HVSL系列型式测试大纲

Documenttype:TestPlanDocumentstateTitle,DescriptionTypetestplanofconnectorandcableassemblyRevisionLang.En/ChSheet/NUMPAGES16highvoltagewithconnectorandcableassemblytypetestplan高压连接器及线缆型式试验计划FOREWORDNote:Fundamentalmodifications,comparedwiththepreviousedition,areindicatedbyaverticallineintherightmargin.MODIFICATIONSREVISIONDATE2013.11.13LOC.DESCRIPTIONPre-releaseA2014.5.10FirstreleaseB2017.02.13UPDATEPERJILI

SCOPE适用范围ThisTestReviewcontainstestitemsandmethodsforHVSL1000connectorandcableassembly.此测试规范定义HVSL1000高压互锁连接器及组装线束的测试项目及测试方法REFERENCE参考文件IEC61984SafetyrequirementsandtestsEN60529Degreesofprotectionprovidedbyenclosures(IPcode)DIN40050-9Roadvehiclesdegreesofprotection(IPcode)EN60512Electromechanical

components

for

electronic

equipment

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Basic

testing

procedures

and

measuring

methodsEN60068-2

EnvironmentaltestingLV215Electrical/ElectronicRequirementsofHVConnectorsVW80302High-VoltageConnectorsinMotorVehiclesRequirementsandTestConditionsforVOLKSWAGENSAEJ1742ConnectionsforHighVoltageOn-BoardVehicleElectricalWiringHarnesses-TestMethodsandGeneralPerformanceRequirements…TESTGROUP测试项目TestrequirementsandproceduresTestdescriptionRequirementProcedureT1Conditioningandinspectionofas-receivedcondition检验测试条件Beforeatest,everyspecimenmustbeconditioned16hoursunderstandardtestconditions,thencheckthedimensionsaccordingtoAmphenol’sdrawings.测试前，每一样品须在测试标准条件下放置16后，然后根据图纸检查尺寸。T2Visualinspection目视检查Nodefectsoffabrication,nochangesbeforeandafterseveraltestingprocedures,mechanicalbasicfunctionaretocheck测试前后无任何不良EN60512-1-1T3Basicfunctionaltest基本功能测试Allspecimensmustgothroughthefollowinginitialmeasurementsinordertomakeitpossibletochecktheirbasicelectricfunctionsandthereforemeettherelevantbasicrequirements.ThecontactresistancemustbecompliancewithLV215specificationsandtheinsulationresistancemustbe>200Mohmsat1075Vdc;andwithstandingvoltage2700VACnoflash-overoccurred.所有测试样品须作初始基本功能性检验，测试条件同后；接触阻抗符合LV215要求；绝缘阻抗大于200Mohms；耐2700V电压无闪花等。EN60512-2-1EN60512-2-2EN60512-3-1MECHANICALTESTOfContactT4Materialandsurfacetest材料及表面测试Acc.toAmphenoldrawingsandspecificationstocheckthecontactmaterialandplatingthickness.根据Amphenol的图纸及规范，检验端子的材质及表面处理的厚度及外观。T5Contactinsertionandextractionforce端子的插入及拔出力ThecontactinsertionandextractionforcemustbecompliancewithAmphenolspecifications.端子的插入及拔力须符合Amphenol的规范（插入力最大7lbf,拔出力最小3lbf）。EN60512-8T6Durability耐久性Thecyclesofinsertionandextractionmustbemorethan50.端子须耐至少50次插拔。EN60512-8T7Crimpretentionforce压接保持力ThecrimpretentionforcemustbecompliancewithLV215specification.端子的压接保持力须符合LV215规范。EN60512-8T8Thermaltimeconstant(Temperaturerise)温升Loadacontactwithnormalcurrentacc.toAmphenoldrawingsandspecifications.Themaxtemperatureriseis55℃温升不超过55℃EN60512-5-2T9Contactresistance接触阻抗Acc.toLV215specification.接触阻抗符合LV215规范要求。EN60512-2-2ELECTRICALTESTOfContactT10Voltagedrop电压降Thevoltagedropismeasuredwiththemaximumnominalcurrentcorrespondingtotheplugcontactandlinecombination.Thenvoltagedropisnotexceed80mV.压降依据端子及其线缆的最大负载电流作测试。压降不超过80mV.EN60512-5-2MECHANICALTESTOfconnectorhousingT11Materialandsurfaceanalysis,housing外壳材料及表面分析Injectionmoldedskinsandmoldseparationmarksmustnotimpairthehandlingorfunction.Burrsandtooloffsetonmatingsurfacesareimpermissible.缩水及分模线等无损害操作或功能；毛边和顶针印等可接受。T12Non-reversibilitytest(Polarization)极性Testload300N,nodamageofnon-matedconnectorstoinserted非配对的连接器用300N的力不能插入EN60512-13-5T13Determiningthemaximumextractionforce外壳最大分离力Specimensetup:thespecimenswithoutsecondarylatchmechanism.Theextractionforcemustgreaterthan110N.样品不使用次级锁紧机构，外壳最大分离力大于110N。EN60512-8T14Durabilityofhousinglatch外壳卡钩的耐久Themaximumvalueis75%ofthemaximumExtractionuptoamaximumof110N.Themaximumtestforcemustbemaintainedfor15s.保持力为最大分离力的75%，最大110N，持续15秒。EN60512-15-6T15Connectorengageandseparationforce连接器的插入及分离力Theconnectorengageandseparationforcemustnotexceed100N.连接器的插入及分离力不超过100N.EN60512-13-1T16Effectivenessofsecondarylatchmechanism次级卡钩的保持力Themaximumvalueis110N.Themaximumtestforcemustbemaintainedfor15s.保持力为最大110N，持续15秒。EN60512-8ELECTRICALTESTT17Insulationresistance绝缘阻抗Testvoltage1075VDC,theinsulationresistancemustbe>200Mohms.测试电压1075VDC，绝缘阻抗大于200Mohms.EN60512-3-1T18Withstandvoltage耐电压测试Acc.toLV215specification.接触阻抗符合LV215规范要求ENVIROMENTALTESTT19Coastalclimateload盐雾试验周期(氯化钠溶液)Themaintestconsistsof8hourssprayingand16hofbreak;durationcycles:6cycles8小时氯化钠溶液喷雾然后中止16小时再继续，共计6个循环。EN60068-2-52T20Changeoftemperature温度改变Cycles:20cycles;Duration3hoursat-40℃,then3hoursat140℃;-40℃~140℃循环冲击20次；每个温度阶段维持3小时。EN60068-2-14T21Dryheat高温试验Period:120H;Temperature140℃140℃120小时EN60068-2-2T22Humidheat,cyclic湿热循环Thespecimensaretestedataconstantrelativehumidityof95%.Thetemperaturechangesfrom25℃to55℃withinacycle.Duration10cycles.相对湿度95%，温度20℃-50℃，10个循环。EN60068-2-30T23Humidheat,constant恒定湿热Thespecimensareagedfor10daysat40℃.Therelativehumidityduringthisprocessis95%.温度40℃，相对湿度95%，时间10天。EN60068-2-30T24Low-temperatureaging低温老化Period:48H;Temperature-40℃-40℃48小时EN60068-2-1T25Agingindryheat高温老化Period:48H;Temperature80℃80℃48小时EN60068-2-2T26Chemicalresistance耐化学Undilutedcommerciallyavailablecold-cleaningagentPenetratingoil,e.g.,"Caramba"UndilutedcommerciallyavailablewasherfluidantifreezeUndilutedmethylatedspiritLubricatinggreaseBrakefluid,e.g.,TevesATEDOT4Premium-gradegasolineacc.toDIN51604-2DieselfuelaccordingtoDINEN590Multi-grademotoroilSAE10W‑50Hypoidgearboxoil,classSAE80/90Radiatorantifreeze:50%H2O/50%ethyleneglycolBatteryfluid2):undilutedsulfuricacid,density:1,28g/cm3Thespecimensareimmersedinthecorrespondingmediumfor5min.Allowtodrip-dryafterwardsandage48hat50℃intemperaturetestchamberVW75174/PG22BVW60306-1T27High-pressurespraytest（IP6K9K）高压喷射试验（IP6K9K）TheIPX6K/IPX9Kprotectioncategorymustbefulfilled满足IP6K9KDIN40050-9MECHANICALTESTT28Droptest跌落测试"Connectorsforelectronicequipment-Testsandmeasurements-Part7-1:Impacttests(freecomponents)-Test7a:Freefall(repeated)"VW75174/PG20C;DINIEC60512-7-1T29Contactsextractionforceforremovalfromhousing端子从塑胶最大的拔出力Acc.toLV215specification(>500N)符合LV215规范(>500N)EN60512-15-6T30Contactretentionforceforremovalfromthehousing端子在塑胶的保持力500Nfor15s,discontinuousness<200nswith10V100mAmax.monitoring.500N保持15秒，期间用10V最大100mA来监视瞬断小于200ns。EN60512-15-6T31Dynamicload,sinusoidal动态负载Duration:22hours*3axialThenormalcurrentisloaded.FordetailsseeVW80302Section9.3.2.1.Frequency(Hz)Accelerationamplitude(m/s2)100302006044060Duringthetest,atemperaturecyclemustbeloaded.MinuteTemperature(℃)02060-40150-402102030012041012048020GBT28046.3乘用车变速器T32RandomVibration随机振动Duration:22hours*3axialThenormalcurrentisloaded.FordetailsseeVW80302Section9.3.2.1.Frequency(Hz)Powerdensityspectrum(m/s2)2/Hz1010100103000.51500520005Duringthetest,atemperaturecyclemustbeloaded.MinuteTemperature(℃)02060-40150-402102030012041012048020GBT28046.3乘用车变速器T33Shock机械冲击A=30g,no.ofshock12000cyclesofhalfwaves(2000perdirection,in6directions)IEC60512-6-3T34Deratingwithhousing成品的降额曲线Dependonvariouscables.根据不同的线缆。EN60512-5-2T35Fingerproof(IP2XB)手指防触摸Acc.toEN60529依据EN60529.EN60529ADDITIONALTESTT36Airclearanceandcreepagedistance空气间隙和爬电距离PollutionII,Ratedvoltage:1000VDC;Altitude:2000MAirclearance>2mmCreepagedistance>5.05mm污染等级2级，额定电压1000VDC,海拔高度2000米，空气间隙大于2mm,爬电距离大于5.05mmIEC60664-1T37HVInter-Lockfunction高压互锁功能Acc.toLV215LV215T38汽车非金属材料阻燃性试验Acc.ToT39非金属零部件耐光老化性试验Acc.ToT40Acc.ToJLYY-JT36-08ITEMSequenceMechanicaltestforcontactsElectricaltestforcontactsMaterialandsurfacetestContactinsertionandextractionforceDurabilityThermaltimeconstant(Temperaturerise)Voltagedrop/ContactreisistanceDeratingwithouthousingSpecimenQ’ty51010Pairs3Pairs10Pairs3PairsT1Conditioningandinspectionofasreceivedcondition111111T2Visualinspecton254552,5T4Materialandsurfacetest3T5Contactinsertionandextractionforce2,4T6Durability3T7Crimpretentionforce6T8Thermaltimeconstant(Temperaturerise)3T9Contactresistance2,52,42,43,4T10Voltagedrop3T21Dryheat3ITEMSequenceMechanicaltestforconnectorhousingsMaterialandsurfacetestNon-reversibilitytest(Polarization)DeterminingthemaximumextractionforceDurabilityofhousinglatchConnectorengageandseparationforceEffectivenessofsecondarylatchmechanismSpecimenQ’ty1Pair1Pair3Pairs5Pair5Pair5PairT1Conditioningandinspectionofas-receivedcondition111111T2Visualinspecton3333T3Basicfunctionaltest22T11Materialandsurfaceanalysishousing3T12Polarization3T13Determiningthemaximumextractionforce2T14Durabilityofhousinglatch2T15Connectorengageandseparationforce2T16Effectivenessofsecondarylatchmechanism2ITEMENVIROMENTALTESTFORCONNECTORHOUSINGSequenceENVIROMENTALTESTFORCONNECTORHOUSINGCoastalclimateloadEnvironmentalsimulationClimateloadChemicalresistanceWatertightnessSpecimenQ’ty3Pairs20Pairs10Pairs3Pair10PairT1Conditioningandinspectionofas-receivedcondition11111T2Visualinspecton55,8,115,8,10,12,145T3Basicfunctionaltest2,42,222T9Contactresistance4,7,10T17Insulationresistance4,7,1344,T19Coastalclimateload3T20Changeoftemperature3T21Dryheat63T22Humidheat,cyclic9T23Humidheat,constant6T24Low-temperatureaging9T25Agingindryheat11T26Chemicalresistance3T27High-pressurespraytest3