1、Shipping Caps, Torque Caps, and Body PlugsErgonomic Design CriteriaSAE/USCAR-43 March 2015ISBN: 978-0-7680-8217-3 TABLE OF CONTENTS 1.0 SCOPE 2 2.0 REFERENCED DOCUMENTS . 2 3.0 GENERAL . 2 4.0 DESIGN GUIDELINES SHIPPING CAPS . 2 5.0 DESIGN GUIDELINES TORQUE CAPS . 5 6.0 DESIGN GUIDELINES BODY PLUGS
2、6 7.0 APPENDICES . 8 7.1 GLOSSARY 8 7.2 TORQUE MEASUREMENT 9 7.3 REFERENCES 10 7.4 REVISIONS . 10 SAE/USCAR-43 Issued 2015-03 Shipping Caps, Torque Caps, and Body Plugs Ergonomic Design Criteria _ The research data, analysis, conclusion, opinions and other contents of this document are solely the pr
3、oduct of the authors. Neither the SAE International (SAE) nor the United States 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 pur
4、pose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes. Copyright 2015 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
5、 FAX (724) 776-0790 SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 2 - 1.0 SCOPE This document describes the design and assembly force guidelines for conventional shipping caps, torque caps, and body plugs. All possible design and applications coul
6、d not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department. 2.0 REFERENCED DOCUMENTS SAE/USCAR-25 Electrical Connector Assembly Ergonomic Design Criteria 3.
7、0 GENERAL In all cases, assembly forces should be as low as possible while maintaining satisfactory performance and quality. Part packaging, process, and workstation design requirements/constraints all have the potential to negatively impact the forces specificed in this document. Such situations in
8、clude but are not limited to: - Obstructed Access - Awkward or non-neutral postures, such as wrist deviation or extended reaches - Force applied laterally across the body. Reference the Hand Clearance guidelines in SAE/USCAR-25 Section 9.0. Consult the Ergonomics Department with any questions or if
9、clarifications are needed. 4.0 DESIGN GUIDELINES SHIPPING CAPS A shipping cap is used to prevent leakage or contamination during shipping and can be made from different materials, such as vinyl, rubber or plastic. They may be installed and/or removed by the operators without an assist (i.e. hand too
10、l). Key factors that must be considered in the design or selection of shipping caps/plugs are the push/pull forces required for insertion/removal, the grasp/grip surface area, the hand or finger grip posture utilized, and the composition/material of the cap or plug. Shipping caps fall into three cla
11、sses as shown in Table 4.0 (See page 4). Each class is defined by maximum assembly force and corresponding surface area requirements. 4.1 MAXIMUM ASSEMBLY FORCE Under the ideal conditions described under these guidelines, the maximum assembly forces must not exceed 75N. When these conditions cannot
12、be met, the maximum assembly force is reduced as shown in Table 4.0. 4.2 DESIGN REQUIREMENTS Required surface area dimensions are determined by the hand or finger grip utilized. Surface area requirements are derived from a large male gloved hand or small female gloved hand as appropriate. Shipping c
13、aps/plugs should be designed according to the surface area requirements shown in Table 4.0. For large caps that can be assembled and/or removed with the whole hand, a minimum surface area of 500mm2is required. Shipping caps/plugs should have features to facilitate their removal such as: rings, tabs,
14、 or raised flanges. a. Pull rings should be designed with an inside diameter of at least 25.4 mm (See Figure 1). b. The optimal measurements of a pull tab (See Figure 2) should be a minimum of 23 mm in length by 6 mm in width. c. A raised flange or ridge (See Figure 3) around the periphery of a cap
15、should have a minimum height of 2 mm from the surface of the cap. SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 3 - Figure 1: Pull Ring Example Figure 2: Pull Tab Example Figure 3: Shipping Caps with a Minimum of 2mm Ridge from Surface To improve
16、grip (and reduce the operators need to grip the cap harder), slippery surfaces should be avoided. Sharp edges should also be avoided. a. Raised surfaces (Figure 4) or “bumps” may be used to help operators push/pull or twist caps or plugs, but must not exceed a height of 0.8 mm from the surface. b. F
17、inger indentions can also improve grip. These indentations should be optimally angled between 30 and 90 (perpendicular) from the force insertion direction (Figure 5) in order to comply with the maximum allowable force shown in Table 4.0. If an optimal angle is not provided, undesirable pinch grips m
18、ay occur and maximum assembly force will be reduced. Figure 4: Shipping Cap with “Bumps” Figure 5: Optimally Angle Finger Indentations 30 45 LENGTH WIDTH SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 4 - Table 4.0: Shipping Caps Design Guidelines
19、Max Assembly ForceTypical Hand Posture Options for DesignShipping Cap Minimum Contact Surface AreaExamples Fingertip push 15 mm2(with optimally angled push surface)Minimum Dimension of 3mmPinch Grip with Thumb and Finger push/pull 100 mm (without optimally angled push surface or pull ridge or for ca
20、ps with a slippery surface)With a min. of 50 mm push/pull surface provided on two opposing sides of shipping cap/plugOne Thumb or One Finger Pad push (with optimally angled push surface)One Finger pull with Ring 25.4 mm i nsi de di ameter(with minimum inside di ameter)(minimum thickness of 6mm)Pinch
21、 Grip with Thumb and Finger push/pull 100 mm(with optimally angled push surface or pull ri dge)With a min. of 50 mm push/pull surface provided on two opposing sides of shipping cap/plugHand Grasp push/pull 150 mm(key gri p without optimally angled push surface or pull ridge and a non-slippery surfac
22、e)With a min. of 50 mm push/pull surface provided on one side of the cap/plug (for the thumb) and 100 mm provided on the opposing si de (for the fi nger)Hand Grasp push/pull 150 mm(key grip with optimally angled push surface or pull ridge)With a min. of 50 mm push/pull surface provided on one side o
23、f the cap/plug (for the thumb) and 100 mm provided on the opposing si de (for the fi nger)150 mm2With a min. of 50 mm push/pull surface provided on one side of the cap/plug (for the thumb) and 100 mm provided on the opposing si de (for the fi ngers)Two Finger push 150 mm2 (with optimally angled push
24、 surface)With a min.of 75 mm2 provided for each fingerTwo Finger pull with Ring 50 mm i nsi de di ameter (with minimum inside di ameter)(minimum thickness of 6mm)75 NFull hand grasp push/pull500 mm2 with minimum 25 mm outer diameter and maximum 75 mm outer di ameter 22 N 45 N100 mm 75 NPinch Grip wi
25、th Thumb and Two Finger push/pull (with optimally angled push surface or pull ridge)SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 5 - 5.0 DESIGN GUIDELINES TORQUE CAPS Torque caps require a twisting motion for installation or removal by the operat
26、or. Key factors that must be considered in the design or selection of torque caps are the twist forces required for insertion/removal, the grasp/grip surface area, the hand or finger grip posture utilized, and the composition/material of the cap. Similar to shipping caps, torque caps fall into three
27、 classes as shown in Table 5.0. Each class is defined by maximum assembly torque and corresponding surface area requirements. 5.1 TORQUE REQUIREMENTS The maximum assembly torques must not exceed 2.5 Nm under ideal conditions. When these conditions cannot be met, the maximum assembly force is reduced
28、 as shown in Table 5.0. For instructions on how to measure Torque, see Appendix 7.2. 5.2 DESIGN REQUIREMENTS Required surface area dimensions are determined by the hand or finger grip utilized. Surface area requirements are derived from a large male gloved hand or small female gloved hand as appropr
29、iate. Torque caps should be designed according to the surface area requirements shown in Table 5.0. Table 5.0: Torque Caps Design Requirements Max Assembly TorqueTypical Hand Posture Options for DesignTorque Cap Minimum Contact Surface AreaExamples 100 mm2 and 10 mm diameterWith a min. of 50 mm surf
30、ace provided on two opposing sides of shipping cap/plug150 mm2 With a min. of 50 mm push/pull surface provided on one side of the cap/plug (for the thumb) and 100 mm provided on the opposing side (for the fi nger) 2.5 Nm Hand twist/turn500 mm2and 25.2 mm di ameter 0.75Nm Pulp Pinch twist/turn 1.5 Nm
31、 Lateral Key Gri p twist/turnSAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 6 - 6.0 DESIGN GUIDELINES BODY PLUGS Body plugs are installed and/or removed by the operators without an assist (i.e. hand tool). Maximum allowable assembly force is determ
32、ined by surface area assuming optimal access and posture. This force may be reduced if the application and/or packaging compromises the operators ability to fully access the plug as shown in Table 6.0. Please see Ergonomics Department for further information. 6.1 FORCE REQUIREMENTS The maximum assem
33、bly forces must not exceed 75N under ideal conditions. When these conditions cannot be met, the maximum assembly force is reduced as seen in Table 6.0. 6.2 DESIGN REQUIREMENTS Required surface area dimensions are determined by the hand or finger grip utilized. Surface area requirements are derived f
34、rom a large male gloved hand or small female gloved hand as appropriate. Where possible, every effort should be made to design the plugs to meet the minimum surface area dimensions. Body plugs should be designed according to the surface area requirements shown in Table 6.0. SAE/USCAR-43 Issued 2015-
35、03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 7 - Table 6.0: Body Plug Design Requirements ClassMaximum Assembly ForceContact Surface Area RequirementTypical Installation Method 22N 3mm - 6mm Finger Tip push 22N 3mm - 6mm Finger Tip push 45N 7mm 1 Finger/Thumb push 22N 3m
36、m - 6mm Finger Tip push 22N 3mm x 6mm Finger Tip push7mm 1 Finger/Thumb push 22N 3mm x 6mm Finger Tip push2 Finger push 75N 51mm 3-Finger / Palm push2Round, Rigid Plugs with Recessed Surface7mm 1 Finger/Thumb push 1Round, Rigid Plugs with Flat or Mushroom Top Surface7mm - 33mm 1 Finger/Thumb push 45
37、N34mm - 50mm3Round, Flexible Plugs with Recessed Surface and “Button“4Round, Flexible Plugs 45N34mm - 50mm 2 Finger push 75N 45N7mm - 33mm 1 Finger/Thumb push 51mm 3-Finger / Palm push5Oblong, Flexible Flat Plugs6Oblong, Rigid Plugs with Isolated Retention Features7mm - 33mm 1 Finger/Thumb push 45N3
38、4mm - 50mm 2 Finger push 75N 51mm 3-Finger / Palm push 45N7Round, Rigid Plugs with Isolated Retention Features7mm - 33mm 1 Finger/Thumb push 45N34mm - 50mm 2 Finger push 75N 51mm 3-Finger pushOblong, Rigid Plugs7mm - 33mm 1 Finger/Thumb push 45N34mm - 50mm 2 Finger push 75N 51mm 3-Finger / Palm push
39、Typical Body Plug Designs 45N34mm - 50mm 2 Finger push 75N 51mm 3-Finger / Palm push9Round, Rigid with thread-like fins7mm - 33mm 1 Finger/Thumb push 8SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 8 - 7.0 APPENDICES 7.1 GLOSSARY Finger push Applic
40、ation of force by the finger pad(s) or tip(s). Grip span The distance between the thumb and opposing finger(s) which are in contact with the cap or plug Grip surface A contact surface that is not optimally angled and requires a pinch grip in addition to the force required for insertion. Hand clearan
41、ce The amount of space required for access to assemble as defined by either large male (95th percentile) for openings. Hand grasp A grip which allows the hand to fully surround cap or plug. Key grip Grasping of a cap or plug between the thumb and the side of the index finger. Maximum assembly force
42、The force required to install or remove the cap or plug Neutral wrist posture A posture which aligns the hand and forearm naturally with minimal radial/ulnar deviation or flexion/extension of the wrist. Optimally Angled Push Surface A surface angled between 30 and 90 (perpendicular) from the directi
43、on of force insertion (see Figure 2). Pinch grip Grasping of a cap or plug between the thumb and one or more fingers. Power grip Type of grip in which the thumb, fingers, and palm of the hand form a clamp around the object. Push surface A contact surface that is optimally angled which provides an ar
44、ea for application of force in the direction of insertion. Shipping Cap - Used to prevent leakage or contamination during shipping and can be made from different materials, such as vinyl, rubber or plastic. They may be installed and/or removed by the operators without an assist. Torque Cap - Require
45、s a twisting motion for installation or removal by the operator SAE/USCAR-43 Issued 2015-03 SHIPPING CAPS, TORQUE CAPS, AND BODY PLUGS ERGONOMIC DESIGN CRITERIA - 9 - 7.2 TORQUE MEASUREMENT The measurement technique used may depend on the part geometry and/or the equipment available. In all cases, u
46、se a slow, steady turning motion until the part is secured and document the peak value obtained. a. Digital torque gage Method: Use the chuck on the handheld sensor attachment to clamp the part to be measured. Slowly turn the handheld sensor attachment in the tightening direction until the part is s
47、ecured. In some cases, a special attachment that interfaces with the part can be manufactured. b. Torque wrench Method: Secure the socket to the square drive of the torque wrench. Then attach the socket to the part to be measured. Slowly turn the torque wrench in the tightening direction until the p
48、art is secured. In some cases, a special attachment that interfaces with the part can be manufactured. The special attachment can then be fixed to a traditional torque wrench socket in order to obtain measurements. c. Push/Pull Force gage: Use this method when a digital torque gage or torque wrench
49、will not attach to the part. Method: Attach a rigid lever of known length to the part being measured and then apply a linear force using a push/pull gage to the rigid lever until the part is secured. Calculate the peak torque by multiplying the peak force indicated on the force gage by the distance between the point of force application and the c
