dǎo)體壓接的步驟中的核心與絕緣工具壓接工具幾何的基礎(chǔ)上SAE/USCAR-2PerformanceSpecificationforAutomotiveElectricalConnectorSystemsSAE/USCAR-20FieldCorrelatedLifeTestSupplementtoSAE/USCAR-2汽車電氣插頭系統(tǒng)SAE/USCAR-2性能規(guī)範(fàn)SAE/USCAR-20場(chǎng)相關(guān)壽命試驗(yàn)補(bǔ)充到

SAE/USCAR-2

2.REFERENCEDDOCUMENTS2.1DocumentHierarchyIntheeventthereisaconflictbetweenperformancespecification,partdrawings,andotherrelatedstandardsorspecifications,therequirementsshallbeprioritizedasfollows:1st-ApplicableFMVSSrequirementsandotherapplicablestateandFederalrequirements.2nd-Applicablepartdrawings3rd-Applicableproductdesignspecification)4th-AutomotiveIndustryActionGroup(AIAG)ProductionPartApprovalProcess(PPAP)5th-ApplicableUSCAR/EWCAPperformancespecifications6th-Otherapplicablestandardsandspecifications2.1文件層次結(jié)構(gòu)事件有性能規(guī)格、部件的圖面和其他相關(guān)的標(biāo)準(zhǔn)或規(guī)格之間的衝突，要求須被優(yōu)先，如下所示：1st-適用FMVSS要求以及其他適用的狀態(tài)和聯(lián)邦的要求。2、-適用零件圖面3rd-適用產(chǎn)品設(shè)計(jì)規(guī)範(fàn)。4th-汽車工業(yè)行動(dòng)集團(tuán)（機(jī)動(dòng)車)生產(chǎn)部件審批過程(提交)5th-USCAR/EWCAP適用性能規(guī)範(fàn)6th-其他適用的標(biāo)準(zhǔn)和規(guī)範(fàn)2.2TestRequest/Order2.2.1Samples,TestTypeandSpecialTestsThelaboratorytestrequest/ordershallprovidelocationanddocumentationoftestsamples,identifythetypeoftesttobeperformed(development,validation,specialpurpose,etc.)anddescribeanyspecialteststhatarenotapartofthisspecification.Anyrequiredrevisionsto,ordeviationsfromanytestsinthisspecificationmustincludedetailedinstructionsforeachchange.2.2測(cè)試要求/命令2.2.1樣本、測(cè)試類型和特別的試驗(yàn)實(shí)驗(yàn)室測(cè)試要求/命令須提供位置和測(cè)試樣本的文件，識(shí)別要測(cè)試的類型描述非此種規(guī)格的零件的任何特殊測(cè)試和執(zhí)行（開發(fā)、驗(yàn)證、特殊用途等）。任何所需的修訂或本規(guī)範(fàn)中的所有測(cè)試的不同都必須包括每個(gè)詳細(xì)更改的說明。2.3MaterialsandProcessesSpecificationsSuppliersareexpectedtoadheretotheappropriateMaterialsandProcessthatarereferencedinthisspecificationandanyassociateddrawingsandreferencedocuments.Unlessotherwisespecifiedorrequiredbylaw,suppliersareexpectedtousethemostrecentversionsofanyapplicabledrawings,referencedocuments,andstandards.2.3材料和過程規(guī)格供應(yīng)商預(yù)計(jì)將遵守適當(dāng)?shù)牟牧虾瓦^程在此規(guī)範(fàn)和任何相關(guān)的圖面和參考文件中引用的。除非另有規(guī)格，或者所需的法律供應(yīng)商預(yù)計(jì)將使用最新版本的任何適用的圖面、引用的文件和標(biāo)準(zhǔn)。2.4OtherReferencedDocuments?SAEJ1128:LowTensionPrimaryCable?JISC3406:LowTensionPrimaryCable?ISO/DIS6722LowTensionPrimaryCable?AIAG:MeasurementSystemsAnalysisReferenceManual?SAE/USCAR-2PerformanceSpecificationforAutomotiveElectricalConnectorSystems?SAE/USCAR-20FieldCorrelatedLifeTestSupplementtoSAE/USCAR-22.4其他參考文件?SAEJ1128:LowTensionPrimaryCable?JISC3406:LowTensionPrimaryCable?ISO/DIS6722LowTensionPrimaryCable?AIAG:MeasurementSystemsAnalysisReferenceManual?SAE/USCAR-2PerformanceSpecificationforAutomotiveElectricalConnectorSystems?SAE/USCAR-20FieldCorrelatedLifeTestSupplementtoSAE/USCAR-23.1RecordRetentionThesuppliershallmaintainacentralfileforthestorageoflaboratoryreportsandcalibrationrecords.SuchrecordstoragemustbeinaccordancewithestablishedISOandAIAGpoliciesandpractices.3.2SampleDocumentationAlltestsamplesshallbeidentifiedinaccordancewiththerequirementsofISOandtheAIAGPPAP.3.1記錄保留對(duì)實(shí)驗(yàn)室報(bào)告的存儲(chǔ)和校準(zhǔn)記錄供應(yīng)商應(yīng)保留核心文件。這種記錄存儲(chǔ)必須按照既定的ISO和AIAG政策和做法。3.2樣本文件所有的測(cè)試樣本須按照ISO和AIAG的要求進(jìn)行標(biāo)識(shí)。3.GENERALREQUIREMENTS3.3SampleSizeMinimumsamplesizesaregivenforeachtestinthisspecification.Agreaternumberofsamplesmayberequiredbythetestrequest/order.However,nopartordevicemayberepresentedashavingmetthisspecificationunlesstheminimumsamplesizehasbeentestedandallsamplesofthegrouptestedhavemettheapplicableAcceptanceCriteriaforthattest.Itisneverpermissibletotestalargergroup,thenselecttheminimumsamplesizefromamongthosethatpassedandrepresentthatthisspecificationhasbeenmet.Anyalternativesamplesizeand/ormethodologiesmustbeapprovedbytheAuthorizedPerson.3.3樣本尺寸本規(guī)範(fàn)中的每個(gè)測(cè)試，給出最小樣本量。依測(cè)試要求/命令，可能需要更多的樣本。不過，沒有的零件或設(shè)備，可作為代表符合該規(guī)範(fàn)除非最小樣本尺寸已符合測(cè)試並所有樣本的測(cè)試組都符合該測(cè)試適用的驗(yàn)收標(biāo)準(zhǔn)。它不允許測(cè)試一個(gè)較大的群組，然後選擇那之間最小樣本並表示已符合了該技術(shù)指標(biāo)。任何替代示範(fàn)尺寸和/或方法必須由有關(guān)的認(rèn)可人士批準(zhǔn)3.4DefaultTestTolerancesDefaultTolerances,expressedasapercentageofthenominalvalueunlessotherwiseindicated:A.Temperature=±3oCB.Voltage=±5%C.Current=±5%D.Resistance=±5%E.Length=±5%F.Time=±5%G.Force=±5%H.RelativeHumidity=±5%3.4預(yù)設(shè)測(cè)試公差預(yù)設(shè)公差表示為公稱值的百分比，除非另有說明：A.溫度=±3oCB.電壓=±5%C.電流=±5%D.阻抗=±5%E.長(zhǎng)度=±5%F.時(shí)間=±5%G.力=±5%H.相對(duì)濕度=±5%3.5TestDefaultConditionsWhenspecifictestconditionsarenotgiveneitherintheproductdesignspecification,thetestrequest/orderorelsewhereinthisspecification,thefollowingbasicconditionsshallapply:A.RoomTemperature=23±5oCB.RelativeHumidity=AmbientC.Voltage=14.0±0.1VDC3.5測(cè)試預(yù)設(shè)條件當(dāng)在產(chǎn)品設(shè)計(jì)技術(shù)指標(biāo)，測(cè)試要求/命令或在本規(guī)範(fàn)中其它地方?jīng)]有規(guī)格測(cè)試的條件時(shí)，適用下列基本條件：A.室溫=23±5oCB.相對(duì)濕度=環(huán)境C.電壓==14.0±0.1VDC3.6EquipmentNeitherthelistshowninTable3.6,northelistineachtestsectionisall-inclusive.Itismeanttohighlightspecializedequipmentordeviceswithparticularaccuracyrequirements.Manyotheritemsofcustomarylaboratoryequipmentandsupplieswillalsoberequired.3.6設(shè)備不論表3.6所示的清單和清單中在每個(gè)試驗(yàn)階段都包括。它是為了突出顯示專業(yè)的設(shè)備或設(shè)備有特定的精度要求。許多其他項(xiàng)目的一般的實(shí)驗(yàn)室設(shè)備和供應(yīng)商也將需要。DESCRIPTION

說明REQUIREMENTS

要求ACorDCPowerSupply(Regulated)交流或直流電源(規(guī)管)?0-20V?0-100AMicro-ohmmeter微歐姆計(jì)

?0-20mVmaximumopencircuitvoltage最大的開電路電壓

?

0-100mAmaximumtestcurrent最大的測(cè)試電流?

0.03mΩresolution變化

DigitalMultimeter(DMM)數(shù)位多用表Capableofmeasuringthefollowing:?0-50VoltsDCwithanaccuracyof0.5%offullscale電壓直流精度0.5%的全尺寸

?

0-10MegOhmswithanaccuracyof0.5%offullscale百萬歐姆有0.5%的全尺寸精度

CurrentShunts電流分流術(shù)100mAorasrequiredwithaccuracyof±1%ofnominal100mA或根據(jù)需要的精度±1%的公差毫伏特

MeterCapableofmeasuring0-100mVDCanaccuracyof0.5mVorbetter能夠測(cè)量0-100的mV直流0.5mV或更高的準(zhǔn)確度

Thermocouples熱電偶Type"J"or"T"asrequired鍵入"J"或"T"為所需ForceTester強(qiáng)力測(cè)試儀Capableofanaccuracyof≤1%ofmeasurement有能力的≤1%的測(cè)量準(zhǔn)確度DataLogger資料記錄儀AsRequired要求TemperatureCyclingand/orThermalshockChamber溫度循環(huán)和/或熱衝擊室?-40oCto125oC?0%to98%RH?-40oC到125oC?0%到98%RHForcedAirOven強(qiáng)制的空氣爐?+85±3°CTemperatureChamber溫度室?-40+/-3oCTemperature/HumidityChamber溫度/濕度室?95to98%RHat+65+/-3oCNote:Useofequipmentwithalesserrangeisacceptableforspecifictestswheretherequiredrangeforthattestcanbemet.Theequipmentrangespecifieddoesnotprecludeuseofequipmentwithalargerrange,buttheaccuracymustremainwithinthespecifiedtolerance.Forexample,aDMMwitharangeof0-100voltscouldbesubstitutedforonespecifiedas0-50volts,withtheprovisionthattheaccuracycouldbemaintainedas0.25mVorbetter.注意：對(duì)規(guī)格測(cè)試符合該測(cè)試在所需的範(fàn)圍，配備一個(gè)較小範(fàn)圍的使用是可以接受的。規(guī)格的設(shè)備範(fàn)圍並不使用設(shè)備的一個(gè)更大的範(fàn)圍，但精度必須在規(guī)格的公差範(fàn)圍內(nèi)。例如DMM常用0-100伏特的範(fàn)圍可能被替換為規(guī)格為0-50伏特可提供準(zhǔn)確性維持為0.25mV或更好的。

Table3.6-Equipment

3.7TestOrderandSet-UpDiagramsareprovidedwherenecessarytoclarifythedetailsofthevarioustestprocedures.Thetestsineachsectionmustbeperformedintheordergivenunlessotherwisespecifiedinthetestrequest/order.Constructiondetailsforselectedtestfixturesandequipmentareprovidedineachsection.3.7測(cè)試順序與安裝在有需要時(shí)提供圖去說明各種測(cè)試過程的詳細(xì)資訊。每個(gè)部分中的測(cè)試必須按循序給予執(zhí)行，除非有其它指定的測(cè)試要求/順序。每個(gè)部分中提供施工選定的測(cè)試固定裝置及設(shè)備的詳細(xì)資訊。3.8DefinitionsandGlossaryofTermsTermsdefinedinthedefinitionsorglossaryarecapitalized(i.e.RoomTemperature,SteadyState,PLR,etc.).AlistofdefinitionsisprovidedinAppendixB.AglossaryoftermsisprovidedinAppendixC.3.8定義和術(shù)語定義或術(shù)語表中定義的術(shù)語字母都大寫（即室溫、穩(wěn)態(tài)、PLR等）。在附錄B中提供了定義的清單附錄C.中提供術(shù)語表3.9MeasurementResolutionUnlessotherwisespecified,metersandgagesusedinmeasurementsofthetestsample(s)shallbecapableofmeasuringwitharesolutiononedecimalplacebetterthanthespecifiedvalue.Forexample,eventhoughawirediameterspecifiedas0.1mmmightactuallybethesameasonespecifiedas0.10mm,caliperscapableof0.01mmresolutionmaybeusedtomeasurethefirstwirebutamicrometerwith0.001mmresolutionisrequiredtomeasurethesecondwire.3.9測(cè)量解析度除特別指定外尺及量規(guī)測(cè)使用試樣本中須能夠測(cè)量解析度比指定的值更好的小數(shù)點(diǎn)設(shè)置。例如即使規(guī)格為0.1mm的線徑實(shí)際上可能相同，其中一個(gè)規(guī)格為0.10mm，卡尺能夠有0.01mm解析度的可用於測(cè)量第一線，但微米0.001mm解析度需求可測(cè)量第二線。3.10TestRepeatability&CalibrationAllequipmentusedfortestsampleevaluationshallbecalibratedandmaintainedaccordingtotheapplicablestandardsandrequirementssetforthbyISOandtheAIAGpublicationMeasurementSystemsAnalysisReferenceManual.CopiesofthisManualcanbeobtainedfromtheAIAGbycalling(248)358-3570orwritingtoAIAG,Dept.77839,PostOfficeBox77000,Detroit,MI48277-0839,Attn:CustomerService.InformationmayalsobeobtainedattheAIAGwebsite,

.DocumentationistoberecordedandretainedinaccordancewithSection4.1ofthisUSCAR/EWCAPspecification.Alistofinstrumentsandequipmentused,dateofthelastcalibration,andwhenthenextcalibrationisdueistobeincludedineachtestreport.3.10測(cè)試重複性、校正用於測(cè)試樣本求所有設(shè)備須是校準(zhǔn)並按照適用的標(biāo)準(zhǔn)維護(hù)要求提出依ISO和AIAG發(fā)佈測(cè)量系統(tǒng)分析參考手冊(cè)和。本手冊(cè)的副本，可從AIAG（248）358-3570或?qū)懭階IAG，部77839，郵政署77000，底特律，MI48277-0839，經(jīng)辦人：客戶服務(wù)。資訊也可從AIAG的網(wǎng)站

獲得。記錄並保留按照第4.1本USCAR/EWCAP規(guī)範(fàn)的文件。包括在每個(gè)測(cè)試報(bào)告使用清單的儀器、設(shè)備，在上次的校正日期和下一個(gè)預(yù)計(jì)校正。3.11ConformanceDeterminationTestconformanceshallbedeterminedbytheperformancerequirementsofthetestbeingconducted.Allsamplesmustsatisfytheperformancerequirementsregardlessofsampleage,testcycles,ortesttemperature,exceptwhereatesttofailureisspecified.3.11一致性檢測(cè)正在進(jìn)行測(cè)試的性能要求須進(jìn)行符合性測(cè)試。所有樣本必須都滿足性能的樣本年齡，無論測(cè)試週期，或測(cè)試溫度要求，除非有測(cè)試失敗的描述。4.TEST&ACCEPTANCEREQUIREMENTS

4.1GeneralTestingRequirementsThetestproceduresthatfollowwerewrittenasstand-alonetestsandmaybeusedassuch.However,theyarenormallyusedinasequentialtestformatandcommonsenseisrequiredtoovercomeanyredundanciesinsamplepreparationorinprocedures.Forexample,ifsampleshavealreadybeenpreparedfortheprecedingtestinasequence,itshouldbeobviousthatthesamplepreparationstepforthatindividualtest(includedsothattestcanbeusedasastandalonetest)shouldbeskipped.Shouldanyconflictsorquestionsariseconcerningproceduresand/orrequirements,contacttheAuthorizedPerson.AnytestplanapprovedbytheAuthorizedPersonthatshowscompliancetotheminimumperformancerequirementswithtestdataisacceptable.4.1一般測(cè)試要求遵循的測(cè)試過程的獨(dú)立測(cè)試和可以使用。但是，它們通常使用依序測(cè)試格式和共同需要去克服樣品準(zhǔn)備或過程中的任何重覆。例如如果樣本已經(jīng)準(zhǔn)備好了有了程序中上述測(cè)試的話，很明顯(包括使該測(cè)試，可以使用作為獨(dú)立測(cè)試)該樣品準(zhǔn)備步驟個(gè)別測(cè)試應(yīng)跳過。應(yīng)任何衝突或問題出現(xiàn)有關(guān)過程和/或要求，聯(lián)繫有關(guān)的認(rèn)可人士。有關(guān)的認(rèn)可人士，顯示該測(cè)試資料的最低性能要求遵守符合任何測(cè)試計(jì)畫是可以接受的。4.1.1DimensionalCharacteristicsPartconstructionshallconformtothedimensions,shape,anddetailattributesspecifiedonthelatestrevisionoftheapplicablepartdrawing(s).4.1.1尺寸特徵部分施工須符合該的尺寸、形狀，並詳細(xì)的屬性規(guī)格在最新版本的適用零件圖中。4.1.2MaterialCharacteristicsAllmaterialusedineachtestsampleshallconformtothematerialspecificationsonthelatestrevisionoftheapplicablepartdrawing(s).1.Anyengineeringdevelopment,prototype,orproductionpartsmaybesubmittedfortest.2.Thesamplessubmittedfortestshouldbeidentifiedbydescription,partnumber,andrevisionletter.3.Forvalidationtesting,allpartsaretobeintheir"asfurnishedforvehicleassembly"conditionwhentestingbegins.Forexample,electricalterminalstypicallyhaveresidualdielubricantonthemwhenfinallyassembledintoavehicle.Thissameconditionmustprevailfortestsamples.4.SamplessubmittedforanytestshallbepreparedperAppendixE.4.1.2材料特性每個(gè)測(cè)試樣本中使用的所有材料應(yīng)當(dāng)都符合最新修訂的材料規(guī)格的適用零件圖。1.任何工程的發(fā)展、原型或生產(chǎn)的零件可以提交測(cè)試。2.申請(qǐng)測(cè)試的樣本應(yīng)由描述、部品件號(hào)和版本標(biāo)識(shí)。3.測(cè)試時(shí)開始時(shí)，對(duì)驗(yàn)證測(cè)試，所有零件都要在他們"按車輛組立提供"狀況。例如電氣端子最後裝配到汽車上時(shí)通常有殘餘模具潤(rùn)滑劑。對(duì)測(cè)試樣品相同的條件必須是普遍的。4.申請(qǐng)任何測(cè)試的樣本須準(zhǔn)備依附錄E。4.2VisualInspection4.2.1PurposeThistestisusedtodocumentthephysicalappearanceoftestsamplesandtoassistintheevaluationoftheeffectsofenvironmentalconditioningontestsamples.Acomparisoncanthenbemadewithothertestsamples.Examinationsinmostcasescanbeaccomplishedbyapersonwithnormalorcorrectedvision,andnormalcolorsensitivity,undercoolwhitefluorescentlighting.Photographsand/orvideosareencouragedasamorecompletemeansofdocumentation.Anappropriatelyidentifieduntestedsamplefromeachtestgroupmustberetainedforpost-testphysicalcomparisonsifphotographs/video’sarenottaken.4.2外觀檢查4.2.1目的此測(cè)試用於測(cè)試樣本的物理外觀的文件並且協(xié)助測(cè)試樣本對(duì)環(huán)境狀況影響的評(píng)價(jià)。然後可以與其他測(cè)試樣本進(jìn)行比較。執(zhí)行在大多數(shù)情況下可以通過正?；虺C正目視，與正常顏色敏感的冷白色螢光燈下個(gè)別完成。照片和/或錄影促進(jìn)更完整的文件。假如無照片/攝影提供，適時(shí)定義未經(jīng)測(cè)試的樣本，從每個(gè)測(cè)試組必須保留後期測(cè)試的物理比較。4.2.2Samples1.Thesamplesshouldconformtotherequirementsofthespecifiedconditioningandanyadditionalmeasurementsthataretobeperformed.2.Forpurposesofcomparisonandespeciallywhenonlysubtleappearancechangesareanticipated,itisdesirabletosubmitanadditionalsampletoserveasacontrol.4.2.3EquipmentVideo/photographyequipment.4.2.2樣品

1.樣本應(yīng)確認(rèn)規(guī)格情況的要求和任何額外量測(cè)的執(zhí)行。

2.為比較和特別的目的，預(yù)計(jì)只有當(dāng)細(xì)微的外觀變化，最好是提交增加的樣本作為一個(gè)控制項(xiàng)。

4.2.3設(shè)備目視/攝影設(shè)備。4.2.4ProcedureVisuallyexamineeachtestspecimenpriortotestingand/orconditioning,notingindetailanymanufacturingormaterialdefectssuchascracks,bending,deformation,etc.Whenspecifiedinthetestrequest/order,takephotographsand/orvideorecordingsofrepresentativesamplestobetestedandkeepaproperlylabeledcontrolsample.

1.目視直接觀察每個(gè)試樣，在測(cè)試和/或環(huán)境之前，詳細(xì)指出諸如裂縫、彎曲、變形缺陷等任何製造或物料。當(dāng)所述測(cè)試要求/命令採(cǎi)取照片或錄影的代表性樣本進(jìn)行測(cè)試，並保持正確標(biāo)記的控制項(xiàng)樣本。2.Aftertestingand/orconditioning,re-examineeachtestsampleandnoteindetailanyobservablechanges,suchasphysicaldistortions,cracks,etc.Comparethetestedand/orconditionedsamplestothecontrolsamples,thevideos,and/orthephotographs,recordinganydifferencesinthetestreport.TheAuthorizedPersonwillneedtoprovideanadditionalsampleforthispurpose.2.測(cè)試及或環(huán)境後，重新研究每個(gè)測(cè)試樣本和註記詳細(xì)任何外觀改變，如物理變形、裂縫等。比較測(cè)試和/或條件樣本控制項(xiàng)樣本，該攝影和/或照片，記錄任何差異在測(cè)試報(bào)告中。要為此目的有關(guān)的認(rèn)可人士將需提供附加的樣本。3.Iftheterminalsupplier’sappearancerequirementsaremorestrictthanthosespecifiedbelow,thentheterminalsupplierspecificationsshouldbeapplied.4.Returntestsamplestorequestorafteralltestsarecompletedandallnecessarydatahavebeenobtained.3.如果端子供應(yīng)商的外觀要求比下面規(guī)格更嚴(yán)格，該端子供應(yīng)商規(guī)範(fàn)是適用。4.在所有測(cè)試完成和所有必需的資料都已經(jīng)獲得後，返回測(cè)試樣本對(duì)要求。4.2.5AcceptanceCriteriaGeneralAppearance–RefertoFigure4.2.5.Thecrimpingoperationshouldnotaffectthecontact,locking,connectormating,orinsertionfunctionsoftheterminal.ThesecharacteristicsareverifiedaspartofUSCAR-2testing.4.2.5驗(yàn)收標(biāo)準(zhǔn)

1.一般外觀–請(qǐng)參閱圖4.2.5。壓接的操作不會(huì)影響接觸、鎖定、該插頭的配合或端子插入的功能。這些特性將驗(yàn)證如USCAR-2測(cè)試。Figure4.2.5:AppearanceAcceptanceCriteria

外觀標(biāo)準(zhǔn)2.EndofconductorTheendofconductormustextendbeyondthefrontedgeoftheconductorcrimp.Theinsertionandlockingfunctionsoftheterminalmustnotbeaffectedbytheprojectingendoftheconductor.Matseals(plugthroughseals)mustnotbedamagedbythecore,andmayrequirecoredepressorsandstriplengthcontroltodepressthecoreinfrontofthecorewing.2.導(dǎo)體末端導(dǎo)體的末尾必須超過導(dǎo)線壓接的前緣。端子的插入和鎖定功能不會(huì)影響導(dǎo)體投影的末端。配合密封(密封件通過插頭）必須不會(huì)被核心損壞和可能需要核心壓著，並帶狀長(zhǎng)度控制壓著核心在核心翼之前。3.EndofinsulationTheendoftheinsulationmustbevisibleinthewindowbetweentheconductorcrimpwingsandtheinsulationcrimpwingssuchthatconductorisvisibleandshouldbecentralizedasmuchaspossible.Innocasemayinsulationbecrimpedintheconductorcrimp.3.絕緣端絕緣材料的末尾必須在視窗中導(dǎo)體壓接翼和絕緣壓接翼之間為可見並且盡可能可見而且在中間。在任何情況下可能絕緣材料被壓接在導(dǎo)體壓接。4.Cut-offa.Thecut-offlengthshallnotexceed0.5mmunlessotherwisespecifiedonthecomponentprint.b.Theburronthecut-offmustnotexceed0.3mmunlessotherwisespecifiedonthecomponentprint.c.Thecut-offandburrmustnotaffecttheinsertionfunctionoftheterminalintotheconnector.4剪裁。a.剪裁長(zhǎng)度不得超逾0.5mm，除非其它規(guī)格在元件列印上。b.毛邊在剪裁上不能超過0.3mm，除非其它規(guī)格在列印元件上。c.剪裁和毛邊必須不影響端子插入插頭的插入功能。5.Bellmouth(Flare)喇叭口(呈喇叭形展開)Bellmouth(Flare)isrequiredhere.喇叭口(呈喇叭形展開)是必需的。Theconductorcrimp(d.)shallhaveabellmouth(flare)onthesideofthegripnearesttheinsulationcrimp.導(dǎo)體壓接(d.)須有一個(gè)喇叭口(呈喇叭形展開)緊握最近的絕緣壓接側(cè)。

Theconductorcrimpmayalsohaveabellmouth(flare)onthefrontedgeoftheconductorcrimp,nearesttheterminalbody.導(dǎo)體壓接可能還有一個(gè)喇叭口(呈喇叭形展開)在導(dǎo)體壓接的前緣接近端子體。Bellmouth(flare)ontheinsulationcrimp(e.)shouldnotexceedtheinsulationcrimptolerances.在絕緣壓接(e）上的喇叭口(呈喇叭形展開)不應(yīng)超過絕緣壓接公差。dTwoStageConductorCrimp(Flarenotrequiredonsecondstage)兩階段導(dǎo)體壓接(呈喇叭形展開不需要對(duì)第二階段)6.ConductorCrimpAllindividualstrandsmustbeenclosedinthecrimp.Crimpswithstrandslyingoutsidethecrimporbrokenoffbeforethecrimp,arenotpermitted.6.導(dǎo)體壓接所有個(gè)別線束在壓接必須隔絕。壓接線束橫臥在壓接外或壓接之前斷裂是不允許的。7.InsulationCrimpa.Thepurposeoftheinsulationcrimpistoaddstrainrelieftotheconductorcrimp.b.TheInsulationCrimpmustcontactthesurfaceoftheinsulatedcableinatleast3locationsaroundthecircumferenceoftheCrimp(threepointcontact).c.TheInsulationCrimpdimensionsarereferencedimensions.d.TheInsulationCrimpmustnotinterferewithanysubsequentoperations.e.TheInsulationCrimpmustnotinterferewithseatingofaterminalintoaplasticconnectorcavityf.TheInsulationCrimpmustnotdamagethecable(seeParagraph4.3.5-3)7.絕緣接線

a.絕緣壓接的目的是消除添加到導(dǎo)體壓接所的應(yīng)力。b.絕緣壓接必須與表面絕緣電纜接觸(三個(gè)點(diǎn)接觸)壓接觸沿圓周至少3區(qū)。c.絕緣壓接尺寸是參考尺寸。d.絕緣壓接不得干擾任何後續(xù)的操作。e.在絕緣壓接不得干擾端子塑膠插頭腔內(nèi)的位置f.絕緣壓接必須不損壞電纜（請(qǐng)參閱第4.3.5-3）8.CableConductorAppearancepriortocrimpingStrandsshallnotbecut,missing,excessivelynicked(strandareareductionwhichmayaffectpull-outforce),orelongated.b.Insulationshallnotbestuckorimbeddedinstrands.8.電纜導(dǎo)體壓接前外觀

a.線束須不會(huì)切割、遺漏、超過頸部(線束面積減少可能會(huì)影響拉拔力)，或拉長(zhǎng)。b.絕緣材料須不會(huì)卡住或嵌入在線束。9.IndividualCableSealNote:Thisspecificationdoesnotincludeanyrequirementsforsealslidingforceduetothelargenumberofvariables.Itisnecessarythatindividualcablesealsbeproperlyseatedinplasticconnectorstofunction.a.Thesealmustbefirmlysecuredbytheinsulationcrimp.b.Thesealmustshownosignsofdamage.c.Theendofthesealneckmustbevisibleintheareabetweentheinsulationcrimpandtheconductorcrimp.d.Thecableinsulationmustbevisibleundertheseal.9.個(gè)別電纜密封

注意：此規(guī)範(fàn)並不包括對(duì)任何密封滑動(dòng)力由於大量變數(shù)的要求。有必要單獨(dú)的電纜密封件正確放置在塑膠插頭的功能。

a.密封，必須牢固的絕緣壓接的保護(hù)。b.密封必須沒有顯示損壞的跡象。c.密封頸部端在絕緣壓接和導(dǎo)體壓接之間的區(qū)域必須是可見的。d.在密封下電纜絕緣必須可見。4.3Cross-SectionAnalysis4.3.1PurposeCross-sectionalanalysisisusedasadiagnosticaidindeterminingwhyacrimppassesorfailsaportionofthistest.Failuretopassanelectricaltestmaybeduetounevenstranddispersion,inadequatewingclosure,voids,wingsbottomingout,etc.4.3剖面分析4.3.1目的剖面分析診斷説明確定壓接為什麼通過或失敗此測(cè)試的部分。失敗到通過一個(gè)電氣試驗(yàn)的可能是由於線束不均勻分散、翼的密封不充分、空洞、翼底端的突出等。4.3.2SampleSizeAtleastonesampleforeachcrimpheighttobeevaluated.Datashallbeobtainedandrecordedforminimum,maximumandnominalproductioncrimpheights.4.3.3EquipmentVariousspecializedequipmentexistsforcross-sectioningsamples.Thechoiceofequipmentisuptothesupplier,butshouldbecapableofsectioningthecrimpwithminimaldisturbancetotheterminalandcablestranding.4.3.2樣本尺寸至少要一個(gè)樣本對(duì)每個(gè)壓接高度評(píng)價(jià)。資料須獲得並紀(jì)錄最小值、最大和公稱生產(chǎn)壓接高度。4.3.3設(shè)備對(duì)剖面分析的樣本，有各種專業(yè)的設(shè)備存在。設(shè)備的選擇由該的供應(yīng)商，但應(yīng)該有能力剖切端子和電纜線束最小擾動(dòng)壓接部份。4.3.4Procedure1.Cross-sectionandphotographeachsampleforanalysis2.Cross-sectionanalysisshallbeperformedonallconductorcrimpapplicationsateachcrimpheightsetting(nominal,min.andmax.tolerance).3.Cross-sectionsshallbeperformedbetweentheserrations,asneartothemid-pointofthecorecrimpaspossible.4.Comparethesamplestotheacceptancecriteriaofparagraph4.3.5.AcceptanceCriteria4.3.4過程1.分析截面和拍攝每個(gè)樣本2.截面分析須執(zhí)行在(公稱、最小和最大公差)所有導(dǎo)線壓接應(yīng)用在每個(gè)壓接高度設(shè)置過程上。3.剖面須執(zhí)行在鋸齒之間，盡可能靠近核心壓接的中點(diǎn)進(jìn)行。4.將驗(yàn)收標(biāo)準(zhǔn)第4.3.5段的驗(yàn)收標(biāo)準(zhǔn)樣本進(jìn)行比較。4.3.5AcceptanceCriteria驗(yàn)收標(biāo)準(zhǔn)Acceptancecriteriaforthecross-sectionedsamplesaredescribedbelow.截面樣本為驗(yàn)收標(biāo)準(zhǔn)的說明如下。Cross-sectionviewsofconductorcrimpConductorcrimpattributesconsideredideal1.截面的導(dǎo)體壓接的觀察被視為理想導(dǎo)體壓接屬性Symmetric對(duì)稱

Compactionofallstrands壓實(shí)的所有線束Wingstouchonlyconductor翼只接觸導(dǎo)體Terminalstockfreeofcracks/breaksCorewings

端子材料無裂紋/破裂

"Locked"(NoGap)attopofcrimp\在頂部的壓接核心翼"已鎖定"(無間隙)Conductorcrimpattributesconsideredundesirable

認(rèn)為不當(dāng)?shù)膶?dǎo)體壓接屬性O(shè)verlappingwings重疊的翼Extreme“ram-horning”

極端公羊角ConductorcrimpattributesconsideredunacceptableOpenwingswithconductorexposedorfoldeddownintocorebutnottouching(notlocked)翼打開有導(dǎo)體暴露或向下摺向核心但不接觸（未鎖定）Oneorbothwings(grips)penetrate(“crash”)totheterminalfloororwall一個(gè)或兩個(gè)翼(緊握)穿透(碰撞到