SAE J 3008-2017 Sealed Trailer Tow Connector.pdf

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4、0 (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:/standards.sae.org/J3008_201705 SURFACE VEHICLE STANDARD J3008 MAY2017 Issued 2017-05 Sealed Trailer Tow Connector

5、 RATIONALE To provide an auxiliary interface for future needs offering additional optional functionality between a (towed trailer and light truck or other vehicle), as to improve the towing experience. 1. SCOPE This SAE Standard provides the auxiliary requirements for automotive or RV, additional 12

6、 position, sealed Trailer Tow Connector Plug and Receptacle. The information included within this specification is intended to cover the test methods, design, and performance requirements of optional features for additional power, clean ground for electronic functions, video, data communication, and

7、 supplementary electric brake control. 2. REFERENCES 2.1 Applicable Documents The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, P

8、A 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE/USCAR-2 Performance Standard for Automotive Electrical Connection Systems SAE/USCAR-21 Performance Specification for Cable-to-Terminal Electrical Crimps SAE J1939-1 On-Highway Equipment Control

9、 and Communication Network SAE J1939DA Digital Annex 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 B117-94 Standard Method of Salt Spray (Fog) Testing ASTM G154 Standard Practic

10、e for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials SAE INTERNATIONAL J3008 MAY2017 Page 2 of 17 2.1.3 AIAG Publication Available from Automotive Industry Action Group, Box 77000, Detroit, MI 48277-0839, Tel: 248-358-3570, www.aiag.org. Measurement Systems Analysis R

11、eference Manual 3. 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 res

12、ponsible as the final 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 decisi

13、on as to any question 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 re

14、port. 3.4 BENCHMARK Performance measurements of a specific design which serve as a standard by which the performance of other connector systems and terminals can be compared. 3.5 BULK RESISTANCE That part of total connection resistance attributed to the terminal body. Bulk resistance does not includ

15、e 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 adversely affect the perform

16、ance 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 axis. 3.10 DEVICE CONNE

17、CTOR An electrical connector that mates with the electrical interface of a device (e.g., headlamp, switch, horn, etc.). SAE INTERNATIONAL J3008 MAY2017 Page 3 of 17 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 prov

18、ide an electrical interface. Typically direct connect type connectors will contain the male terminals. Syn: Panel mount. 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. T

19、he intent is to assure that design specifications 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 a

20、ctual testing. 3.14 ENGAGING FORCE The force required 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

21、that houses the female terminal(s). 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

22、.31 RH 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

23、 at all times. SAE INTERNATIONAL J3008 MAY2017 Page 5 of 17 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 a

24、nother test, or may itself form part of a given test. 3.37 SPRUNG 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 enviro

25、nment or current flow that remains stable for 1 minute 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 co

26、nductor to terminal grip is included. Included is the “bulk resistance of the terminal material itself. 3.40 TUT Terminal Under Test. 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 U

27、N-SPRUNG Describes any component of a motor vehicle that is not supported by the suspension system (see Sprung). 3.43 USCAR United States Council for Automotive Research LLC. A consortium of representatives from Ford, General Motors, and Chrysler to promote joint research in noncompetitive areas tha

28、t can strengthen the U.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 REQUIREMENTS General req

29、uirements of this specification follow the requirements specified in SAE/USCAR-2, Section 4. 5. TEST AND ACCEPTANCE REQUIREMENTS 5.1 Test Sequence Tests sequences 5.2.3, 5.2.4, 5.2.5, and 5.2.6 must be run and meet the acceptance criteria for a connector to pass SAE J3008. Run tests per the test seq

30、uences of 5.2.3. When tests reference SAE/USCAR-2, use the current revision level and test in accordance with Temperature Class 2, Vibration Level 1, and Sealing Class 3 or as defined by test requestor. SAE INTERNATIONAL J3008 MAY2017 Page 6 of 17 5.2 Test Requirement Structure 5.2.1 Global Variance

31、s to SAE/USCAR-2 Tests SAE/USCAR-2 is the basis for this test specification. However, there are some differences that apply. The list below identifies the differences that apply in every case a test is applied. These exceptions apply due to the specific needs of the 12-way trailer tow connector. 1.

32、Connector mate and unmate cycling shall be 2000 durability cycles rather than 10 cycles called out in SAE/USCAR-2 wherever SAE/USCAR-2, Section 5.1.7 conditioning is called out. This is to match the expected life use of 2000 mate/unmate cycles. 2. When a resistance or voltage drop criteria is made,

33、use the values for 2.8 mm blade as the acceptance criteria. This is needed since round pins are used in the SAE J3008 design, but only flat blades are identified in the SAE/USCAR-2 specification. 2.8 mm was selected since the surface area of the 1.5 mm round pin is very close in size to the 2.8 x 0.

34、8 mm flat blade. 4. The wire size to be used for electrical testing shall be 1.5 mm2. 5. Current rating 12 shall be amperes minimum (to align with promise of availability of at least 12 A to trailer-side electrical loads). 6. Sealing effectiveness: Sealing tests are to be performed in both the mated

35、 and unmated conditions. This is a unique configuration where the connector is moved while not in use and the holder must be evaluated. 5.2.2 Test Table Table 1 lists the tests called-out in this specification. Test paths with a letter designation are from SAE/USCAR-2. When exceptions from the SAE/U

36、SCAR-2 method are listed in the far right column, they apply as a mandatory change from the published SAE/USCAR-2 test. SAE INTERNATIONAL J3008 MAY2017 Page 7 of 17 Table 1 - Test listing and exceptions from SAE/USCAR-2 method Test Path Test Name Exceptions from SAE/USCAR-2 method that apply to SAE

37、J3008 A Term. - Term. Engage/Disengage Force Optional; since design has discrete terminals, this test is possible but not useful. Perform for info only. B Terminal Bend Resistance Optional; since design has large round terminals bend resistance is not a concern. Perform for info only. C Current Cycl

38、ing Current rating must 15 A. (Since spec says 12 A load on trailer is assured. 15 A rating is prior to 20% terminal current de-rating. D Term. - Conn. Insertion/Retention No changes to SAE/USCAR-2 as-written. E Misc. Component Engage No changes to SAE/USCAR-2 as-written. However, no misc. component

39、s are expected. F Audible Click Not applicable. Do not test. G Conn. Conn Mating/Un-mating No changes to SAE/USCAR-2 as-written. H Polarization Effectiveness Applicable since there are 2 keys. No changes to SAE/USCAR-2 as-written. I Drop No changes to SAE/USCAR-2 as-written. J Cavity Damage No chang

40、es to SAE/USCAR-2 as-written. Does not apply to overmolded connectors. K Header Pin Retention Modify SAE/USCAR-2, Section 5.7.1 with receptacle terminals pushed at a force of 175 N for 1 minute duration. L Mounting Feature Strength Typically not applicable. User and customer may request based on nee

41、d on a connector-specific concern. M Vibration/Mechanical Shock Test to Body profile (V1). Set-up per 5.2.8. N Thermal Shock Done in combined sequence, RSAA. For reference only. O Temp/Humidity Done in combined sequence, RSAA. For reference only. P High Temp Exposure Apply 2000 instead of 10 durabil

42、ity cycles. Q Fluid Resistance Exposure to fluids may be performed using surrogate parts. R Temp/Humidity-Submersion Done in combined sequence RSAA. S Temp/Humidity-PV Leak Done in combined sequence RSAA. RSAA Temp/Humidity-PV Leak, Submersion, HP Spray Perform SAE/USCAR-2 but cycle connectors 2000X

43、 instead of 10 times. Check that door fully closes at end of test. T High Temp Exposure/Submersion Done in combined sequence, TUAB. U High Temp - P/V Leak Done in combined sequence, TUAB. TUAB High Temp. Exposure - PV Leak, Submersion, HP Spray No changes to SAE/USCAR-2 but cycle connectors 2000X in

44、stead of 10 times. X Mechanical Assist Integrity Typically will not be applicable. Perform only if mechanical assist function is present. Y Connector Seal Retention- No changes to SAE/USCAR-2 as-written. Z Connector Seal Retention - Mated Connector No changes to SAE/USCAR-2 as-written. AA Temp/Humid

45、ity - High Pressure Spray Done in combined sequence, RSAA. AB High Temp Exposure - High Pressure Spray Done in combined sequence, TUAB. SAE J3008-1 Salt Fog Test (this is a test of the door spring only) Expose connector to 96 hours per ASTM B117. Test in BOTH mated and not mated conditions. Criteria

46、: Spring needs to function and no evidence of corrosion is on spring. SAE J3008-2 Ultraviolet (UV) Resistance Expose connector per ASTM G154. Test is optional with user-defined criteria. SAE J3008-3 Sealing of receptacle connector “A” to “B” path (by pressurizing side “A” and looking for leaks on si

47、de “B”) Use samples from completed RSAA sequence. Apply SAE/USCAR-2, Section 5.6.6.3 test with cover open and side “A” pressurized to 28 kPa (4 psig). Criteria are per SAE/USCAR-2, Section 5.6.6.4. If new parts are used, apply 48 kPa (7 psig) in 5.6.6.3 Step 7. SAE INTERNATIONAL J3008 MAY2017 Page 8

48、 of 17 5.2.3 Test Sequence - Performance Perform all 12 test procedures listed in Table 2 (A, B, C, D, E, G, H, I, J, K, Y, Z) using the cables and sample sizes called out. Note that Paths A, B, E, H, and J may not apply or be required. Test numbers refer to SAE/USCAR-2. Refer to Table 1 for test li

49、stings and exceptions from SAE/USCAR-2 method. Table 2 - Test sequence - performance Test Name Term.- Term.Engage/DisengageForce(Optional) Terminal BendResistance (Optional)MaximumCurrent/Current CyclingTerm.- Conn. Insertion/RetentionMisc. Component Engage/Disengage Conn. ConnMating/Un-matingPolarization EffectivenessDropCavityDamage- (Does not apply toovermold designs) Header PinRetentionConn. Seal Retention- Unmated Connector