通用压缩率 45页USCAR21

1、PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMP端子压接的性能规范1. SCOPE范围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 simula

2、ting 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 are not to be used in applications where conditions may exceed those for whic

3、h the product has been satisfactorily tested.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

4、 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.重要提示：在任何汽车应用中，对于本规范没有涉及到的情况，产品必须通过相应的特殊试验，该试验的试验条件应该模仿汽车在实际使用中的条件。对于通过了该规范中要求的试验的产品，使用时也不能应用于超过该试验条件的场合。权威人士是最终有权指出他或她的产品需要做哪

5、些试验并且这些试验有哪些目的的人。对于解决该规范中出现的任何试验问题，对于与该规范中包含的试验设备和试验程序相违背的情况，他或她仍然是有最终决定权的人。试验中出现的任何不符合性都必须作记录，并记录在最终试验报告中。1. This specification defines basic test methods and requirements for solder-less crimpedconnections.1.在该规范中定义了关于纯压接连接（没有焊接）的基本试验方法和试验要求。2. Crimp applications validated to this specification su

6、percede any crimp information on Ford, GM, or DaimlerChrysler component prints. It is preferred that the terminal supplier do testing and selection of crimp tooling and supply detailed crimp information or make crimp tooling available to the wiring assembly supplier actually doing the production cri

7、mping. 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 harness su

8、pplier.2.该生效的压接规范代替了Ford,GM, or DaimlerChrysler的任何压接信息。端子供应商做试验和选择压接工具和提供详细的压接信息，或需要端子压接的供应商制作压接工具。假如与该规范违背或不适用，那么该规范的试验或关于证明符合预期压接功能的试验数据得到顾客的批准的责任将由线束供应商承担。3. New or revised terminals shall be designed to meet this specification.3.新设计或修改的端子设计需要符合该规范。4. All new crimp applications shall meet this sp

9、ecification. New crimp applications are defined as terminal/wire crimp combinations not previously specified on Ford, GM, orDaimlerChrysler vehicle wiring harness assemblies. Existing crimp applications may becarried over if approved by the customer engineering department.4.所有新的压接应用需要符合该规范。新的压接应用定义为

10、端子/导线的压接连接，不是以前在Ford, GM、DaimlerChrysler汽车应用中规定的线束装配。如果顾客的工程部门批准，现存的压接应用可以继续使用。5. Electrical tests in this specification have been proven by past experience to ensure thatcrimps will meet the requirements in SAE/USCAR-2 and SAE/USCAR-20 by includingThermal Shock, Temperature Humidity, and Power Curr

11、ent 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 the nominal crimp height

12、and usually only with the largest gauge size. Therefore, crimps within the production crimp height range may not necessarily pass this test.5.该规范中的电性能试验已经由过去的经验证明能确保压接符合SAE/USCAR-2和SAE/USCAR-20规范要求，其中包含了热冲击、温度循环和电流循环试验。电性能试验和电性能试验接收标准，该接收标准涉及了检测压接工具的几何缺陷，镀层的质量，不合理的压线角（包括没有充分包住线芯或电缆线芯，所包芯线两边不对称）、芯线断股

13、。已经通过SAE/USCAR-2和SAE/USCAR-20规范的压接情况通常只是通过名义压接高度并且通常只用最大线规压接。所以对于那些在此压接高度范围内的情况没有必要做试验。6. Procedures included within this specification are intended to cover performance testing at development of electrical terminal crimps that are part of the electrical connection systems in low voltage (0 - 48 VDC

14、) 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.6.该规范中包含的程序覆盖了端子压接开发过程中需要思考的性能试验，端子压接是电连接系统的一部分，该电连接系统应用在电压是0 - 48 VDC，最高环境温度是125C的汽车中。对于超过该电压和该环境温度的情况，如果要使用该规范中的试

15、验程序，需得到OEM顾客的批准。7. These procedures are applicable only to terminals used for in-line, header, edge board, and device connector systems.7.该程序只是适用于以下应用情况中的端子：in-line, header, edge board, and device connector systems.1.1 Crimping Parameters1.1压接参数1.1.1 The Crimp connection performance is characterized

16、 by:Mechanical performance is measured by terminal to conductor Pull-Out Force.Electrical performance is measured by terminal-to-conductor Crimp Resistance.1.1.1压接连接的性能由以下方法来判断：机械性能通过测试端子与导线的拉脱力来判断；电性能通过测量端子与导线的压接电阻来判断。1.1.2 The geometry of a conductor crimp is characterized by:Conductor crimp heigh

17、t (CCH)Conductor crimp width (CCW)Insulation crimp height (ICH)Insulation crimp width (ICW)Cut-offEnd of conductorEnd of insulationBellmouth (flare)Burr (anvil flash) dimension on the base of the conductor crimpStep between the core and insulation toolsCrimp tooling geometry1.1.2压接的几何尺寸由以下方法判断：导体压接高

18、度(CCH)导体压接宽度(CCW)绝缘体压接高度(ICH)绝缘体压接宽度(ICW)料带切断截面（料带分离处）导体末端绝缘体末端喇叭口（张开）导体压接处低部的毛刺尺寸导体压线脚和绝缘体压线脚之间的台阶（即压接模具前后角的台阶）压接工具的几何尺寸2. REFERENCED DOCUMENTS2.参考文件2.1 Document HierarchyIn the event there is a conflict between performance standards, part drawings, and other related standards or specifications, th

19、e requirements shall be prioritized as follows:1st-Applicable FMVSS requirements and other applicable state and Federal requirements. 2nd-Applicable part drawings 3rd - Applicable product design specification(s). 4th-Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) 5th

20、-Applicable USCAR/EWCAP performance specifications6th-Other applicable standards and specifications2.1文件层次假如性能标准，零件图和其它相关的标准或规范有冲突则按照以下顺序执行：1st- 适用的FMVSS（联邦汽车安全标准）和国家法律法规和联邦要求2nd-适用的零件图3rd-适用的产品设计规范4th- Automotive Industry Action Group (AIAG)、PPAP5th-适用的USCAR/EWCAP性能规范6th-其它适用的标准和规范2.2 Test Request/

21、Order2.2试验要求/规则2.2.1 Samples, Test Type and Special TestsThe 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 s

22、pecification. Any required revisions to, or deviations from any tests in this specification must include detailed instructions for each change.2.2.1样品，试验类型和特殊试验实验室试验要求/规则要提供试验样品的场所和文件，识别试验的类型（开发，确认，特殊目的等）并且描述该规范没有提到的特殊试验。对于任何与该规范的修订或违背的情况要求作出详细的说明、记录。2.3 Materials And Processes StandardsSuppliers ar

23、e expected to adhere to the appropriate Materials and Process Standards that are referenced in this specification and any associated drawings and reference documents. Unless otherwise specified or required by law, suppliers are expected to use the most recent versions of any applicable drawings, ref

24、erence documents, and standards.2.3材料和过程标准供应商要符合该规范提到的材料和过程标准，要符合任何相关的图纸和参考文件。除非法律另外说明和要求，否则供应商应该要使用相应图纸，参考文件和标准的最新版本。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 Ref

25、erence Manual SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems SAE/USCAR-20 Field Correlated Life Test Supplement to SAE/USCAR-22.4其它参考文件 SAE J1128: 低压电线电缆 JISC 3406: 低压电线电缆 ISO/DIS 6722 低压电线电缆 AIAG: 测量系统参考手册 SAE/USCAR-2 汽车电连接系统性能规范 SAE/USCAR-20 补充SAE/USCAR-2的寿命试验3.

26、GENERAL REQUIREMENTS3.总体要求3.1 Record Retention3.1保存记录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.供应商应该保存试验报告和校准记录。这些保存情况必须符合QS-9000 and AIA

27、G的体系要求。3.2 Sample DocumentationAll test samples shall be identified in accordance with the requirements of QS-9000 and the AIAG PPAP.3.2样品记录所有的样品必须符合QS-9000 and the AIAG PPAP的要求进行标识。3.3 Sample SizeMinimum sample sizes are given for each test in this specification. A greater number of samples may be

28、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 gr

29、oup, then select the minimum sample size from among those that passed and represent that this specification has been met.3.3样品数量该规范中的每一个试验都规定了最小样品数量。如果试验要求/规则需要，允许使用更多的样品。除非数量符合最小样品数量要求并且所选的样品都符合接收标准才证明该样品符合规范要求。若只是部分样品符合或没有达到要求的数量就不能证明该样品符合规范。决不允许选择较多的样品数量，然后从中选择符合要求的样品。若是这样，即使满足规定的最小数量要求，也不能证明该样品符

30、合本试验规范。3.4 Default Test TolerancesDefault Tolerances, expressed as a percentage of the nominal value unless otherwiseindicated:A. Temperature = 3 CB. Voltage = 2%C. Current = 1%D. Resistance = 1%E. Length = 1%F. Time = 5%G. Force = 5%H. Distance = 1%I. Relative Humidity = 5%3.4默认的试验公差除非另外说明，否则默认的试验公

31、差以基本值的百分比来描述。A. 温度 = 3 CB. 电压 = 2%C. 电流 = 1%D. 电阻 = 1%E. 长度 = 1%F. 时间 = 5%G. 力 = 5%H. 距离 = 1%I. 相对湿度 = 5%3.5 Test Default ConditionsWhen specific test conditions are not given either in the product design specification, the test request/order or elsewhere in this specification, the following basic c

32、onditions shall apply:A. Room Temperature = 23 5o CB. Relative Humidity = AmbientC. Voltage = 14.0 0.1 VDC3.5默认的试验条件如果在产品设计规范、试验要求/规则、该规范的其它地方没有提到试验条件，则按照如下的基本条件做试验：A. 室温 = 23 5 CB. 相对湿度 = 环境湿度C. 电压 = 14.0 0.1 VDC3.6 EquipmentNeither the list shown in Table 3.6, nor the list in each test section is

33、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.3.6设备既没有在表格3.6中描述，也没有在试验段落中描述的设备都包含在内。对于高亮度显示的设备或仪器表明有特殊精度要求。其它一些通常用到的设备仪器或物品也可能需要。描述要求AC/DC电源（可调节） 0-

34、20 V0-100 A微欧计最大开路电压：0-20 mV 最大试验电流： 0-100 mA 分辨率：0.03 m. 多功能数字测试表（外用表）测量能力:0-50 Volts DC 全刻度精度 0.5%0-10 MegOhms全刻度精度0.5% 分流器100 mA，精度 1% 毫伏计0-100 mV DC，精度0.5mV或更好热电耦J或T类型测力计测量精度小于等于1%数据记录器若必要温度循环/热冲击试验箱 -40 C to +125 C 0% to 98% RH空气烘箱/炉+85 3 C温度试验箱-40 +/- 3C温度/湿度试验箱95 to 98% RH at +65 +/- 3 CNote:

35、 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

36、 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.TABLE 3.6 - Equipment注意：只要量程能满足试验的要求，适当的减小量程的范围是允许的。并不排除使用更大量程范围的设备，只要精度符合要求。例如，量程是0-100 volts的外用表可以代替量程是0-50 volts的外用表，只要精度有0.25mV或更好。表3.6设备3.7 Test Ord

37、er And Set-UpDiagrams 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

38、 each section.3.7试验顺序和设置后面列出了试验顺序的简图。除非另外说明，否则按照规定的顺序做试验。在每一个试验还详细叙述了相应的工装和设备。3.8 Definitions And Glossary Of TermsTerms 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 pr

39、ovided in Appendix c.3.8定义和术语表定义和术语表中项目内容描述以大写字母开头（如 Room Temperature, Steady State, PLR, etc.）附件B中叙述了定义。附件C提供了术语表。3.9 Measurement ResolutionUnless otherwise specified, meters and gages used in measurements of the test sample(s) shall be capable of measuring with a resolution one decimal place bette

40、r 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 wi

41、re.3.9测量精度除非另外说明，否则测量仪器的分辨率比所标参数数值要高一个等级，即小数点要往后移一位。如：导线直径是0.1mm与0.10mm数值是相等的，但前面的导线可以用0.01精度测量，但后面的导线必须用0.001精度来测量。3.10 Test Repeatability & CalibrationAll equipment used for test sample evaluation shall be calibrated and maintained according to the applicable standards and requirements set forth b

42、y 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 r

43、etained in accordance with Section 4.1 of this USCAR/EWCAP specification. A list of instruments and equipment used, date of the last calibration, and when the next calibration is due is to be included in each test report.3.10试验的重复性、再现性和校准所有的设备都必须要校准并且始终符合QS9000和AIAG出版的测量系统分析参考手册。如果要得到该份文件的复引件可以拨打电话(

44、248) 358-3570，或写信到AIAG, Dept. 77839, Post Office Box 77000, Detroit, MI 48277-0839, Attn: Customer Service。文件的记录和保存要符合该USCAR/EWCAP规范。3.11 Conformance DeterminationTest conformance shall be determined by the performance requirements of the test being conducted. All samples must satisfy the performanc

45、e requirements regardless of sample age, test cycles, or test temperature, except where a test to failure is specified.3.11符合性判断试验完成后需要进行符合性判断。所有的样品不管试验周期，试验的循环数或试验温度如何，必须满足相应的接收标准，若不符合需要另外说明。4. TEST & ACCEPTANCE REQUIREMENTS4.试验和接收要求4.1 General Testing RequirementsThe test procedures that follow we

46、re 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 sequen

47、ce, 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.4.1总的试验要求下面的试验程序是按照单独试验列出来的

48、，实际中也可能这样做。但是它们经常是用于一系列试验中某个试验。比如，做了某些试验后的样品还可以用于随后的试验，这样就减少了冗余样品准备步骤和其它冗余的步骤。外一出现关于步骤和/或要求的冲突或问题，与相关负责人联系。4.1.1 Dimensional CharacteristicsPart construction shall conform to the dimensions, shape, and detail attributes specified on the latest revision of the applicable part drawing(s).4.1.1外观特性零件结构

49、应该符合最新版本零件图中的尺寸，形状和详细属性的要求。4.1.2 Material CharacteristicsAll material used in each test sample shall conform to the material standards specified on the latest revision of the applicable part drawing(s).1. Any engineering development, prototype, or production parts may be submitted for test.2. The sa

50、mples submitted for test should be identified by description, part number, andrevision letter.3. For validation testing, all parts are to be in their as furnished for vehicle assembly condition when testing begins. For example, electrical terminals typically have residual die lubricant on them when

51、finally assembled into a vehicle. This same condition must prevail for test samples.4. Samples submitted for any test shall be prepared per Appendix E.4.1.2材料特性试验中样品的材料必须符合适用的零件图中材料标准的要求。1. 任何工程开发，原型样件或生产零件都可能提交用于试验。2. 用于提交做试验的样品必须要有标志，如描述性文字，零件号和修订字母。3. 对于确认试验，所有的零件都要在与其实际使用条件相同的情况下做试验（用于汽车中的组件）。例如

52、，端子经常在装入汽车中时会有残留的模具润滑剂。那么试验的端子应该也有相同的条件。4.2 Visual Inspection4.2目测4.2.1 PurposeThis test is used to document the physical appearance of test samples and to assist in the evaluation of the effects of environmental conditioning on test samples. A comparison can then be made with other test samples. Ex

53、aminations 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 tes

54、t group must be retained for post-test physical comparisons if photographs/videos are not taken.4.2.1目的该试验是用于检查试验样品的物理外观，也用于样品进行环境试验后的外观情况。与其它样品进行比较。在大多数情况下该项检查由一个人（正常视力或纠正视力）在白炽灯下完成即可。鼓励用相片或视频录象的形式记录检查结果。假如没有使用相片或视频录象的形式记录检查结果就需要留几个样品（需要作出标志）用于与经过试验的样品作比较。4.2.2 Samples1. The samples should conform

55、to the requirements of the specified conditioning and anyadditional measurements that are to be performed.2. For purposes of comparison and especially when only subtle appearance changes areanticipated, it is desirable to submit an additional sample to serve as a control.4.2.2样品1. 样品应符合规定的试验条件和任何附加的

56、测量方法。2. 出于比较的目的，特别是预期的微妙的外观变化，要求提交附加的样品用作控制。4.2.3 EquipmentVideo/photography equipment.4.2.3设备视频设备/照相设备4.2.4 Procedure4.2.4步骤1. Visually examine each test specimen prior to testing and/or conditioning, noting in detail anymanufacturing or material defects such as cracks, bending, deformation, etc. W

57、henspecified in the test request/order, take photographs and/or video recordings ofrepresentative samples to be tested and keep a properly labeled control sample.1.在试验和/或条件处理前目测每一个样品，详细记录由于制造或材料原因引起的诸如裂缝，弯曲，变形等。当有要求时采取相片或视频的形式记录样品并且恰当保存贴了标签的受控样品。2. After testing and/or conditioning, re-examine each

58、test sample and note in detail anyobservable changes, such as physical distortions, cracks, etc. Compare the tested and/orconditioned 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 fo