1、Electrical Connector Design CriteriaSAE/USCAR12$XJXVWISBN: 978-0-7680-_ The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United States Council for Automotive Research (USCAR) certi
2、fies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purpo
3、ses. Copyright 2017 USCAR Printed in U.S.A. All rights reserved. QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494 TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790 Notice about interim revisions: (GLWRULDOXSGDWHVRUFODULILFDWLRQVPDEHPDGHDVLQWHULPUHYLVLRQVLIWKH(: applica
4、ble performance specifications (USCAR-2, etc.) must still be performed. SAE/USCAR-12 REVISION 5 Issued 1999-09 Revised 2017-08 ELECTRICAL CONNECTOR DESIGN CRITERIA SAE/USCAR-12 REVISION 5 Revised 2017-08 ELECTRICAL CONNECTOR DESIGN CRITERIA -2- Items in this document are grouped by component as foll
5、ows: A. Terminals B. Secondary Terminal Locks C. Connectors D. Connector Locks E. Secondary Connector Locks (Connector Position Assurance, CPA) F. Connector Seals G. Serviceability H. +LJK9ROWDJH 9 $SSOLFDWLRQ5HTXLUHPHQWV I. Drawing and General Requirements 2. REFERENCES 1. SAE/USCAR-2 * Performance
6、 Specification for Automotive Electrical Connector Systems 2. SAE/USCAR-21 Performance Specification for Cable -to-Terminal Electrical Crimps 3. SAE/USCAR-25 Electrical Connector Assembly Ergonomic Design Criteria 4. SAE/USCAR-37 High Voltage Connector Performance Supplement to SAE/USCAR-2 5. USCAR/
7、EWCAP-001 Blade Chart (on USCAR/EWCAP website) 6. USCAR/EWCAP-002 1.5mm Female Cavity (on USCAR/EWCAP website) 7. USCAR/EWCAP-003 0.64mm Female Cavity (see USCAR/EWCAP website) 8. USCAR/EWCAP-004 Anti-Carbon Tracking Design Feature (see USCAR/EWCAP website) 9. USCAR/EWCAP-005 Connector Clip Slot (se
8、e USCAR/EWCAP website) 10. USCAR/EWCAP P105 Drawing Requirements (see USCAR/EWCAP website) * SAE/USCAR specs are available from SAE at http:/store.sae.org/ordering/ 3. USAGE USCAR-12 is a design requirement for new terminals and connectors. Compliance provides the following advantages: 1. Common con
9、nector terminal blade sizes 2. Common connector pitch (to facilitate similarity of USCAR footprints) 3. Common plating (to avoid material incompatibility or retesting) 4. Common blade travel (to assure complete mating) 5. Common terminology (naming parts, gender, additional parts, etc the same) 6. C
10、ommon terminal cavities (to allow for consistent harness assembly operations) 7. Common ergonomic features WRJHQHUDWHDFRPPRQORRNDQGIHHOEHWZHHQFRQQHFWRUV 8. Common retention (clip slot) features to allow for common clips 9. Common drawing layout (to facilitate interpretation of drawings) 10. Common e
11、rror-proofing methods (contrasting color, etc) to allow for common assembly processes 11. Common seal design requirements to (to allow for common seal suppliers) 12. For all new header connectors comply with the requirements specified in P105 Drawing Requirements. SAE/USCAR-12 REVISION 5 Revised 201
12、7-08 ELECTRICAL CONNECTOR DESIGN CRITERIA -3- 4. DESIGN REQUIREMENTS 4.1 TERMINALS # Requirement Criteria X T1 Design the male terminal per USCAR standards Confirm male blade designs are per EWCAP-001 (reference section item number 5). T2 Design female terminals to avoid snagging (or DVVHPEOHUVKDQGG
13、DPDJH at harness assembly plants a) Confirm no sharp projections on terminals. b) Confirm no protruding features. (Protected tangs, rounded shark fins, etc. are acceptable.) T3 Design the female terminal to protect the electrical contact using closed-box technology. Confirm full-metal closed box des
14、ign T4 Design for robust terminal retention: a) plastic lock fingers (preferred), or b) protected tangs Confirm use of robust plastic lock finger or protected tang. Check for OEM-specific requirements (tang may not be allowed). T5 Design female terminals with plated copper alloys. Disclose terminal
15、materials including temper on drawings supplied to end users for crimp analysis. Plating must be compatible with mating device platings per EWCAP-001. a) Confirm plating is compatible with EWCAP-001 drawing. b) Confirm thickness, method of plating, type of material are disclosed and documented on th
16、e part drawing. T6 Silver-plated terminals must have anti-tarnish protection. a) Confirm anti-tarnish material is utilized (ref. EWCAP-001 drawing). b) Confirm sulfur-free interleave paper is used for terminals and low sulfur packaging is specified. c) Drawing to specify, Black and gray tarnish on t
17、he silver surface is not recommended but may be accepteGEWKHFXVWRPHU T7 When a terminal is designed and released the supplier must provide necessary information needed to process or use the terminal. This information must be disclosed and readily available to the harness supplier Figure 1 Figuer 2 C
18、onfirm drawing or handling manual shows applicable information for terminals: a) Chart wire range and insulation diameter range b) USCAR-21 compliant crimp dimensions for all tested crimps applicable types and sizes either on the drawing or as a separate document. c) Additional Dimensional Informati
19、on: x Datum for measurement of crimp location and orientation as shown in Figure 1 and 2 x Crimp Offset if applicable (not shown) x Parallel or Angularity Tolerance (not shown) x If the design assumes coaxial features note it in the specification. SAE/USCAR-12 REVISION 5 Revised 2017-08 ELECTRICAL C
20、ONNECTOR DESIGN CRITERIA -4- 4.2 SECONDARY TERMINAL LOCKS # Requirement Criteria X STL1 All connector designs must include a secondary terminal lock. Known methods are: TPA, ISL, PLR A secondary lock must be used and must meet this criteria: Confirm the design includes a TPA PLR or ISL STL2 Secondar
21、y lock must be effective in meeting corresponding pull test values. Assure secondary lock is present. Verify design is mature carry-over or complete FEA or prototype test. Note: OEMs often have additional requirements for this category and design engineers are advised to recheck their statement of w
22、ork.) STL3 Make the secondary lock a contrasting color to the connector housing for separate piece designs. Confirm contrasting color. T8 Any outside surface or blade-contacting surface must be free of burrs. Confirm that the tooling simulation predicts no burrs. T9 Design the terminal to prevent mi
23、s-orientation into the connector housing. (Note: not all terminals require a polarization feature.) For designs that require polarization, design the terminal with an external terminal orientation feature which is visually obvious. a) Confirm orientation feature is visually obvious. b) Confirm an in
24、correctly oriented terminal inserted into the connector housing will have at least the terminal insulation grip fully protruding from the rear of the connector housing when fully pushed against orientation feature. c) If a mat seal with a rear cap is used, the terminal insulation grip must be visibl
25、e if orientation feature has stopped a terminal. T10 Terminal winding must be left-to-right payout. With crimp wings oriented up. Having a 86 2 Only for 1.0mm and smaller wire. 3 Only for 0.75mm and smaller wire. 4 Typically with blades facing each other SAE/USCAR-12 REVISION 5 Revised 2017-08 ELECT
26、RICAL CONNECTOR DESIGN CRITERIA -19- 5.4 REVISIONS Any revisions since that date have been incorporated into the specification. Revisions which altered the content of the specification are recorded below: REV DATE SECTION SUMMARY OF CHANGES MADE * NOTES 1 10/26/01 All See Appendix A of original docu
27、ment for specific changes 2 12/2001 All See Appendix A of original document for specific changes 3 05/2009 All See Appendix A of original document for specific changes 4 1/13/2016 All Re-write. Changed title from WIRING COMPONENT to ELECTRICAL CONNECTOR and changed *XLGHOLQHVWR&ULWHULD5HYLVLRQLVDFRP
28、SOHWHOQHZdocument. No part of the prior document can be used as evidence of compliance to Revision 4. 5 3/30/2017 Contents Add revision letter statement 3/30/2017 C1 Was inline connectors 3/30/2017 C2 Added colors reserved for specific applications. 3/30/2017 C13 and SE2 Added requirement Roughness Ra 0.4 Max. 3/30/2017 T7 Added c) Crimp Dimensions for Angularity and Parallelism 7/11/2017 C24 Added 050 exception for .07 engagement 7/11/2017 C25 Removed C25 5mm Linear distance requirement because it does not apply. 7/11/2017 CPA6 Removed 1mm requirement
