SAE-USCAR-中英对照版课件

PERFORMANCESPECIFICATIONFORCABLE-TO-TERMINALELECTRICALCRIMPS

電線及端子壓著性能規格

SAE/USCAR-21Revision1TABLEOFCONTENTS

楊建均IssuedMay2002RevisedApril2004IMPORTANTNOTICE:Inanyintendedvehicleapplication,iftheproductscoveredbythisspecificationare,ormaybe,subjectedtoconditionsbeyondthosedescribedinthisdocument,theymustpassspecialtestssimulatingtheactualconditionstobeencounteredbeforetheycanbeconsideredacceptableforactualvehicleapplication.Productscertifiedbytheirsupplierashavingpassedspecificapplicableportionsofthisspecificationarenottobeusedinapplicationswhereconditionsmayexceedthoseforwhichtheproducthasbeensatisfactorilytested.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，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

Thisspecificationdefinesbasictestmethodsandrequirementsforsolder-lesscrimpedconnections.Somesectionsofthisdocumentmayalsobeapplicabletootherterminalattachmentmethodssuchassonicorelectricalweldingorsoldering.Inthesecases,applicabilityoftheproceduresinthisdocumentshallbedeterminedbytheResponsibleEngineer.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.CrimpapplicationsvalidatedtothisspecificationsupercedeanycrimpinformationonFord,GM,orDaimlerChryslercomponentprints.Theterminalsupplierhastheprimaryresponsibilityfortestingandselectionofcrimptoolingandtosupplydetailedcrimpinformationormakecrimptoolingavailabletothewiringassemblysupplieractuallydoingtheproductioncrimping.Ifthewiringsupplierdeviatesfromthisinformationoritisnotavailable,thentheresponsibilityfortestingtothisspecificationorgettingapprovalfromthecustomerwithappropriatetestdatashowingthatthecrimpwillfunctioninit’sintendedcircuitlieswiththewiringharnesssupplier.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.Neworrevisedterminalsshallbedesignedtomeetthisspecification.4.Allnewcrimpapplicationsshallmeetthisspecification.Newcrimpapplicationsaredefinedasterminal/wirecrimpcombinationsnotpreviouslyspecifiedonFord,GM,orDaimlerChryslervehiclewiringharnessassemblies.Existingcrimpapplicationsmaybecarriedoverifapprovedbythecustomerengineeringdepartment.3.新的或修改的端子在設計上須符合此規格。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.ElectricaltestsinthisspecificationhavebeenprovenbypastexperiencetoensurethatcrimpswillmeettherequirementsinSAE/USCAR-2andSAE/USCAR-20byincludingThermalShock,TemperatureHumidity,andPowerCurrentCycling.Testingandelectricalacceptancecriteriawilldetectdefectsincrimptoolinggeometry,platingquality,inadequatestranddistributioninthegrip,orcablestranding.CrimpapplicationsthathavepassedSAE/USCAR-2andSAE/USCAR-20normallyhaveonlypassedthenominalcrimpheightandusuallyonlywiththelargestgaugesize.Therefore,crimpswithintheproductioncrimpheightrangemaynotnecessarilypassthistest.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.Proceduresincludedwithinthisspecificationareintendedtocoverperformancetestinganddevelopmentofelectricalterminalcrimpsthatarepartoftheelectricalconnectionsystemsinlowvoltage(0-48VDC)roadvehicleapplicationsatambienttemperaturesof125°Cmaximum.TheOEMcustomermustapproveuseofthesetestproceduresforuseatvoltagesandtemperaturesbeyondtheselimits.7.Theseproceduresareapplicableonlytoterminalsusedforin-line,header,edgeboard,anddeviceconnectorsystems.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(0-48VDC)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。1.1CrimpingParameters1.1.1TheCrimpconnectionperformanceischaracterizedby: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(ICW)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-2PerformanceSpecificationforAutomotiveElectricalConnectorSystemsSAE/USCAR-20FieldCorrelatedLifeTestSupplementtoSAE/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.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，如下所示：1st-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3rd-適用產品設計規範。4th-汽車工業行動集團（機動車)生產部件審批過程(提交)5th-USCAR/EWCAP適用性能規範6th-其他適用的標準和規範2.2TestRequest/Order2.2.1Samples,TestTypeandSpecialTestsThelaboratorytestrequest/ordershallprovidelocationanddocumentationoftestsamples,identifythetypeoftesttobeperformed(development,validation,specialpurpose,etc.)anddescribeanyspecialteststhatarenotapartofthisspecification.Anyrequiredrevisionsto,ordeviationsfromanytestsinthisspecificationmustincludedetailedinstructionsforeachchange.2.2測試要求/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。2.3MaterialsandProcessesSpecificationsSuppliersareexpectedtoadheretotheappropriateMaterialsandProcessthatarereferencedinthisspecificationandanyassociateddrawingsandreferencedocuments.Unlessotherwisespecifiedorrequiredbylaw,suppliersareexpectedtousethemostrecentversionsofanyapplicabledrawings,referencedocuments,andstandards.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、引用的文件和標準。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.GENERALREQUIREMENTS3.3SampleSizeMinimumsamplesizesaregivenforeachtestinthisspecification.Agreaternumberofsamplesmayberequiredbythetestrequest/order.However,nopartordevicemayberepresentedashavingmetthisspecificationunlesstheminimumsamplesizehasbeentestedandallsamplesofthegrouptestedhavemettheapplicableAcceptanceCriteriaforthattest.Itisneverpermissibletotestalargergroup,thenselecttheminimumsamplesizefromamongthosethatpassedandrepresentthatthisspecificationhasbeenmet.Anyalternativesamplesizeand/ormethodologiesmustbeapprovedbytheAuthorizedPerson.3.3樣本尺寸本規範中的每個測試，給出最小樣本量。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3.4DefaultTestTolerancesDefaultTolerances,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=±3oCB.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%3.5TestDefaultConditionsWhenspecifictestconditionsarenotgiveneitherintheproductdesignspecification,thetestrequest/orderorelsewhereinthisspecification,thefollowingbasicconditionsshallapply:A.RoomTemperature=23±5oCB.RelativeHumidity=AmbientC.Voltage=14.0±0.1VDC3.5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.室溫=23±5oCB.相對濕度=環境C.電壓==14.0±0.1VDC3.6EquipmentNeitherthelistshowninTable3.6,northelistineachtestsectionisall-inclusive.Itismeanttohighlightspecializedequipmentordeviceswithparticularaccuracyrequirements.Manyotheritemsofcustomarylaboratoryequipmentandsupplieswillalsoberequired.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。DESCRIPTION

說明REQUIREMENTS

要求ACorDCPowerSupply(Regulated)交流或直流電源(規管)⇒0-20V⇒0-100AMicro-ohmmeter微歐姆計

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

⇒

0-100mAmaximumtestcurrent最大的測試電流⇒

0.03mΩresolution變化

DigitalMultimeter(DMM)數位多用表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100mAorasrequiredwithaccuracyof±1%ofnominal100mA或根據需要的精度±1%的公差毫伏特

MeterCapableofmeasuring0-100mVDCanaccuracyof0.5mVorbetter能夠測量0-100的mV直流0.5mV或更高的準確度

Thermocouples熱電偶Type"J"or"T"asrequired鍵入"J"或"T"為所需ForceTester強力測試儀Capableofanaccuracyof≤1%ofmeasurement有能力的≤1%的測量準確度DataLogger資料記錄儀AsRequired要求TemperatureCyclingand/orThermalshockChamber溫度循環和/或熱衝擊室⇒-40oCto125oC⇒0%to98%RH⇒-40oC到125oC⇒0%到98%RHForcedAirOven強制的空氣爐⇒+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：對規格測試符合該測試在所需的範圍，配備一個較小範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。

Table3.6-Equipment

3.7TestOrderandSet-UpDiagramsareprovidedwherenecessarytoclarifythedetailsofthevarioustestprocedures.Thetestsineachsectionmustbeperformedintheordergivenunlessotherwisespecifiedinthetestrequest/order.Constructiondetailsforselectedtestfixturesandequipmentareprovidedineachsection.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。3.8DefinitionsandGlossaryofTermsTermsdefinedinthedefinitionsorglossaryarecapitalized(i.e.RoomTemperature,SteadyState,PLR,etc.).AlistofdefinitionsisprovidedinAppendixB.AglossaryoftermsisprovidedinAppendixC.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3.9MeasurementResolutionUnlessotherwisespecified,metersandgagesusedinmeasurementsofthetestsample(s)shallbecapableofmeasuringwitharesolutiononedecimalplacebetterthanthespecifiedvalue.Forexample,eventhoughawirediameterspecifiedas0.1mmmightactuallybethesameasonespecifiedas0.10mm,caliperscapableof0.01mmresolutionmaybeusedtomeasurethefirstwirebutamicrometerwith0.001mmresolutionisrequiredtomeasurethesecondwire.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0.1mm的線徑實際上可能相同，其中一個規格為0.10mm，卡尺能夠有0.01mm解析度的可用於測量第一線，但微米0.001mm解析度需求可測量第二線。3.10TestRepeatability&CalibrationAllequipmentusedfortestsampleevaluationshallbecalibratedandmaintainedaccordingtotheapplicablestandardsandrequirementssetforthbyISOandtheAIAGpublicationMeasurementSystemsAnalysisReferenceManual.CopiesofthisManualcanbeobtainedfromtheAIAGbycalling(248)358-3570orwritingtoAIAG,Dept.77839,PostOfficeBox77000,Detroit,MI48277-0839,Attn:CustomerService.InformationmayalsobeobtainedattheAIAGwebsite,

.DocumentationistoberecordedandretainedinaccordancewithSection4.1ofthisUSCAR/EWCAPspecification.Alistofinstrumentsandequipmentused,dateofthelastcalibration,andwhenthenextcalibrationisdueistobeincludedineachtestreport.3.10測試重複性、校正用於測試樣本求所有設備須是校準並按照適用的標準維護要求提出依ISO和AIAG發佈測量系統分析參考手冊和。本手冊的副本，可從AIAG（248）358-3570或寫入AIAG，部77839，郵政署77000，底特律，MI48277-0839，經辦人：客戶服務。資訊也可從AIAG的網站

獲得。記錄並保留按照第4.1本USCAR/EWCAP規範的文件。包括在每個測試報告使用清單的儀器、設備，在上次的校正日期和下一個預計校正。3.11ConformanceDeterminationTestconformanceshallbedeterminedbytheperformancerequirementsofthetestbeingconducted.Allsamplesmustsatisfytheperformancerequirementsregardlessofsampleage,testcycles,ortesttemperature,exceptwhereatesttofailureisspecified.3.11一致性檢測正在進行測試的性能要求須進行符合性測試。所有樣本必須都滿足性能的樣本年齡，無論測試週期，或測試溫度要求，除非有測試失敗的描述。4.TEST&ACCEPTANCEREQUIREMENTS

4.1GeneralTestingRequirementsThetestproceduresthatfollowwerewrittenasstand-alonetestsandmaybeusedassuch.However,theyarenormallyusedinasequentialtestformatandcommonsenseisrequiredtoovercomeanyredundanciesinsamplepreparationorinprocedures.Forexample,ifsampleshavealreadybeenpreparedfortheprecedingtestinasequence,itshouldbeobviousthatthesamplepreparationstepforthatindividualtest(includedsothattestcanbeusedasastandalonetest)shouldbeskipped.Shouldanyconflictsorquestionsariseconcerningproceduresand/orrequirements,contacttheAuthorizedPerson.AnytestplanapprovedbytheAuthorizedPersonthatshowscompliancetotheminimumperformancerequirementswithtestdataisacceptable.4.1一般測試要求遵循的測試過程的獨立測試和可以使用。但是，它們通常使用依序測試格式和共同需要去克服樣品準備或過程中的任何重覆。例如如果樣本已經準備好了有了程序中上述測試的話，很明顯(包括使該測試，可以使用作為獨立測試)該樣品準備步驟個別測試應跳過。應任何衝突或問題出現有關過程和/或要求，聯繫有關的認可人士。有關的認可人士，顯示該測試資料的最低性能要求遵守符合任何測試計畫是可以接受的。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，並詳細的屬性規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材料特性每個測試樣本中使用的所有材料應當都符合最新修訂的材料規格的適用零件圖。1.任何工程的發展、原型或生產的零件可以提交測試。2.申請測試的樣本應由描述、部品件號和版本標識。3.測試時開始時，對驗證測試，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通常有殘餘模具潤滑劑。對測試樣品相同的條件必須是普遍的。4.申請任何測試的樣本須準備依附錄E。4.2VisualInspection4.2.1PurposeThistestisusedtodocumentthephysicalappearanceoftestsamplesandtoassistintheevaluationoftheeffectsofenvironmentalconditioningontestsamples.Acomparisoncanthenbemadewithothertestsamples.Examinationsinmostcasescanbeaccomplishedbyapersonwithnormalorcorrectedvision,andnormalcolorsensitivity,undercoolwhitefluorescentlighting.Photographsand/orvideosareencouragedasamorecompletemeansofdocumentation.Anappropriatelyidentifieduntestedsamplefromeachtestgroupmustberetainedforpost-testphysicalcomparisonsifphotographs/video’sarenottaken.4.2外觀檢查4.2.1目的此測試用於測試樣本的物理外觀的文件並且協助測試樣本對環境狀況影響的評價。然後可以與其他測試樣本進行比較。執行在大多數情況下可以通過正常或矯正目視，與正常顏色敏感的冷白色螢光燈下個別完成。照片和/或錄影促進更完整的文件。假如無照片/攝影提供，適時定義未經測試的樣本，從每個測試組必須保留後期測試的物理比較。4.2.2Samples1.Thesamplesshouldconformtotherequirementsofthespecifiedconditioningandanyadditionalmeasurementsthataretobeperformed.2.Forpurposesofcomparisonandespeciallywhenonlysubtleappearancechangesareanticipated,itisdesirabletosubmitanadditionalsampletoserveasacontrol.4.2.3EquipmentVideo/photographyequipment.4.2.2樣品

1.樣本應確認規格情況的要求和任何額外量測的執行。

2.為比較和特別的目的，預計只有當細微的外觀變化，最好是提交增加的樣本作為一個控制項。

4.2.3設備目視/攝影設備。4.2.4ProcedureVisuallyexamineeachtestspecimenpriortotestingand/orconditioning,notingindetailanymanufacturingormaterialdefectssuchascracks,bending,deformation,etc.Whenspecifiedinthetestrequest/order,takephotographsand/orvideorecordingsofrepresentativesamplestobetestedandkeepaproperlylabeledcontrolsample.

1.目視直接觀察每個試樣，在測試和/或環境之前，詳細指出諸如裂縫、彎曲、變形缺陷等任何製造或物料。當所述測試要求/命令採取照片或錄影的代表性樣本進行測試，並保持正確標記的控制項樣本。2.Aftertestingand/orconditioning,re-examineeachtestsampleandnoteindetailanyobservablechanges,suchasphysicaldistortions,cracks,etc.Comparethetestedand/orconditionedsamplestothecontrolsamples,thevideos,and/orthephotographs,recordinganydifferencesinthetestreport.TheAuthorizedPersonwillneedtoprovideanadditionalsampleforthispurpose.2.測試及或環境後，重新研究每個測試樣本和註記詳細任何外觀改變，如物理變形、裂縫等。比較測試和/或條件樣本控制項樣本，該攝影和/或照片，記錄任何差異在測試報告中。要為此目的有關的認可人士將需提供附加的樣本。3.Iftheterminalsupplier’sappearancerequirementsaremorestrictthanthosespecifiedbelow,thentheterminalsupplierspecificationsshouldbeapplied.4.Returntestsamplestorequestorafteralltestsarecompletedandallnecessarydatahavebeenobtained.3.如果端子供應商的外觀要求比下面規格更嚴格，該端子供應商規範是適用。4.在所有測試完成和所有必需的資料都已經獲得後，返回測試樣本對要求。4.2.5AcceptanceCriteriaGeneralAppearance–RefertoFigure4.2.5.Thecrimpingoperationshouldnotaffectthecontact,locking,connectormating,orinsertionfunctionsoftheterminal.ThesecharacteristicsareverifiedaspartofUSCAR-2testing.4.2.5驗收標準

1.一般外觀–請參閱圖4.2.5。壓接的操作不會影響接觸、鎖定、該插頭的配合或端子插入的功能。這些特性將驗證如USCAR-2測試。Figure4.2.5:AppearanceAcceptanceCriteria

外觀標準2.EndofconductorTheendofconductormustextendbeyondthefrontedgeoftheconductorcrimp.Theinsertionandlockingfunctionsoftheterminalmustnotbeaffectedbytheprojectingendoftheconductor.Matseals(plugthroughseals)mustnotbedamagedbythecore,andmayrequirecoredepressorsandstriplengthcontroltodepressthecoreinfrontofthecorewing.2.導體末端導體的末尾必須超過導線壓接的前緣。端子的插入和鎖定功能不會影響導體投影的末端。配合密封(密封件通過插頭）必須不會被核心損壞和可能需要核心壓著，並帶狀長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體壓接。4.Cut-offa.Thecut-offlengthshallnotexceed0.5mmunlessotherwisespecifiedonthecomponentprint.b.Theburronthecut-offmustnotexceed0.3mmunlessotherwisespecifiedonthecomponentprint.c.Thecut-offandburrmustnotaffecttheinsertionfunctionoftheterminalintotheconnector.4剪裁。a.剪裁長度不得超逾0.5mm，除非其它規格在元件列印上。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.導體壓接(d.)須有一個喇叭口(呈喇叭形展開)緊握最近的絕緣壓接側。

Theconductorcrimpmayalsohaveabellmouth(flare)onthefrontedgeoftheconductorcrimp,nearesttheterminalbody.導體壓接可能還有一個喇叭口(呈喇叭形展開)在導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)不應超過絕緣壓接公差。dTwoStageConductorCrimp(Flarenotrequiredonsecondstage)兩階段導體壓接(呈喇叭形展開不需要對第二階段)6.ConductorCrimpAllindividualstrandsmustbeenclosedinthecrimp.Crimpswithstrandslyingoutsidethecrimporbrokenoffbeforethecrimp,arenotpermitted.6.導體壓接所有個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體壓接所的應力。b.絕緣壓接必須與表面絕緣電纜接觸(三個點接觸)壓接觸沿圓周至少3區。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的操作。e.在絕緣壓接不得干擾端子塑膠插頭腔內的位置f.絕緣壓接必須不損壞電纜（請參閱第4.3.5-3）8.CableConductorAppearancepriortocrimpingStrandsshallnotbecut,missing,excessivelynicked(strandareareductionwhichmayaffectpull-outforce),orelongated.b.Insulationshallnotbestuckorimbeddedinstrands.8.電纜導體壓接前外觀

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

注意：此規範並不包括對任何密封滑動力由於大量變數的要求。有必要單獨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。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體壓接之間的區域必須是可見的。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試的部分。失敗到通過一個電氣試驗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樣本對每個壓接高度評價。資料須獲得並紀錄最小值、最大和公稱生產壓接高度。4.3.3設備對剖面分析的樣本，有各種專業的設備存在。設備的選擇由該的供應商，但應該有能力剖切端子和電纜線束最小擾動壓接部份。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樣本2.截面分析須執行在(公稱、最小和最大公差)所有導線壓接應用在每個壓接高度設置過程上。3.剖面須執行在鋸齒之間，盡可能靠近核心壓接的中點進行。4.將驗收標準第4.3.5段的驗收標準樣本進行比較。4.3.5AcceptanceCriteria驗收標準Acceptancecriteriaforthecross-sectionedsamplesaredescribedbelow.截面樣本為驗收標準的說明如下。Cross-sectionviewsofconductorcrimpConductorcrimpattributesconsideredideal1.截面的導體壓接的觀察被視為理想導體壓接屬性Symmetric對稱

Compactionofallstrands壓實的所有線束Wingstouchonlyconductor翼只接觸導體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

認為不當的導體壓接屬性Overlappingwings重疊的翼Extreme“ram-horning”

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