SAE J 2863-2016 Automotive Trailer Tow Connector.pdf

1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2863_201607 SURFACE VEHICLE STANDARD J2863 JUL2016 Issued 2010-04 Revised 2016-

5、07Superseding J2863 NOV2013 Automotive Trailer Tow Connector RATIONALE This SAE document is being modified to add a vibration setup to better simulate the actual application. 1. SCOPE This SAE Standard provides the minimum requirements for Automotive or RV, 7 Position, Self-Draining Trailer Tow Conn

6、ector Interface. The procedures included within this specification are intended to cover the test methods, design, and performance requirements, of the electrical interface of the 7 position trailer tow connector in low voltage (0 to 20) road vehicle applications. 2. REFERENCES 2.1 Applicable Docume

7、nts The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323

8、 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J1128 Low Voltage Primary Cable SAE J1944 Truck and Bus Multipurpose Vehicle Windshield Washer System SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems SAE INTERNATIONAL J2863 JUL2016 Page 2 o

9、f 36 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 117-94 Standard Method of Salt Spray (Fog) Testing ASTM G 153 Standard Practice for Operating Enclosed Carbon Arc Light Appa

10、ratus for Exposure of Nonmetallic Materials ASTM G 154 Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials 2.1.3 AIAG Publication Available from Automotive Industry Action Group, Box 77000, Detroit, MI 48277-0839, Tel: 248-358-3570, www.aiag.org. Meas

11、urement Systems Analysis Reference Manual 2.1.4 Connector Labeling Identification A connector and/or vehicle inlet manufactured to this Recommended Practice may optionally visibly display the following identification on its outer surface in Arial font: “SAE J2863”. Any party providing such identific

12、ation warrants that the connector and/ or vehicle inlet complies with all mandatory requirements of this Recommend Practice and agrees to indemnify and hold SAE harmless from any and all liability arising out of any failure to comply and any resulting injury or damage arising from such failure.” 3.

13、DEFINITIONS 3.1 ACCEPTANCE CRITERIA Generally, the final section in each test description. It specifies the requirements that all test samples must meet during or at the conclusion of that test. 3.2 AIAG Automotive Industry Action Group 3.3 AUTHORIZED PERSON One person will be responsible as the fin

14、al authority for releasing a given part for production and/or for testing that part. Such person may delegate authority for testing that part, or may retain the authority. The Authorized Person, as used in the Specification, is the person with authority for making the final decision as to any questi

15、on arising during testing to this Specification or for any deviations from any requirement of this Specification. Such Authorized Person is responsible for documenting any deviation he/she authorizes from this Specification. This documentation must be included in the final test report. 3.4 BENCHMARK

16、 Performance measurements of a specific design which serve as a standard by which the performance of other connector systems and terminals can be compared. SAE INTERNATIONAL J2863 JUL2016 Page 3 of 36 3.5 BULK RESISTANCE That part of total connection resistance attributed to the terminal body. Bulk

17、resistance does not include crimp resistance or interface resistance. 3.6 CT Continuity Tester. A made-up test device composed of a data analyzer and a continuity monitor. 3.7 CUT Component Under Test 3.8 CRITICAL DIMENSION Any dimension noted on the part drawing or otherwise specified that can adve

18、rsely affect the performance or function of the part or assembly if it exceeds the applicable tolerance. 3.9 CROSS AXIS RESONANCE Resonance measured on a vibration set up at right angles to the intentionally induced axis of motion. Example: X or Y measured resonance when shaker is operating in the Z

19、 axis. 3.10 DEVICE CONNECTOR An electrical connector that mates with the electrical interface of a device (e.g., headlamp, switch, horn, etc.). 3.11 DIRECT CONNECT TYPE CONNECTION A connector that is fixed to a module or panel that a plug or wired connector is mated with.to provide an electrical int

20、erface. Typically, direct connect type connectors will contain the male terminals. 3.12 DMM Digital Multimeter 3.13 DUE CARE The proper use of sound engineering judgment to assure a part is fit for its intended use and meets all applicable FMVSS requirements. The assurance that design specifications

21、 and test plans satisfy all applicable FMVSS requirements. Use of sound, accepted engineering and laboratory practice to safeguard the integrity of all data and to ensure that no degradation of any sample occurs in any fashion except as specified in actual testing. 3.14 ENGAGING FORCE The force requ

22、ired to mate a separate pair of contacts (terminals) or a contact and mating test gage. 3.15 EXTRACTION FORCE The force required to completely remove an individual contact (terminal) from its cavity in a connector. 3.16 FEMALE CONNECTOR The connector that houses the Female Terminal(s). SAE INTERNATI

23、ONAL J2863 JUL2016 Page 4 of 36 3.17 FEMALE TERMINAL The electrical receptacle that receives the male blade or pin. 3.18 FMVSS Federal Motor Vehicle Safety Standard 3.19 FS Full Scale 3.20 GD one with the associated Wedge (TPA, PLK, etc.) installed and a second value without such assistance. 3.31 RH

24、 Relative Humidity 3.32 ROA Rise over ambient (temperature) 3.33 ROOM TEMPERATURE 23 C 5 C 3.34 SEPARATING FORCE The force required to disengage a mated pair of contacts (terminals) or a contact and a mating test gage. 3.35 SIGNAL CIRCUIT Any electrical circuit expected to carry 5 A or less at all t

25、imes. 3.36 SOAK Refers to a time period during which the device under test is exposed to stated environmental conditions, such as temperature, humidity, current flow, etc. This exposure may be for the purpose of conditioning the sample prior to another test, or may itself form part of a given test.

26、3.37 SPRUNG (Adj.) Describes any portion or component of a motor vehicle that is supported by the suspension system. Sprung components do not include tires, wheels, hubs, or outboard disc. or drum brake assemblies. 3.38 STEADY STATE A condition of environment or current flow that remains stable for

27、1 min or more. 3.39 TOTAL CONNECTION RESISTANCE Electrical resistance of one terminal to terminal interface plus the resistance of the conductor to terminal grip for each terminal. For Direct connect type connections, only the resistance of the one conductor to terminal grip is included. Included is

28、 the “bulk resistance of the terminal material itself. 3.40 TUT Terminal Under Test SAE INTERNATIONAL J2863 JUL2016 Page 6 of 36 3.41 UNMATING FORCE The force required to un-mate male and Female Connector halves or a connector from a Direct connect or panel mount connector or receptacle. 3.42 UN-SPR

29、UNG Describes any component of a motor vehicle that is not supported by the suspension system. 3.43 USCAR United States Council for Automotive Research. A consortium of representatives from Ford, General Motors and Chrysler to promote joint research in noncompetitive areas that can strengthen the U.

30、S. automotive industry. 3.44 VOLTAGE DROP (VD) The difference in potential between two points in an electrical circuit caused by resistance at nominal current. Voltage drop may be used to calculate resistance when the current value is known. 4. GENERAL REQUIREMENT 4.1 Sample Size Minimum sample size

31、s are given for each test in this specification. A greater number of samples maybe 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 applic

32、able 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 specification has been met. 4.2 Default Test Tolerances Default tolerances, expressed as a percentage of the nominal value

33、unless otherwise indicated: Temperature = 3 C Voltage = 5% Current = 5% Resistance = 5% Length = 5% Time = 5% Force = 5% Frequency = 5% Flow Rate = 5% Relative Humidity = 5% (when controlled) Speed = 5% Sound = 5% Pressure = 5% Vacuum = 5% 4.2.1 Test Default Conditions When specific test conditions

34、are not given either in the product design specification, the test Request/order or elsewhere in this specification, the following basic conditions shall apply: Room Temperature = 23 C 5 C Relative Humidity = Ambient (uncontrolled as in lab ambient conditions) SAE INTERNATIONAL J2863 JUL2016 Page 7

35、of 36 4.3 Equipment Neither this list nor the list in each test section is 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. NOTE: On requirements: Use

36、 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 of

37、0 to 100 V could be substituted for one specified as 0 to 50 V, with the provision that the accuracy could be maintained as r0.5% of the 50 V full scale, or 0.25 V, not 0.5% of the 100 V full scale of the substituted equipment. Table 1 - Equipment Item Description Requirements 1 DC Power Supply (Reg

38、ulated) 0-20 V Current as necessary 3 Digital Multimeter (DMM) &DSDEOHRIPHDVXULQJWKHIROORZLQJDWDQDFFXUDFRI of full scale: 0-50 V DC 0-10 M: 4 Current Shunts As required with accuracy of 1% of nominal 5 Millivolt Meter Capable of measuring 0-100 mVDC at 0.5% full scale 6 7 Insertion/Extraction Force

39、Tester Capable of 1.0% accuracy, full scale 8 Data Logger As Required 9 Temperature Chamber -40 to +85 C 0 to 95% RH 10 Vibration Controller As Required 11 Vibration Table 2640 N (600 lbs.) Sine Force 2200 N (500 lbs.) RMS Force 13 Megohmeter Accuracy 5% of full scale 4.4 Measurement Resolution Unle

40、ss 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 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,

41、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. 4.5 Test Repeatability and Calibration All equipment used for test sample evaluation shall be calibrated and maintained according to the appl

42、icable standards and requirements set forth by ISO TS16949 and the AIAG publication Measurement Systems Analysis Reference Manual. Copies of this Manual can be obtained from the AIAG. Go to www.aiag.org for further information. 4.6 Conformance Determination Conformance shall be determined by the spe

43、cified requirements of the test being conducted. All samples must satisfy the requirements regardless of sample age, test cycles, or test temperature, except where a test to failure is specified. SAE INTERNATIONAL J2863 JUL2016 Page 8 of 36 4.7 Part Endurance Successful completion of all requirement

44、s of this specification is intended to demonstrate that the design and construction of the components and connector systems tested are capable of operating in their intended vehicle environment and application. 5. TEST AND ACCEPTANCE REQUIREMENTS 5.1 General The tests detailed in this specification

45、are qualitative in nature and are not expected to stress any part beyond its anticipated application limit, except where tests to failure are specified. The test procedures that follow were written as stand-alone tests and may be used as such. 5.1.1 Performance Requirements Trailer tow connection sy

46、stems must meet all performance test requirements. 5.1.2 Dimensional Characteristics Part construction shall conform to the dimensions, shape, and detail attributes specified on the latest revision of the applicable part drawing(s). 5.1.3 Material Characteristics Parts are intended to be in their “a

47、s furnished for vehicle assembly“ condition when testing begins, unless specific instructions as to any pre-test “conditioning“ are contained in the test request/order. For example, electrical terminals typically have residual die lubricant on them when finally assembled into a vehicle. This same co

48、ndition must prevail for test samples unless part cleaning is specified in the Test Request/Order. All material used in each test sample shall conform to the material specifications shown on the latest revision of the applicable part drawing(s). The material hardness specified for electrical termina

49、ls refers to the blank strip material and not the finished product because the terminal manufacturing process can modify the hardness values. 5.1.4 Temperature, Sealing, and Vibration 5.1.4.1 Temperature Performance Requirements The trailer tow interface is intended to operate in -40 to +85 C environmental conditions