SAEUSCAR21中英对照版.ppt

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1、PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS 電線及端子壓著性能規格 SAE/USCAR-21 Revision 1 TABLE OF CONTENTS,楊建均,Issued May 2002 Revised April 2004,IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions

2、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. Products certified by their supplier as having passed specific applicable portions of this specification a

3、re not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. 重要的說明：在任何預期的車輛應用，是否產品在此規格或，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際情況，可將他們視為可以接受的實際車輛應用過程前遇到的特殊測試。 由其供應商，通過這種規格的具體適用部分認證產品不會在條件可能超過所為其產品已進行了令人滿意地測試應用過程中使用。 有關的認可人士是最終的權力，以測試執行他或她的部分是什麼和什麼目的，

4、這些測試所需。 他或她也是最終的權力，以解決任何有關測試此規格，並授權任何設備或套裝過程含在本規範中的偏差的問題。 必須記錄並包含任何偏差在最終的測試報告中。,1.SCOPE,This specification defines basic test methods and requirements for solder-less crimped connections. Some sections of this document may also be applicable to other terminal attachment methods such as sonic or elec

5、trical welding or soldering. In these cases, applicability of the procedures in this document shall be determined by the Responsible Engineer. 1. 本規範定義了基本試驗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責的工程師決定在此文件中過程的適用性。,2. Crimp applications validated to this specification super cede

6、any crimp information on Ford, GM, or DaimlerChrysler component prints. The terminal supplier has the primary responsibility for testing and selection of crimp tooling and to supply detailed crimp information or make crimp tooling available to the wiring assembly supplier actually doing the producti

7、on crimping. If the wiring supplier deviates from this information or it is not available, then the responsibility for testing to this specification or getting approval from the customer with appropriate test data showing that the crimp will function in its intended circuit lies with the wiring harn

8、ess supplier. 2. 壓接應用過程驗證用規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。 端子供應商的責任對已用於測試和選擇的壓接工具，提供詳細的壓接資訊或使壓接工具可供做生產壓著佈線元件供應商。 如果偏離此資訊的佈線供應商，或者它不可對該技術指標測試批准得到適當的測試資料顯示，會在壓接過程它運行的客戶負責的擬電路佈線工具供應商。,3. New or revised terminals shall be designed to meet this specification. 4. All new crimp applications shall meet th

9、is specification. New crimp applications are defined as terminal/wire crimp combinations not previously specified on Ford, GM, or DaimlerChrysler vehicle wiring harness assemblies. Existing crimp applications may be carried over if approved by the customer engineering department. 3.新的或修改的端子在設計上須符合此規

10、格。 4.所有新壓接申請須符合此規格。 新壓接的應用過程定義端子/線壓接組合以前沒有被福特、 通用汽車公司或戴姆勒-克萊斯勒汽車規格的配線元件上。 如果經客戶工程部門批准，可以持續保留壓接的現有應用過程。,5. Electrical tests in this specification have been proven by past experience to ensure that crimps will meet the requirements in SAE/USCAR-2 and SAE/USCAR-20 by including Thermal Shock, Temperatur

11、e Humidity, and Power Current Cycling. Testing and electrical acceptance criteria will detect defects in crimp tooling geometry, plating quality, inadequate strand distribution in the grip, or cable stranding. Crimp applications that have passed SAE/USCAR-2 and SAE/USCAR-20 normally have only passed

12、 the nominal crimp height and usually only with the largest gauge size. Therefore, crimps within the production crimp height range may not necessarily pass this test. 5.電氣測試本規範中的已被證實過去的經驗，以確保金屬線是否壓接將通過包隔絕熱衝擊、 溫濕度，和電源電流循環滿足 SAE/USCAR-2 和 SAE/USCAR-20 的規定的。 測試和電氣驗收標準將檢測中壓接幾何形狀的模具、 電鍍品質、 抓地力，或電纜線束不足線束分

13、佈的缺陷。 壓接的應用過程通常已通過 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，生產壓接高度範圍內的金屬線壓接可能不一定通過這個試驗。,6. Procedures included within this specification are intended to cover performance testing and development of electrical terminal crimps that are part of the electrical connection systems in low volt

14、age (0 - 48 VDC) road vehicle applications at ambient temperatures of 125C maximum. The OEM customer must approve use of these test procedures for use at voltages and temperatures beyond these limits. 7. These procedures are applicable only to terminals used for in-line, header, edge board, and devi

15、ce connector systems. 6.此規範中包括的過程是覆蓋性能測試及發展的電子端子壓接在低電壓(0-48 VDC) 道路車輛應用的電子連接系統在環境溫度最大125 C下。 OEM 客戶必須被批准使用這些測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，和設備插頭系統。,1.1 Crimping Parameters 1.1.1 The Crimp connection performance is characterized by: Mechanical performance is measured by terminal to cond

16、uctor Pull-Out Force. Electrical performance is measured by terminal-to-conductor Crimp Resistance. 1.1.2 The geometry of a conductor crimp is characterized by: Conductor crimp height (CCH) Conductor crimp width (CCW) Insulation crimp height (ICH) Insulation crimp width (ICW) Cut-off End of conducto

17、r End of insulation Bell mouth (flare) Burr (anvil flash) dimension on the base of the conductor crimp Step between the core and insulation tools Crimp tooling geometry 1.1 壓接參數 1.1.1 壓接連線性能的特點是： 機械性能是量測端子到插頭的拉出力。 電氣性能測量通過端子到導體壓接電阻。 1.1.2導體壓接幾何形狀的特點是： 導體壓接高度 (CCH) 導體壓接寬度 (CCW) 絕緣壓接高度 (ICH) 絕緣壓接寬度 (I

18、CW) 斷端導體的結束絕緣喇叭口(呈喇叭形展開) 毛邊 (鐵屑) 尺寸導體壓接的步驟中的核心與絕緣工具壓接工具幾何的基礎上,SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems SAE/USCAR-20 Field Correlated Life Test Supplement to SAE/USCAR-2 汽車電氣插頭系統 SAE/USCAR-2 性能規範 SAE/USCAR-20 場相關壽命試驗補充到 SAE/USCAR-2,2. REFERENCED DOCUMENTS,2.1

19、Document Hierarchy In the event there is a conflict between performance specification, part drawings, and other related standards or specifications, the requirements shall be prioritized as follows: 1st-Applicable FMVSS requirements and other applicable state and Federal requirements. 2nd-Applicable

20、 part drawings 3rd - Applicable product design specification) 4th-Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) 5th-Applicable USCAR/EWCAP performance specifications 6th-Other applicable standards and specifications 2.1 文件層次結構 事件有性能規格、部件的圖面和其他相關的標準或規格之間的衝突，要求須被優先，如下

21、所示： 1 st-適用 FMVSS 要求以及其他適用的狀態和聯邦的要求。 2 、-適用零件圖面 3 rd-適用產品設計規範。 4 th-汽車工業行動集團 （機動車) 生產部件審批過程 (提交) 5 th -USCAR/EWCAP 適用性能規範 6 th-其他適用的標準和規範,2.2 Test Request/Order 2.2.1 Samples, Test Type and Special Tests The laboratory test request/order shall provide location and documentation of test samples, iden

22、tify 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. 2.2 測試要求/

23、命令 2.2.1樣本、 測試類型和特別的試驗 實驗室測試要求/命令須提供位置和測試樣本的文件，識別要測試的類型描述非此種規格的零件的任何特殊測試和執行 （開發、 驗證、 特殊用途等）。 任何所需的修訂或本規範中的所有測試的不同都必須包括每個詳細更改的說明。,2.3 Materials and Processes Specifications Suppliers are expected to adhere to the appropriate Materials and Process that are referenced in this specification and any asso

24、ciated drawings and reference documents. Unless otherwise specified or required by law, suppliers are expected to use the most recent versions of any applicable drawings, reference documents, and standards. 2.3 材料和過程規格 供應商預計將遵守適當的材料和過程在此規範和任何相關的圖面和參考文件中引用的。 除非另有規格，或者所需的法律供應商預計將使用最新版本的任何適用的圖面、 引用的文件和

25、標準。,2.4 Other Referenced Documents SAE J1128: Low Tension Primary Cable JISC 3406: Low Tension Primary Cable ISO/DIS 6722 Low Tension Primary Cable AIAG: Measurement Systems Analysis Reference Manual SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems SAE/USCAR-20 Field

26、 Correlated Life Test Supplement to SAE/USCAR-2 2.4 其他參考文件 SAE J1128: Low Tension Primary Cable JISC 3406: Low Tension Primary Cable ISO/DIS 6722 Low Tension Primary Cable AIAG: Measurement Systems Analysis Reference Manual SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Sy

27、stems SAE/USCAR-20 Field Correlated Life Test Supplement to SAE/USCAR-2,3.1 Record Retention 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 ISO and AIAG policies and practices. 3.2 S

28、ample Documentation All test samples shall be identified in accordance with the requirements of ISO and the AIAG PPAP. 3.1 記錄保留 對實驗室報告的存儲和校準記錄供應商應保留核心文件。這種記錄存儲必須按照既定的 ISO和AIAG政策和做法。 3.2 樣本文件 所有的測試樣本須按照 ISO 和AIAG的要求進行標識。,3. GENERAL REQUIREMENTS,3.3 Sample Size Minimum sample sizes are given for each

29、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 Crit

30、eria 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. Any alternative sample size and/or methodologies must be approved by the Authorized Person. 3.3 樣本尺寸 本規範中的每個測試，給出最小

31、樣本量。 依測試要求/命令，可能需要更多的樣本。 不過，沒有的零件或設備，可作為代表符合該規範除非最小樣本尺寸已符合測試並所有樣本的測試組都符合該測試適用的驗收標準。 它不允許測試一個較大的群組，然後選擇那之間最小樣本並表示已符合了該技術指標。 任何替代示範尺寸和/或方法必須由有關的認可人士批准,3.4 Default Test Tolerances Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated: A. Temperature = 3 o C B. Vo

32、ltage = 5% C. Current = 5% D. Resistance = 5% E. Length = 5% F. Time = 5% G. Force = 5% H. Relative Humidity = 5% 3.4 預設測試公差 預設公差表示為公稱值的百分比，除非另有說明： A.溫度 = 3 o C B.電壓 = 5% C.電流 = 5% D.阻抗 = 5% E.長度 = 5% F.時間 = 5 % G.力 = 5% H.相對濕度 = 5%,3.5 Test Default Conditions When specific test conditions are not g

33、iven either in the product design specification, the test request/order or elsewhere in this specification, the following basic conditions shall apply: A. Room Temperature = 23 5o C B. Relative Humidity = Ambient C. Voltage = 14.0 0.1 VDC 3.5 測試預設條件 當在產品設計技術指標，測試要求/命令或在本規範中其它地方沒有規格測試的條件時，適用下列基本條件： A

34、.室溫 = 23 5 o C B.相對濕度=環境 C.電壓 = = 14.0 0.1 VDC,3.6 Equipment Neither the list shown in Table 3.6, 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 an

35、d supplies will also be required. 3.6 設備 不論表 3.6所示的清單和清單中在每個試驗階段都包括。 它是為了突出顯示專業的設備或設備有特定的精度要求。許多其他項目的一般的實驗室設備和供應商也將需要。,Note: 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

36、 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 0.25mV or better.,注意： 對規格測試符合該測試在所需的範圍，配備一個較小範

37、圍的使用是可以接受的。 規格的設備範圍並不使用設備的一個更大的範圍，但精度必須在規格的公差範圍內。 例如DMM常用 0-100 伏特的範圍可能被替換為規格為 0-50 伏特可提供準確性維持為 0.25mV 或更好的。 Table 3.6 - Equipment,3.7 Test Order and Set-Up Diagrams are provided where necessary to clarify the details of the various test procedures. The tests in each section must be performed in the

38、 order given unless otherwise specified in the test request/order. Construction details for selected test fixtures and equipment are provided in each section. 3.7 測試順序與安裝 在有需要時提供圖去說明各種測試過程的詳細資訊。每個部分中的測試必須按循序給予執行，除非有其它指定的測試要求/順序。 每個部分中提供施工選定的測試固定裝置及設備的詳細資訊。,3.8 Definitions and Glossary of Terms Terms

39、 defined in the definitions or glossary are capitalized (i.e. Room Temperature, Steady State, PLR, etc.). A list of definitions is provided in Appendix B. A glossary of terms is provided in Appendix C.,3.8 定義和術語 定義或術語表中定義的術語字母都大寫 （即室溫、 穩態、 PLR 等）。 在附錄 B 中提供了定義的清單 附錄 C.中提供術語表,3.9 Measurement Resoluti

40、on 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

41、.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. 3.9 測量解析度 除特別指定外尺及量規測使用試樣本中須能夠測量解析度比指定的值更好的小數點設置。 例如即使規格為 0.1 mm的線徑實際上可能相同，其中一個規格為 0.10 mm，卡尺能夠有0.01mm 解析度的可用於測量第一線，但微米 0.001 mm解析度需求

42、可測量第二線。,3.10 Test Repeatability or USCAR-2 Performance Specification for Automotive Electrical Connector Systems Dry Circuit Resistance). EWCAP Electrical Wiring Component Applications Partnership. One of several consortia under USCAR. Has the task of creating specifications for electrical component

43、s and interfaces. ENV “Environmentally Tested” An abbreviation for “Accelerated Environmental” Test (also implies Dry Circuit/Low Energy test measurements per MIL-STD-1344A, method 3002.1, before and after test sequence; or USCAR-2 Performance Specification for Automotive Electrical Connector System

44、s Dry Circuit Resistance). EWCAP 電氣佈線元件應用夥伴關係。 在 USCAR 下的幾個財團之一。 已創建電氣元件及介面技術規範的任務,FMEA Failure Mode and Effects Analysis FMVSS Federal Motor Vehicle Safety Standard FS Full Scale IACS International Annealed Copper Standard IDC Insulation Displacement Connection. A means of attaching a terminal to a

45、 conductor where projections on the terminal pierce the conductor insulation to make electrical contact, rather than requiring the insulation to be removed. FMEA 失效模式及後果分析 FMVSS 聯邦汽車安全標準 財政司司長全規模 船級國際退火銅標準 IDC 絕緣位移連接。 要移除的附加端子到端子上的推算其中皮爾斯進行電氣的接觸的導體絕緣導體，而不是要求在絕緣材料的方法。,MVD 毫伏特 Drop. MVSS Motor Vehicle

46、 Safety Standard. PLR Positive Latch Reinforcement. Also known as a Wedge, Spacer or Terminal Position Assurance (TPA) feature. It is installed or seated after the terminals are inserted into their housing to assure that the terminals are properly positioned. It either reinforces the primary termina

47、l locking mechanism or provides a separate redundant terminal lock. PPAP Production Part Approval Process. 微血管密度毫伏投遞。 MVSS 汽車安全標準。 PLR 正閂鎖加固。 也就是一種楔、 間隔或端子位置保證 (TPA) 功能。 在安裝或坐後端子插入到他們的住屋，以確保該端子位於正確。 它既鞏固了主要端子鎖定機制，也提供了一個單獨的冗余端子鎖定。 提交生產部件的批准進程。,PTO Pull Test Only PTX An abbreviation for “Pull Test and

48、 Cross Section.” RH Relative Humidity. TPA Terminal Position Assurance. Also see PLR TUT Terminal Under Test. USCAR United States Council for Automotive Research. A consortium of representatives from Ford, General Motors and DaimlerChrysler to promote joint research in non-competitive areas that can

49、 strengthen the US automotive industry. (www.uscar.org) 僅 PTO 式測試 紫杉安的縮寫拉試驗和斷面。 RH 濕度。 TPA 端子位置保證。 另請參見 PLR 太原理工大學端子試驗。 USCAR 美國汽車研究的委員會。 一個財團的福特、 通用汽車公司和戴姆勒-克萊斯勒，促進聯合研究非競爭性領域，可以加強美國汽車工業的代表。 () www.uscar.org,APPENDIX D: MATERIAL RESISTANCE TABLES Maximum allowable resistance (milliOhms) for various materials after completion of Electrical Current Cycling (ECC) test or Accelerated Environmental (ENV) test 附錄 d： 材料抗性表 最大允許 (值為毫歐) 各種材料性能後完成的電流循環 (ECC) 測試或加速環境 (ENV) 測試,Table D-1 Maximum allowable resistance (milliOhms) for various materials