1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards PLUG CONNECTION Do Not Use on New Programs. Being Replaced by GMW3191 EDS-T-5240 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3(Superceded) EDS-T-5240PLUG CONNECTION PAGE: 1/13 ISSUED DATE: 1988. 04.
2、01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW3191. 1. PURPOSE In these technical delivery conditions the requirements, test conditions
3、 and test method are determined, which must fulfill the plug and socket in the motor vehicle. This specification is valid for plug and socket made by crimp-connection with multiple-fine-and superfinish wires Cu-conductors. At that time, the question is blade-and pin plug connections in single-and mu
4、ltipolar type, which can differ in the technical type according to case of application. Part 1 of this specification determines the requirements valid for plug connections in general. Because the large scope of plug connections is not clearly limited, it is necessary to agree with the manufacturer a
5、bout the requirements already determined in the additional parts, further supplementary requirements and tests for the special purposes. Further requirements on individual plug connections are determined in the follwing stated additional parts for these technical delivery conditions. 2. REMARK Sampl
6、es of material released to this specification shall be tested according to this spec. and approved by GMDAT TECHNICAL CENTER, prior to the commencement of this bulk supplies. In the event of any intentional deviation from the requirement of this spec., it is the sole responsibility of the supplier t
7、o submit the purchaser unsolicited the samples for reapproval by GMDAT TECHNICAL CENTER prior to the commencement of delivery of deviant bulk supplies. 3. TEST SAMPLE AND TEST QUANTITY If nothing else is specified, min. 40 piece plug and sockets with a works test certificate to DIN 50049. 2.3 are to
8、 be delivered for initial sampling and release test according to this specification. It is expected that the values of all required characteristic quantities represent the tolerance range of production scattering width at the presented test samples. If these supposition is not fulfilled by the test
9、samples, the tolerance ranges of production scattering width for all required characteristic quantities must be specified in the works test certificate apart from the individual values. EDS-T-5240PLUG CONNECTION PAGE: 2/13 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Aut
10、o & Technology 4. TERMS 4.1. Plug connection Plug connections are component parts, with which electrically conducting connections can be mechanically manufactured and detached again. At that time, the question is single-or multipolar connections, consisting of 4.1.1. Plugs Which are component part o
11、f an instrument or connected with electric cables and can be locked in corresponding housing. The plug is the part of plug connection, which is enveloped by the receptacle completely or partly. The question is blade-and pin terminal at that time. 4.1.2. Receptacles Which are connected with electric
12、cables and can be locked in corresponding housing. The receptacle is the part of plug connection, which receives the plug. 4.1.3. Insulating housing The housing with housing chambers is useful for reception and for supporting of a corresponding number of receptacle and plugs. It must be formed that
13、an uncorrect joining is prevented by a clear guide as well as, if necessary, a locking mechanism of plug connection is guaranteed. 4.2. Detachable connection A single-or muitipolar electric connection with plug and receptacle. 4.3. Not detachable connection A connection between conductor and plug an
14、d receptacle, which is manufactured in solderless connection technique. 4.4. Crimp connection Corresponding to DIN 41611, part 3, 06.80 4.5. Insulation crimping (insulation support) Shackling at plug and at the receptacle, which are carried out, so that they surround the insulation firmly at crimpin
15、g and their displacement is prevented. 4.6. Locking lug An elastic lug, which guarantees the locating device or of receptacle in the housing chamber. 4.7. Housing chamber A dimensionally mounted chamber, which receives the receptacle or the plug and guarantees a satisfactory locating device. EDS-T-5
16、240PLUG CONNECTION PAGE: 3/13 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 5. PRETREATMENT If nothing else is specified, the tests were performed at +235K in the delivery condition without pretreatment. plugs and receptacles must be dry and clean. 6. TE
17、ST PROGRESS The tests are to be performed corresponding to the test plan in pos.8.10. The specified sequece is to be observed at tests, otherwise it is not guaranteed that reproducible results are obtained. 7. TEST APPARATUSES 7.1. Test instruments corresponding to the specified test method, test sp
18、ecifications, standards etc. 7.2. Measuring instruments for the dimensional test, e.g. measuring slide to DIN 862. 7.3. Controllable direct-voltage source 0 to 24V to 100A loadable. 7.4. Direct-current ammeter up to 100A, accuracy class 0.5 or better. 7.5. DC Voltmeter 0 to 24 V, accuracy class 0.5
19、or better. 7.6. Test apparatuses for determining the plug-, separating-, axial displacement-and extraction forces (e.g. tensile test machine to DIN 51221, part 1 with a stress speed of (10010) mm/min) 7.7. Test apparatuses for measuring the insulation resistance. 7.8. Test apparatuses for testing th
20、e voltage strength. 7.9. Recirculated air-heating cabinet, controllable, which is in a position to keep constant the demamded temperature within 2.5K (a heating cabinet to DIN 50011, part 1, section 2.2 is suitable for this) 7.10. Cold cabinet controllable up to -403K 7.11. Basically other suitable
21、test apparatuses are permissible. It must be guaranteed that the measured variables are recorded physically correctly in a sense of these techn. delivery conditions. EDS-T-5240PLUG CONNECTION PAGE: 4/13 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Blade
22、 plug connections Pin plug connections Nominal size plug width in mm Nominal cross secionof conductor in mm2Nominal size of pin terminal in mm Nominal cross sectionof conductor in mm22.8 4.8 6.3 7.7 9.5 0.25 to 1.0 0.5 to 2.5 0.5 to 6.0 1.0 to 6.5 2.5 to 10.0 to 1.6 to 3.55 to 4.0 to 5.0 0.5 to 1.0
23、1.5 to 4.0 0.5 to 4.0 0.5 to 4.0 8. REQUIREMENTS 8.1. General requirments 8.1.1. Materials 8.1.1.1 Contact materials 8.1.1.1.1 Outer parts (plug connections for engine compartments and external connections) At the application of Cu-Zn-alloys with a copper portion # 70 mass portion in %, an additiona
24、l surface protection is necessary (e.g. tinned or silver-plated, thickness of layer 3 to 5 m) 8.1.1.1.2 Inner parts(plug connections for passenser compartments and trunk) At the application of Cu-Zn-alloys with a copper potnion # 70 mass portion in %, an additional surface protection is necessary (e
25、.g. tinned or silver-plated, thickness of layer 3 to 5 m) Pos. 8.1.1.1.1 and 8.1.1.1.2 are still supplemented if necessary. 8.1.1.1.3 Permissible material pairing Plugs and receptacles must consist of equal material There, where this is not possible, it must be guaranteed that any negative influence
26、 on the function and durability of plug connection is not formed because of contact pairing and the requirements of this test specification are fulfilled. 8.1.1.2 Materoals of housing The materials are to be selected, so that they are sufficient for the requirements for the respective attaching-or m
27、ounting place and for the environmental requirements to be expected (ambient temperature, humidity). 8.1.1.3 Automotive restricted hazardous substances to GMW 3059. 8.1.2. Characterization 8.1.2.1 Plugs and receptacles are characterized with trade mark. 8.1.2.2 Every housing must be characterized pe
28、rmanently as follows : 8.1.2.2.1 Characterization of chambers. 8.1.2.2.2 Trade mark 8.1.3. Approved nominal sizes for blade-and pin plug connections. The plug connections are carried out, so that cables with following nominal cross sections can be fixed. EDS-T-5240PLUG CONNECTION PAGE: 5/13 ISSUED D
29、ATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 8.1.4. Max. plug in-and detaching force for multiple plug connections. On the basis of plug-and separating forces washing with the number of pole, the max. permissible number of pole is to be derermined for the indiv
30、idual nominal size, so that the plun in- or detaching force of multiple plug connection does not exceed 150N. For plug and sockets, at which the plug in-and detaching forces can not be determined (e.g. plug and socket to be moved with a lever, plug and socket with Bayonet-lock) isolated fixings are
31、to be made. The corresponding forces for single plug and soc 8.1.5. Delivery condition Plugs and receptacles are crimped on cables, and mainly inserted into insulating housing, delivered. The parts must have a smooth surface, must be without cracks, folds and grooves. In the range of contacting surf
32、ace on the part : any punching burr may not exist. 8.1.6. Visual-and dimensional test The plug connections may not show any defect or damage. The dimensions and their tolerances determined in the drawings or releases must be observed. All corners and edges of insulating housings which are placed in
33、the range of grip at the assembley, may not be sharpedged so that any danger of injury is not existing at the handling. 8.2. Mechanical requirements 8.2.1. Detachable connection The detachable single-or multipolar connection must be carried out, so that a number of specified plug cycles with satisfa
34、ctory contact connection is possible without problem, without the measured plug-in-and detaching forces, as well as the electric characteristic values are placed outside the specified tolerance bands. plug-in force : force, that is necessary at least, in order to plug the detachable connection. Deta
35、ching force : force, that is necessary at least, in order to separate the detachable connection. The plug-in-and detaching forces of a plug connection must correspond to definite values to be determined in detail for the individual types of plug and socket. These are determined in the further parts
36、of this test specification for the different types of plug and socket. 8.2.2. Not detachable connection (crimp connection) 8.2.2.1 The single wires of electrical cables must be enveloped over the total length or crimp sleeve. The conductor as well as the insulation may not show any damage injuring t
37、he function. The insulation may not extend into the crimp sleeve. EDS-T-5240PLUG CONNECTION PAGE: 6/13 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Nominal cross section of conductorin mm Min-detaching force in N 0.25 0.5 0.75 1.0 1.5 2.5 4 6 10 50 90 1
38、30 180 250 300 350 500 600 Detaching force (in N) 40 50 70 90 120 Blade terminal (nominal width in mm) 2.8 4.8 6.3 7.7 9.5 Pin terminal ( in mm) to 1.6 to 2.5 to 5.0 The detaching force of conductor from the crimp connection (force, that is necessary at least, n order to pull the conductor from the
39、crimping) of plug sleeve or of plug is determined with a tensile testing machine (stress speed of (10010) mm/min) after detaching the insulation crimping Detaching force of crimp connection 8.2.2.2 Not detachable connection (soldered-or welded joint) Mechanical requirements are to determined separat
40、ely if necessary. With regard to the strength of connection with the conductor the equal requirements such as at the crimp connection are valid. 8.2.3. Contact locating device in the housing The stop spring of receptacle or of plug must be formed, so that the following min. detaching forces from the
41、 housing chamber are obtained. 8.3. Electrical requirements 8.3.1. Current carrying capacity The permissible current load of single-or muptilolar plug connection is dependent. - on the crimped cross section of conductor - on the material of receptacle and of plug - on the surface coating EDS-T-5240P
42、LUG CONNECTION PAGE: 7/13 ISSUED DATE: 1988. 04. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology - on the ambient temperature - on the heat of an instrument-internal heat source flowing to the plug connection (e.g. contact heating or localitation of heat) - on the number of cont
43、act in the insulating housing The max. permissible current load of different plug connection : is specified in the concerning parts of this test specification for the respectively permissible mating of contact material. (Derating-curves for all plug and socket systems). The measurement of current ca
44、rrying capacity is performed to DIN 41640, part 3. 8.3.2. Voltage drop The voltage drop is measured, after a thermal balance has been adjusted at loading with the test current. 8.3.2.1 Voltage drop, detachable connection 8.3.2.1.1 Blade plug connections The voltage drop of detachable connection is d
45、etermined between plug and plugged in receptacle at the measuring points specified in the following sketch : Test current and permissible voltage drop are determined in the further parts of this test specification for every contact system. 8.3.2.1.2 Pin plug connection The voltage drop between pin t
46、erminal and plugged in pin receptacle is determined on the points specified in the following sketch : Test current and permissible voltage drop are determined in the further parts of this test specification for every contact system. EDS-T-5240PLUG CONNECTION PAGE: 8/13 ISSUED DATE: 1988. 04. 01 REVI
47、SED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 8.3.2.1.3 Multiple plug connections Test method and test requirements are also determined. 8.3.2.2 Voltage drop, not detachable connection Both for blade-and for pin plug connection, the voltage drop over the not detachable connection is
48、to be determined on the tollowing measuring points. Requirements : The voltage drop between cable and receptacle or plug is measured at a current density of 5 A/mm2and +235K and must be # 7mV. 8.3.3. Requirements on the housing 8.3.3.1 Insulation resistance The insulation resistance between two adja
49、cent contacts locked in the housing in the unplugged condition may not fallen short of 200 M at a relative humidity of 65% 5%(measuring voltage (10010)V). 8.3.3.2 Voltage strength The insulation between two adjacent plugs of receptacles must endure an effective AC voltage of 2000 V (50HZ) for 60s without disruptive discharge. The test is to be performed at a relative air humidity of 65%5%. 8.4. Thermic requirements 8.4.1. Current carrying capacity At permanent load (test time min. 60 min or up to the adjustment of a temperature equ
