1、Specification for Testing AutomotiveLight Bulb Sockets SAE/USCAR-15 Revision 3 February 2010ISBN: 978-0-7680-3394-6 _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
2、Council for Automotive Research (USCAR) certifies 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 wh
3、ether or not it is applicable for their purposes.Copyright 2010 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 SAE/USCAR-15 REVISION 3 Issued 2004-01 Revised 2010-02 SPECIF
4、ICATION FOR TESTING AUTOMOTIVE LIGHT BULB SOCKETS SUMMARY OF CONTENTS 1. SCOPE 32. REFERENCE STANDARDS . 33. GENERAL REQUIREMENTS . 33.1 Record Retention 33.2 Sample Documentations and Retention . 43.3 Physical Characteristics 43.4 Power Sources 53.5 Equipment Tolerances 53.6 Measurement Accuracy 53
5、.7 Test Repeatability and Calibration 63.8 Test Default Conditions . 63.9 Test Sharing Within Socket Families 73.10 Test Failure Procedure . 73.11 Control Plans . 73.12 Reliability Programs and Methods 73.13 Hazardous Material Restriction . 73.14 Test and Acceptance Requirements . 84. ELECTRICAL PER
6、FORMANCE . 84.1 Voltage Drop . 84.2 Isolation Resistance 104.3 Temperature Rise . 104.4 1008 Hour Current Cycle 115. MECHANICAL PERFORMANCE . 115.1 Bulb Insertion/Removal Force . 115.2 Socket Insertion/Removal Torque/Force 145.3 Connector Insertion/Removal Force . 155.4 Bulb Wobble 155.5 Socket Stre
7、ngth . 155.6 Terminal Retention 165.7 System Seal Integrity 165.8 Wire to Terminal Crimp . 185.9 Vibration 185.10 Mechanical Shock . 20SAE/USCAR-15 REVISION 3 Revised 2010-02 SPECIFICATION FOR TESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 2 - 6. ENVIRONMENTAL PERFORMANCE 216.1 Thermal Shock 216.2 Power Tem
8、perature Cycling . 216.3 High Temperature Exposure . 236.4 Fluid Resistance 236.5 Outgassing 246.6 Ozone Resistance . 256.7 Salt Spray 256.8 Temperature/Humidity Cycling 26APPENDIX A ABBREVIATIONS . 27APPENDIX B GLOSSARY 28APPENDIX C DESIGN GUIDELINES . 29APPENDIX D FIGURES 30APPENDIX E FLOWCHART .
9、43APPENDIX F ANNUAL TEST SEQUENCE 44APPENDIX G FLUID SOURCES . 45APPENDIX H SUPPLIER CONTACT INFORMATION . 46APPENDIX J REVISIONS . 47SAE/USCAR-15 REVISION 3 Revised 2010-02 SPECIFICATION FOR TESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 3 - 1. SCOPE This specification establishes the requirements and test
10、 procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire wedge base sockets, circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs
11、: New design Design, material or process change made to an existing device, which could affect the outcome of the test. The test sequence shown in Appendix F shall be run annually.(NOTE: Production process control data collected at a shorter interval per an approved control plan, may be substituted
12、if approved by customers responsible engineer and purchasing representative.)2. REFERENCE STANDARDS AIAG/APQP-2: Chrysler, Ford, and General Motors Advanced Product Quality Planning and Control Plan Reference Manual AIAG/MSA-3: Measurement Systems Analysis Reference Manual AIAG/FMEA-3: Potential Fai
13、lure Mode and Effects Analysis Reference Manual (SAE J1739) AIAG/PPAP-3: Chrysler, Ford, and General Motors Production Part Approval Process Manual ASTM B 117: (Standard Practice for Operating Salt Spray Fog Testing Apparatus) Chrysler, Ford, and General Motors Quality System RequirementsQS-9000 Man
14、ual SAE/USCAR-2: Performance Specification For Automotive Electrical Connector Systems SAE/USCAR-3: Specification for Testing Automotive Miniature Bulbs SAE/USCAR-12: Wiring Component Design Guidelines SAE/USCAR-21: Performance Specification For Cable-to-Terminal Electrical Crimps AIAG Fundamental S
15、tatistical Process Control Reference Manual SAE J573: Miniature Lamp Bulbs IEC 60061-1: Lamp Caps IEC 60068-2-14: Nb Basic Environmental Testing Procedure EEC R37 SAE J1330: Photometry Laboratory Accuracy Guidelines Q7-K: Chrysler, Ford Motor Company and General Motors QS-9000 Supplier Quality Requi
16、rements *Copies of the AIAG Manuals can be obtained from AIAG (Automotive Industry Action Group) by calling (248) 358-3570 or by writing to AIAG, Dept. 77839, Post Office Box 77000, Detroit, MI 48277-0839, Attn: Customer Service. Unless otherwise specified or required by law, suppliers shall use the
17、 most recent versions of any applicable reference documents or standards. Revisions to these reference standards that drive design or process changes to existing products shall be reviewed for exemption with OEM on an individual basis. 3. GENERAL REQUIREMENTS 3.1 Record Retention Supplier must maint
18、ain a file for the storage of laboratory reports and calibration records, and establish a Record Retention policy per QS9000 concerning these records. These records need not follow a standard format but must present the required data in an orderly professional manner. The file must be made available
19、 to any and all customer personnel upon request, including - but not limited to representatives from the following functions: product engineering, purchasing, quality, and reliability. SAE/USCAR-15 REVISION 3 Revised 2010-02 SPECIFICATION FOR TESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 4 - 3.1.1 Objectiv
20、es of Record Retention The following are the main objectives for retention of test documents or records: Retain records that will evidence compliance so that the supplier can appropriately respond when or if product compliance is challenged. Files must exist for the storage of all laboratory records
21、, data, and calibration records. The files must be available at any time for audit or inspection. Retain records as needed to assist in evidencing the exercise of “due care” in matters relating to product compliance, government requirements, or product liability. Comply with statutory requirements f
22、or the maintenance and retention of specific records. 3.1.2 Retention Methods Methods of retention may include retention of original documents, the use of film, or electronic storage equipment. Store records so that they are accessible in a reasonable amount of time. Storage areas should provide ade
23、quate protection from unauthorized access, moisture, and fire. 3.2 Sample Documentations and Retention Bulbs must be identified by ANSI Trade Number and manufacturer. Sockets must be identified by manufacturer part number. Documentation must identify the type of test performed and describe special t
24、ests that are not a part of this specification.3.2.1 Required Data Package Supplier must submit the data package for the appropriate level of submission to the customers responsible engineer and purchasing division for approval signatures. 3.2.2 Sample Selection Socket assemblies referenced in this
25、specification are to be selected from the same “Test Lot“. The minimum “Test Lot” is defined as a minimum of one hour of production. Test sockets are to be subjected to production intent processing, including final packaging. For example: A test sample size of 10 would consist of one sample piece be
26、ing removed from the test lot, at equal intervals during the production run. It is important that the test samples are identified as to location, within the test lot, throughout all testing.3.2.3 Sample Retention Samples tested to attain part approval must be retained by the socket manufacturer for
27、a period of time specified in the AIAG/PPAP-3: Chrysler, Ford, and General Motors Production Part Approval Process Manual. 3.3 Physical Characteristics Socket identification, markings, absence of any required feature, or any other evidence of nonconformance with the drawing or applicable product des
28、ign specification shall be cause for rejection. Parts shall not exhibit defects or damage resulting from manufacturing, handling, in process testing, or shipping that might impair the performance of the socket. “Flash” shall not exceed 0.20 mm unless otherwise noted. SAE/USCAR-15 REVISION 3 Revised
29、2010-02 SPECIFICATION FOR TESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 5 - 3.3.1 Dimensional Characteristics Part construction shall conform to the dimensions, shape, and detail attributes specified on the latest revision of the applicable part drawing(s). 3.3.2 Material Characteristics All material used
30、in each test sample shall conform to the material standards specified on the latest revision of the applicable part drawing(s). 3.4 Power Sources Supplier must use voltage regulated direct current (DC) Power Sources for all tests to simulate an automotive battery and charging system. 3.4.1 Output Cu
31、rrent The power source must be capable of supplying a continuous output current as required by the design loads, including inrush current. Where required to simulate automotive inrush current conditions, an automotive battery or batteries with sufficient Cold cranking amps may be connected in parall
32、el with the power supply. 3.4.2 Output Voltage The power source must be capable of supplying an output voltage that must not deviate more than 1.0 volt from the nominal setting over the entire load range (including surges). The power source must recover 63% of its maximum excursion within 5.0 millis
33、econds. Ripple voltage must not exceed 300 mV peak to peak.Power supplies used for photometric measurements must conform to SAE J1330. 3.5 Equipment Tolerances Supplier must use test setups and equipment capable of measuring test parameters (expressed in nominals) within the limits found in the Equi
34、pment Tolerances Table. Equipment Tolerances Table Test Chamber Temperature nominal 3CTime nominal 0.5% Forces nominal 0.01 N Distances nominal 0.01 mm Voltages nominal 0.01 V for photometrics nominal 0.1 V for all other tests Mean Spherical Candela nominal 2.0% NOTE: Not to be used for performance
35、dependent variable; see section: Measurement Accuracy. 3.6 Measurement Accuracy Meters and gauges used to assess the performance dependent variable, as defined by the basic function of the test sample, must have a smallest unit of measure one order of magnitude less than the least significant digit
36、specified. For example, even though a 0.6 mm and 0.60 mm wire might be the same diameter, calipers capable of 0.01 mm resolution may be used to measure the first wire, but a micrometer with 0.001 mm resolution is needed for the second wire. SAE/USCAR-15 REVISION 3 Revised 2010-02 SPECIFICATION FOR T
37、ESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 6 - 3.7 Test Repeatability and Calibration 3.7.1 Equipment Repeatability All measurement equipment used for product evaluation must be repeatable to within 10% of the part tolerance according to Chrysler, Ford, and General Motors AIAG publications Measurement Sy
38、stems Analysis Reference Manual and Fundamental Statistical Process Control Reference Manual.3.7.2 Equipment Calibration Equipment re-calibration/re-certification timing shall be calculated based on the capability of any individual instrument to retain its “Manufacture Stated Accuracy“ between recal
39、l periods. However, test equipment must be calibrated within one-year prior to test.3.8 Test Default Conditions When specific test conditions are not given, the following conditions apply: 3.8.1 Environmental Room temperature = 23 5C Relative Humidity = Ambient 3.8.2 Wires for Test 20-gauge wire 3.8
40、.3 Test Voltage/Current Voltage = 14.0 V dc + 0.1/ - 0.0 V dc Current = Socket classification table Socket Classification Table SOCKETCLASSIFICATIONUSED WITH BULB TYPE VOLTAGE TEST DEVICE TEST CURRENT (amps) 1% MAJOR MINOR I S8 Wedge/GT8 Shorted S8/GT8 2.4 0.6 II T3 this information will be used by
41、lamp designers when specifying bulb/socket combinations. 1. The maximum allowable insertion force is 75.0 N (16.8 lbs) for S8/GT8 and 45.0 N 10.0 lbs. for W-2 2. The maximum removal force is 65.0 N (14.6 lbs) for S8/GT8 and 42.0 N (9.4 lbs) for W-2. 3. The minimum required removal force is 15.0 N (3
42、.4 lbs) for S8/GT8 and 5.0 N (1.0 lbs) for W-2. 5.1.2 Bayonet Base Bulb Sockets 5.1.2.1 Test and Measurement Apparatus Maximum material condition bulb gauge Minimum material condition bulb gauge o Material and finish for gauges shall be: Steel with a ground surface finish 0.06 microns 0.01 microns (
43、1.524 nanometers 0.254 nanometers) Bulbs from each supplier. Chatillon force gauge or equivalent Appropriate mechanism to hold socket securely NOTE: Refer to IEC 60061-1 Lamp Caps 5.1.2.2 Procedure Using Maximum/Minimum Material Bulb Gauge: 1. Mount socket in appropriate mechanism to hold it securel
44、y. 2. Using the maximum material force gauge, fully seat the gauge, at a rate of 50 mm/min., into the socket. 3. Stop the insertion when the gauge bottoms out. 4. Record the maximum force in newtons. 5. *Caution* Do not over insert gauge. 6. Using a torque gauge, twist gauge clockwise to locked posi
45、tion. 7. Record the torque required to reach lock position. 8. *Caution* Do not over torque gauge.9. Using the torque gauge twist the gauge counterclockwise at a force of 5 in pounds. 10. Bulb gauge must not unlock. 11. Push downward on gauge until bulb gauge unlocks. 12. Record the force required t
46、o unlock the bulb gauge. SAE/USCAR-15 REVISION 3 Revised 2010-02 SPECIFICATION FOR TESTINGAUTOMOTIVE LIGHT BULB SOCKETS - 14 - 13. Repeat steps 2 through 11 for a total of 5 times per socket. 14. Insert a minimum material bulb gauge into socket. 15. Repeat steps 2 through 11 for a total of 5 times p
47、er socket. 5.1.2.3 Acceptance Criteria Using Maximum/Minimum Material Bulb Gauge: 1. Using a maximum material condition bulb gauge, the maximum allowable downward insertion force for P21W(BA*15), H21W(BA*9) is 20N. 2. Using a minimum material condition bulb gauge, the minimum allowable downward inse
48、rtion force for P21W(BA*15), H21W(BA*9) is 3N. 5.2 Socket Insertion/Removal Torque/Force The device must fasten into the lamp assembly in a positive and secure manner. 5.2.1 Test and Measurement Apparatus (Twist-In Sockets) 1. Test panel with maximum material thickness and minimum dimension socket h
49、ole. 2. Test panel with minimum material thickness and maximum dimension socket hole. 3. Torque wrench capable of 5.7 N-M / 50.0 in.-lb. maximum with 0.5 in.-lb. accuracy.5.2.2 Procedure (Twist-In Sockets) 1. Insert socket into the maximum material thickness test panel. 2. Rotate socket with torque wrench until fully installed. 3. Record maximum force in N-M or in.-
