SAE_USCAR2_Rev3_2001 汽车电子连接器性能标准

1、PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS车用电子连接器系统性能标准*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.如果没有完全符合所有USCAR/EWCAP的要求并作验证确认和文文件记录，任何电子连接器、端子或相关零件都不能宣称已经符合USCAR/EWCA

4、P的规格。至少要达到最少样品数量要求并且其中所有样品都必须通过该测试所对应的“接受标准”。所有要求的确认和文书记录必须由零件供货商完成。如果测试由其它单位完成，供货商并不能豁免记录所有零件测试结果并符合相应“接受标准”的责任。1.0 SCOPE适用范围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. 本规范中的程序意在包括端子、连接器及其部件（这些端子、连接器及其部件构成路面交通工具直流0-20伏低压电子连接系统）的在所有研发、生产和现场分析中的性能测试标准。这些规程只适用于线路中连接器系统中、针类连接器系统中和设备连接器系统中的端子，但不适用于“边板连接器系统”（Edge Board connector systems），交/直流20伏，或针孔（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。注意本规范并没有包含连接器的辅助机械部份。负责人必须提供相关额外测试的信息以满足这些机械作为测试一部分的要求。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：如果被测试零件是用于一些超过本规范所规定范围的车辆，这些零件必须通过和实际情况的相一致的模拟测试才能投入正式使用。例如，这些包括在图5.1.4中显示的超过4级的极端温度、非扭转（unsprung）部分例如轮轴（hub）的振动及摇摆。已通过本规范测试标准的零件不应在超过其测试条件的条件下使用。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.负责人最终决定对零件进行何种测试及测试目的，他/她亦解决任何有关测试的问题并允许设备及程序的偏差。所有这类偏差都必须有所记录并包括在最终测试报告中。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.推荐测试的指导可以在附录C和D的图表中找到。如果负责人没有相反的指示，所有电子连接器及其相

14、关端子和部件都需要符合本文的规定，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. 没有明确要求的测试或在第三部分各层次中规定了额外测试要求的。2.0 OUTLINE & GLOSSARY OF TERMS大纲和术语表2.1 GENERAL通则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.在有必要协助明确各测试程序的细节的地方，本文提供图表。除了特别指出之外，所有测试都必须按照给定的顺序执行。

16、本规则提供测试设备和装置的安装信息。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.附录B提供术语表。术语单词都用大写开头（如：Room Temperature, Steady State, PLR 等）。 附录A提供定义表。For t

17、he purposes of this specification there are only two types of electrical connector: sealed and unsealed.为了说明的目的，本规范只有两种连接器：密封型和不密封型。3.0 REFERENCED DOCUMENTS REQUIRED要求参考文献3.1 DOCUMENT HIERARCHY文件等级层次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:当性能标准、零件图纸和其它相关标准及规则发生不一致时，优先级顺序如下：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 适用的FMVSS和其它的州及美国联邦规定2 适用的零件图纸3 适用的产品设计规范4 汽车行业工作组 (AIAG) 的生产零件批准过程 (PPAP)5 适用的 USCAR/EWCAP 性能标准6 其它适用的标准和规范3.2 PART DRAWING零件图纸The par

20、t drawing for each connection system component should contain or reference:每个连接系统的零件图纸都应该包含或指定以下内容：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. 所有规定尺寸（必须用GD&T格式）B. 性能要求C. 部件号D. 适合本规范部分的参考。E. 使用端子的数量及零件号F. 典型的连接器和端子的装配。G. 零件计划使用或已经成功测试的最大允许温度等级 (根据图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:为了便于控制及标准化起见，每个包含有符合USCAR/ EWCAP footprint

23、的电容器的图纸也必须在图纸说明或其它显著位置标明以下声明：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.该图纸由美国汽车研究协会(USCAR)所属的电子线路零件应用协会(EWCAP)控制。USCAR是戴姆勒-克赖斯勒集团、福特汽车公司和通用汽车集团之间的合伙机构。对于一个EWCAP图纸的任何一个改动，包括一个“记录变化”，都必须得到来自各个USCAR公司EWCAP相关成员的书面许可。每个被授权的EWCAP成员在代表其公司签字前都必须得到其公司内部各相关方的批准。EWCAP明确禁止任何一方在得到所有EWCAP成员认可之前擅自改动EWCAP控制图纸或任何对应模具。在该图纸的控制栏中必须填写同意改动签字的相关证明内容。3.3 PR

27、ODUCT DESIGN SPECIFICATION产品设计规范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.产品设计规范可能是也可能不是零件图纸中独立的部分。如要求相关零件进行特别测试，或对本档中的普通规范及要求做改动或，在产品设计规范中必须说明。3.4 TEST REQUEST/ORDER测试要求/顺序3.4.1 Samples, Test Type and Special Tests样品、测试类型和特殊测试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.实验室测试要求/顺序应该提供

30、测试样品的地点和档、明确将要进行的测试的种类（研发、确认、特别目的等）并描述所有不属于本规范的特殊测试。任何对于本规范中测试的改动或偏离都必须有详细说明。3.4.2 Test Request/Order Instructions测试要求/顺序指示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.如果测试要求/顺序和本规范的内容有所不同，必须加以说明。3.4.3 Performance and Durability Test Instructions性能和持久性测试说明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.如果对于性能和持久性测试的测试要求/顺序（包括极限环境条件的定义）和本规范不同，必须加以说明。3.4.4 Development Tests研发测试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.为评估设计的特定领域会经常使用研发测试，它们是评估其它可能设计方案或改进方案、降低成本和发现实际使用中出现问题的根本原因的有效工具。3.4.5 Validation Tests确认测试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.确认测试或样品认可测试都属于接受型测试。在把本规范的一些测试作为确认或应用测试前必须考虑其内在的可重复性或主观性。3.4.6 Special Purpose Tests特定目的测试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.本规范的部分内容可以用于特定目的测试。例如：为了证实步骤或物料的改变并不会产生不良影响，经负责人判断，只需要一两个特定测试或一个测试的一部分。在产品开发、生产测试或使用现场的零件分析的任何阶段都可以单独使用本规范中的一个测试的任何一部分，或组合使用本规范之外的多个测试。3.5 MATERIALS AND PR

37、OCESSES STANDARDS材料和步骤标准 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.供货商应该遵照本规范所用得适当的材料和步骤标准、对应制图及参考文献。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.除非特别指出，否则供货商应该使用所有制图、参考文献和标准的最新版本。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.在选择来源（source selection）90天内，基于当前设计理念，供货商向负责设计工程师提供一份FMEA样本。经过修订的FMEA必须在模具计划公布(program tooling release)10周之前发布，并且在模具（TOOLING）发布之前由负责人全面批准。在正式生产确认之前90天之前供货商必须完成流程FM

41、EA并提交到负责人及相关质量代表人处。3.7 OTHER REFERENCED DOCUMENTS其它参考文献 SAE J1127: Battery Cable（电池线） SAE J1128: Low Tension Primary Cable（低张力总线） AIAG: Measurement Systems Analysis Reference Manual（测量系统分析参考手册）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.供货商应该为实验室报告和校准记录保持一份主文件。此记录的存储必须符合QS-9000和AIAG的政策和做法。4.2 SAMPLE DOCUMENTATION样本记录存盘All test samples shall be identified in accordance with the requirem

43、ents of QS-9000 and the AIAG PPAP.所有测试样本都应该按照QS-9000和AIAG PPAP的要求确定。4.3 DEFAULT SAMPLE SIZE默认样本数量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.本规范给出每个测试所要求的最少样本样品数量，而测试要求/规定可能要求更多的样本。除非使用了要求的最少样品数量并且其中所有样品都符合接受准则，否则不能宣称被测零件已符合本规范。决不允许选用很多的样本数量做测试，然后合格的样品数量恰好达到或超过最少试验样品数量要求，并且测试结果满足接受准则，就认为被测零件已符合本规范。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.每次测试需要至少10个连接器总成（阴阳连接器或阴连接器和针类连接器（如：又电路板、

47、针和塑件组成的连接器）或设备连接器）。每次测试也需要至少30对端子(扁针或p针和阴性端子)。如果连接器塑件和端子一同测试的话，需要准备满足这两个条件的样品。4.4 DEFAULT TEST TOLERANCES默认测试公差Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated:默认公差，除非另行规定，以百分比形式标示。A. Temperature温度= 3 B. Voltage电压= 2%C. Current电流= 1%D. Resistance电阻= 1%E.

48、Length长度= 1%F. Time时间= 5%G. Force力= 5%H. Frequency频率= 5%I. Distance距离= 1%J. Flow Rate流速= 5%K. Relative Humidity相对湿度= 5%4.5 TEST DEFAULT CONDITIONS默认测试条件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:如果在产品设计规范、测试要求/顺序或本规范的其它方面没有指明，应该满足以下基本条件：Room Temperature = 235室温=235Relative Humidity= Ambient相对湿度=环境湿度Voltage = 14.0 0.1 VDC电压=14.0 0.1 VDC 4.6 EQUIPMENT设备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.以下清单和本文各章节中提到的指示所需设备的一部分，主要用于强调一些专用设备或有特殊精确要求的装置。很多其它常规的实验室设备和供给也是需要的。ITEM项目DESCRIPTION描 述REQUIREMENTS*要 求 *1DC Power Supply (Regulated)直流电源（可调）0-

51、20V 0-10A2DC Power Supply (Regulated)直流电源（可调）0-20V0-100A3Micro-ohmmeter微型欧姆计0-20mV 0-100mA4Digital Multimeter (DMM)数字万用表Capable of measuring the following at an accuracy of *0.5% of full scale:可以在以下精度范围内测量0.5%全程：0-50Volts DC0-10兆欧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%并可测量0-100直流毫伏7Thermocouples热电偶Type “J” or “T” and as required“T”或“J”型和测试特定要求的型号8Insertion/Extraction Force Tester插入/抽取式测力计Capable of1.0% accuracy , full scale全程精度1.0%9Data Logger数据记录器As required根据要求10Tempe

53、rature Chamber恒温腔-40 to 1750%to 95% RH11Vibration Controller振动控制器As required根据要求12Vibration Table振动台2640N(600 Lbs.) Sine Force2200N(500 Lbs.) RMS Force13Vacuum真空As required根据要求14Megohmeter兆欧姆计Capable of measuring100 Megohms at 500 Volts DC能在500直流伏条件下测量100兆欧以上电阻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：如测试允许，可以使用量程比表中要求更小的仪器；也可以使用更大量程的仪器，但精度必须符合规定要

56、求。例如：表中规定应使用全程测量范围50伏、精度0.5%或0.25伏的数字万用表（DIMM）；如果用全程测量范围100伏的DIMM代替，精度应该是0.25伏，而不是100伏的0.5%。4.7 MEASUREMENT RESOLUTION测量精度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.除非另有说明，用于测量的仪表和器

58、具都应该有比所标示值优一个小数点的精度。例如： 虽然线径标示为0.1毫米和0.10毫米实际上可能是一样的，但对于0.1毫米用0.01毫米精度的测径器，而对于后者要0.001毫米精度的测径器。4.8 TEST REPEATABILITY & CALIBRATION测试重复性和校准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