USCAR21(端子压接的性能规范)

PERFORMANCESPECIFICATIONFORCABLE-TO-TERMINALELECTRICALCRIMP端子压接的性能规范1.SCOPE范围IMPORTANTNOTICE:Inanyintendedvehicleapplication,iftheproductscoveredbythisspecificationare,ormaybe,subjectedtoconditionsbeyondthosedescribedinthisdocument,Theymustpassspecialtestssimulatingtheactualconditionstobeencounteredbeforetheycanbeconsideredacceptableforactualvehicleapplication.Productscertifiedbytheirsupplierashavingpassedspecificapplicableportionsofthisspecificationarenottobeusedinapplicationswhereconditionsmayexceedthoseforwhichtheproducthasbeensatisfactorilytested.TheAuthorizedPersonisthefinalauthorityastowhattestsaretobeperformedonhisorherpartsandforwhatpurposethesetestsarerequired.Heorsheisalsothefinalauthorityforresolvinganyquestionsrelatedtotestingtothisspecificationandtoauthorizinganydeviationstotheequipmentorprocedurescontainedinthisspecification.Anysuchdeviationmustbedocumentedandincludedinthefinaltestreport.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。权威人士是昀终有权指出他或她的产品需要做哪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，他或她仍然是有昀终决定权的人。试验中出现的任何不符合性都必须作记录，并记录在昀终试验报告中。1.Thisspecificationdefinesbasictestmethodsandrequirementsforsolder-lesscrimpedconnections.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.CrimpapplicationsvalidatedtothisspecificationsupercedeanycrimpinformationonFord,GM,orDaimlerChryslercomponentprints.Itispreferredthattheterminalsupplierdotestingandselectionofcrimptoolingandsupplydetailedcrimpinformationormakecrimptoolingavailabletothewiringassemblysupplieractuallydoingtheproductioncrimping.Ifthewiringsupplierdeviatesfromthisinformationoritisnotavailable,thentheresponsibilityfortestingtothisspecificationorgettingapprovalfromthecustomerwithappropriatetestdatashowingthatthecrimpwillfunctioninit’sintendedcircuitlieswiththewiringharnesssupplier.2.该生效的压接规范代替了Ford,GM,orDaimlerChrysler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.Neworrevisedterminalsshallbedesignedtomeetthisspecification.3.新设计或修改的端子设计需要符合该规范。4.Allnewcrimpapplicationsshallmeetthisspecification.Newcrimpapplicationsaredefinedasterminal/wirecrimpcombinationsnotpreviouslyspecifiedonFord,GM,orDaimlerChryslervehiclewiringharnessassemblies.Existingcrimpapplicationsmaybecarriedoverifapprovedbythecustomerengineeringdepartment.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.ElectricaltestsinthisspecificationhavebeenprovenbypastexperiencetoensurethatcrimpswillmeettherequirementsinSAE/USCAR-2andSAE/USCAR-20byincludingThermalShock,TemperatureHumidity,andPowerCurrentCycling.Testingandelectricalacceptancecriteriawilldetectdefectsincrimptoolinggeometry,platingquality,inadequatestranddistributioninthegrip,orcablestranding.CrimpapplicationsthathavepassedSAE/USCAR-2andSAE/USCAR-20normallyhaveonlypassedthenominalcrimpheightandusuallyonlywiththelargestgaugesize.Therefore,crimpswithintheproductioncrimpheightrangemaynotnecessarilypassthistest.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。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昀大线规压接。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.Proceduresincludedwithinthisspecificationareintendedtocoverperformancetestingatdevelopmentofelectricalterminalcrimpsthatarepartoftheelectricalconnectionsystemsinlowvoltage(0-48VDC)roadvehicleapplicationsatambienttemperaturesof125C　maximum.TheOEMcustomermustapproveuseofthesetestproceduresforuseatvoltagesandtemperaturesbeyondtheselimits.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0-48VDC，昀高环境温度是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验程序，需得到OEM顾客的批准。7.Theseproceduresareapplicableonlytoterminalsusedforin-line,header,edgeboard,anddeviceconnectorsystems.7.该程序只是适用于以下应用情况中的端子：in-line,header,edgeboard,anddeviceconnectorsystems.1.1CrimpingParameters1.1压接参数1.1.1TheCrimpconnectionperformanceischaracterizedby:MechanicalperformanceismeasuredbyterminaltoconductorPull-OutForce.Electricalperformanceismeasuredbyterminal-to-conductorCrimpResistance.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。1.1.2Thegeometryofaconductorcrimpischaracterizedby:Conductorcrimpheight(CCH)Conductorcrimpwidth(CCW)Insulationcrimpheight(ICH)Insulationcrimpwidth(ICW)Cut-offEndofconductorEndofinsulationBellmouth(flare)Burr(anvilflash)dimensiononthebaseoftheconductorcrimpStepbetweenthecoreandinsulationtoolsCrimptoolinggeometry1.1.2压接的几何尺寸由以下方法判断：导体压接高度(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.REFERENCEDDOCUMENTS2.参考文件2.1DocumentHierarchyIntheeventthereisaconflictbetweenperformancestandards,partdrawings,andotherrelatedstandardsorspecifications,therequirementsshallbeprioritizedasfollows:1st-ApplicableFMVSSrequirementsandotherapplicablestateandFederalrequirements.2nd-Applicablepartdrawings3rd-Applicableproductdesignspecification(s).4th