1、Performance Specification for AutomotiveSAE/USCAR-44 May 2017Wire Harness Retainer ClipsISBN: 978-0-7680-8423-8_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 Counc
2、il 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 whether
3、 or not it is applicable for their purposes.Copyright 2017 USCAR Printed in U.S.A.All rights reserved.QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790RATIONALENotice about interim revisions: Editorial updates or clarific
4、ations may be made as “interim revisions” if the EWCAP review team determines that a formal revision is not needed. Interim revisions are documented as “revision letters” and are available online on the USCAR website. The link is: http:/ewcap.uscarteams.org/revisions.html.TABLE OF CONTENTS1. SCOPE 2
5、2. TEST REQUIREMENTS. 22.1 Test Schedule . 42.2 Test Paths: Required and Optional. 52.3 Applicability to design variants 52.4 Temperature Classifications . 62.5 Water Sealing Classifications . 62.6 Validation by Equivalence. 62.7 Specification of Test Level 62.8 Test Plan Approval 72.9 Test Request
6、Instructions . 72.10 Unique Requirements . 73. REFERENCED DOCUMENTS . 73.1 Documents Required to Perform Tests. 73.2 Documents Helpful to Perform Tests 73.3 Part Details 74. GENERAL REQUIREMENTS. 84.1 Record Retention 84.2 Sample Documentation. 84.3 Sample Size 84.4 Default Test Parameters . 84.5 Eq
7、uipment Requirements 94.6 Measurement Resolution 94.7 Test Repeatability damage is expected after removal.i If UL 62275 has been run, omit section 5.10.3.1. Sample size is reduced to 30 for test 5.10.3.2. j Hand insertion of CUT is allowed with no measurement taken since intent of test is unrelated
8、to insertion.SAE/USCAR-44 Issued 2017-05PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS - 5 -The sequence of USCAR-44 tests is shown in Table 2.1. To be USCAR-44 compliant, the CUT must meet all applicable test requirements at the level appropriate for the intended use. The inte
9、nded use must be listed in the test request by specifying application levels per Tables 2.4 and 2.5. The numbers in the matrix of Table 2.1 represent the order the tests run in the test sequence.2.2 Test Paths: Required and OptionalThe far right column of Tables 2.4 and 2.5 show what test paths must
10、 be performed or applied to be validated for that listed temperature, sealing class, or re-use level. 2.3 Applicability to design variantsUSCAR-44 is written and illustrated for the “fir tree” design type. Table 2.3 describes how to apply USCAR-44 to designs other than fir trees.TABLE 2.3 - APPLICAB
11、ILITY TO TESTS TO VARIOUS RETAINER DESIGNSDesign Type Typical Part Illustration How USCAR-44 is applied differently to this class Test changes required in for this part classFir Tree No differenceTest paths L applicable only for designs with cable tie. Path M applicable to offset parts only. Arrowhe
12、ad No differenceTest plate must match application thickness. Stud-mount No differenceCustom test plan needed. Recommendations are: delete Path F, test and use exact thread intended for production. Edge-biter Clip(attaches to an edge, not a hole)USCAR-44 cannot be used as-written but can be the basis
13、 of custom tests developed using engineering assessment.Custom test plan needed. Recommendation is that test panel should match actual vehicle design.Retainer with integral wire tie strapOptional test to evaluate cable tie strength. Can also be certified separately using UL62275.Add Test Path L as r
14、equested.Retainer with offset between and wire bundleTest Path M is applicable only to offset parts. Add Test Path M only if requested and criteria for acceptance provided.SAE/USCAR-44 Issued 2017-05PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS - 6 -2.4 Temperature Classificat
15、ionsComponents to be tested must be assigned a temperature class from the table below according to the environment in the intended vehicle application. Use the class with a temperature at or above the ambient range.TABLE 2.4 - COMPONENT TEMPERATURE CLASSESTemperature ClassTemperature RangeTypical Ap
16、plicationTypical Materials in Class2Test Paths per Table 2.1T1 -40o C to + 85o C Cabin (lower than IP), trunk, doors POM, PA66 A B C FT2 -40o C to +100o C IP top, headliner POM, PBT, PA66 A B C FT3 -40o C to +125o C Engine compartment POM, PBT, PA66 A B C E F G HT41 -40o C to +150o C Hotter on-engin
17、e applications PA46, Flex PPS A B C E F G HT51 -40o C to +175o C Special high-temp applications Flex PPS A B C E F G H1 T4 and T5 test sequences are identical except for the oven temperature in Section 5.6 (where the setting equals the highest temperature of the target temperature class).2 Listing o
18、f “Typical Materials for this class” is for reference only and is not a product endorsement.2.5 Water Sealing Classifications Components to be tested must be assigned a class from the table below according to the expected environment in the intended vehicle application.TABLE 2.5 - COMPONENT SEALING
19、CLASSESSeal Class Description of ClassTypical Application Test Paths Requiredper Table 2.1S1 Unsealed S1 is applicable for use in passenger compartment and dry vehicle areas. No additional testing requiredS2 Sealed - Static S2 applicable for applications exposed to vehicle exterior. JS3 Sealed - Hig
20、h Pressure Spray S3 is applicable for locations at-risk to direct water spray. J K2.6 Validation by EquivalenceIf a part is identical to the CUT in retainer design and material (where CUT differs only in the design features unrelated tothe retainer section), a “validation by equivalence” is allowed
21、for some tests that eliminates some testing. Instructions for equivalent parts: Exclude testing for test paths B, C, D, E, G, and H if identical parts have successfully passed that section of USCAR-44. Note that test path A is always required.2.7 Specification of Test Level To specify testing per US
22、CAR-44, it is recommended to use the following wording be used to give a consistent format. “Test to USCAR-44 (revision number, if applicable) per Temperature class Tx, Sealing class Sy, and thickness range t1t2” (where x is the desired temperature class per 2.4, y is the desired sealing class per 2
23、.5) and t1 and t2 are the minimum and maximum thicknesses for a specific range per Table 5.3.2. SAE/USCAR-44 Issued 2017-05PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS - 7 -2.8 Test Plan Approval The test request shall identify the tests to be performed, including any additio
24、nal non-USCAR tests. Any revisions or deviations from tests in USCAR-44 must be noted. The customer has the final decision on whether to accept a test result for production part validation. Typically approval is awarded by passing testing on parts made from a prototype mold providing the mold has th
25、e same dimensions and material as the production part mold. Also, it is typical that passing all testing using steel test plates typically allows validation for use in both steel and aluminum applications. 2.9 Test Request InstructionsInstructions must be included in the test request/order concernin
26、g applicable tests and the order in which the tests are to be performed if different than outlined by this specification in Table 2.1. Note that test paths L and M must be specificallycalled out if desired since they are not referenced in any mandatory test path. 2.10 Unique RequirementsIf user requ
27、irements are different than what is described in this specification, instructions must be given in the test request for what changes are needed, including definition of the conditions under which those limits apply.3. REFERENCED DOCUMENTS3.1 Documents Required to Perform Testsx Engineering drawing f
28、or CUT (containing required information per Section 3.3)3.2 Documents Helpful to Perform Testsx USCAR / EWCAP-007 Connector Clip Mating Hole. Available online at: http:/www.uscar.org/guest/teams/10/Electrical-Wiring-Component-Applications-Partnership (select the “Clip Slot bases and sheet-metal” sec
29、tion in the middle column).x SAE/USCAR-2: Performance Specification for Automotive Electrical Connectors. Section 5.4.5 (Miscellaneous Component Engage/Disengage Force). USCAR-2 includes a specification for connector clip slot testing. This specification can be purchased at: http:/standards.sae.org/
30、uscar2-6/x SAE/USCAR-25: Electrical Connector Assembly Ergonomic Design Criteria. Current version can be purchased at: http:/standards.sae.org/uscar25-3/x AIAG: Measurement Systems Analysis (Product Code: MSA-4) http:/www.aiag.org/store/publications/details?ProductCode=MSA-4x ISO TS16949: Automotive
31、 Quality Management Standard http:/www.iso.org/iso/home/store/catalogue_tc/catalogue_detail.htm?csnumber=52844x UL 62275 Cable Tie Test Specification. This specification may be required by customer for retainers integrated with a cable tie in addition to USCAR-44. UL 62275 can be purchased at .3.3 P
32、art DetailsA part drawing or other specification describing the CUT must contain or reference the following to allow USCAR-44testing to be properly specified. :x Dimensional requirements of the mating hole (preferably per a EWCAP-007 reference) including thickness. Note that USCAR-44 tests use nomin
33、al, minimum, and sometimes maximum tolerance for hole dimensions so tests cannot be run without having a fully-toleranced drawing describing the target sheet metal interface. x Temperature and Water Sealing class for which the part is intended. SAE/USCAR-44 Issued 2017-05PERFORMANCE SPECIFICATION FO
34、R AUTOMOTIVE WIRE HARNESS RETAINER CLIPS - 8 -4. GENERAL REQUIREMENTS4.1 Record RetentionThe supplier shall maintain a central file for the storage of laboratory reports and calibration records. Such record storagemust be in accordance with established ISO TS16949 and AIAG policies and practices.4.2
35、 Sample DocumentationAll test samples shall be identified in accordance with the requirements of ISO TS16949 and the AIAG PPAP. When documenting about specific parts of the CUT, use the names in Figure 4.2 to avoid confusion about what is being described.FIGURE 4.2 - NAMES FOR PARTS OF FIR-TREE AND
36、ARROWHEAD CLIP TYPES4.3 Sample Size Minimum sample sizes are given for each test in this specification. A greater number of samples may be 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
37、 and all samples of the group tested have met the applicable 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. 4.4 Default Test Parameters4.4.1 Defaul
38、t TolerancesDefault Tolerances, expressed as a percentage of the nominal value, are shown in Table 4.4.1.TABLE 4.4.1 - DEFAULT TOLERANCESATTRIBUTE AND TOLERANCEATTRIBUTE AND TOLERANCEATTRIBUTE AND TOLERANCETemperature = 3 o CVoltage = 5%Current = 5%Resistance = 5%Length = 5%Time = 5% Force = 5%Frequ
39、ency = 5%Flow Rate = 5%Relative Humidity = 5%Sound = 5%Speed = 5%Pressure = 5%Vacuum = 5%SAE/USCAR-44 Issued 2017-05PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS - 9 -4.4.2 Default Test ConditionsWhen specific test conditions are not given elsewhere in this specification, the
40、following conditions apply:Room Temperature = 23 5o CRelative Humidity = 50%. (RH applies to extraction testing test and samples. RH is uncontrolled for other tests) 4.5 Equipment RequirementsNeither this list nor the list in each test section is all-inclusive. It is meant to highlight specialized e
41、quipment or devices with particular accuracy requirements. TABLE 4.5 - EQUIPMENTITEM DESCRIPTION REQUIREMENTS1. Insertion/retention force testercapable of 25mm/min with heated sample chamber1% accuracy of reading and capable of collecting force-displacement data 3K/s sampling rate. Capable of mainta
42、ining sample at 80C.2. Temperature chamber 1) -40oC to +175oC or as required by Temperature Class2) 0% to 95% RH (at 85C)3. Static leak test equipment Custom water column and plate. See Section 5.84. High pressure spray equipment Custom fixture and spray head. See Section 5.94.6 Measurement Resoluti
43、onMeters 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. 4.7 Test Repeatability other designs, notably arrowhead designs are sensitive to test panel thickness). The test requester may request use
44、of a specific test panel thicknesses in addition to testing called-out in USCAR-44. 5.3.2 Equipment1. Crosshead-style tensile and compression force tester capable of crosshead movement at 25 mm/min. Data recording equipment must be available with peak force identification or (preferably) force-displ
45、acement graphing capability.2. Test panels matching the intended allowable mating openings as described in the supplied part drawing. Refer to Figure 5.3.2 that shows a typical generic test panel drawing. Drawing must indicate the hole shape, nominal hole size, and tolerance. Test requests not havin
46、g this information cannot be tested. Note that any shape hole is allowed using this method. An oval hole is shown only as an example. Holes in test plates for force testing must not be painted. Determine the thickness range to be validated and select the correct thickness per Table 5.3.2.TABLE 5.3.2
47、 - TEST PANEL VALIDATION RANGE FOR FIR TREE DESIGNSITEM FOR VALIDATION IN THIS RANGEUSE TEST PLATE THICKNESS OF: APPLICABILITY NOTES COMMENTS1. 0.6mm 1.8mm1 1.8mm 0.025 CUT must be inserted in same direction as the stamping punch3,4Recommended testing for all CUTs; 1.8mm is the most common test pane
48、l. 2. 0.6mm 4.0mm 4.0mm 0.025 Applicable when inserted into thick metal such as truck frames3,4Use when retainer will be inserted into thick stock material. 3. 4.0mm 6.0mm 6.0mm 0.025 Recommended only when specific customer request is made3,4 Uncommon (use if directed).4. 6.0mm 8.0mm 8.0mm 0.025 Rec
49、ommended only when specific customer request is made3 Uncommon (use if directed).5. Threaded holes PPGHHS Threaded hole 12.7mm depth Applies to threaded holes2,4 Each thread must be separately validated.6. Threaded studs Test plate must match nominal interface per part drawingApplies to threaded studs2,4Use stud with minimum thread engagement length listed on part d
