1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW3191 Connector Test and Validation Specification Copyright 2012 General Motors Company All Rights Reserved June 2012 Originating Department: North American Engineering Standards Page 1 of 79 1 Introduction. 6 1.1 Scope. 6 1.2 Mission/Theme. .
2、 6 1.3 Classification. 6 2 References . 6 2.1 External Standards/Specifications. 6 2.2 GM Standards/Specifications. . 6 2.3 Additional References. 6 3 Test Preparation and Evaluation 6 3.1 Resources. 6 3.1.1 Calibration. 6 3.1.2 Alternatives. 6 3.1.3 Facilities. . 6 3.1.4 Equipment. 6 3.1.5 Test Veh
3、icle/Test Piece. . 6 3.1.6 Test Time 7 3.1.7 Test Required Information. . 7 3.1.8 Personnel/Skills. . 7 3.2 Preparation. . 7 3.2.1 Conditioning. . 7 Figure 1: Terminal Conditioning 7 3.3 Conditions. . 7 3.3.1 Environmental Conditions . 8 3.3.2 Test Conditions . 8 3.4 Instructions. . 8 3.4.1 Visual E
4、xamination. 8 3.5 Data . 8 3.6 Safety. 8 3.7 Documentation 8 3.7.1 Test Results. . 8 3.7.2 Deviations from Test Procedure. 9 3.8 Test Tolerances. 9 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without
5、license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 2 of 79 3.8.1 Default Tolerances. . 9 Table 1: Parameters and Tolerances 9 4 Requirements and Procedure 9 4.1 Classification. 9 4.1.1 Temperature Class . 9 Table 2
6、: Temperature Class (T) 10 4.1.2 Vibration Class. . 10 Table 3: Vibration Class (V) 10 4.1.3 Sealing Class. . 10 Table 4: Sealing Class (S) 10 4.1.4 Connector Mating Force Class. 10 Table 5: Connector Mating Force Class (M) . 11 4.1.5 Test Procedures and Sequences . 11 4.2 Mechanical Tests. 11 4.2.1
7、 Crack Corrosion. . 11 4.2.2 Crimp Weld Integrity. 11 4.2.3 Terminal-to-Terminal Engagement Force. 12 4.2.4 Terminal-to-Connector Engagement Force. . 12 4.2.5 Terminal-from-Connector Extraction Force. . 13 Table 6: Minimum Extraction Force Terminal from Connector Cavity . 14 4.2.6 Terminal Cavity Po
8、larization. 14 4.2.7 Terminal Bend Resistance. . 15 Figure 2: Terminal Design Style 16 Figure 3: Terminal Bend Test 16 Table 7: Terminal Size and Applied Bending Force 16 4.2.8 Connector-to-Connector Engagement Force. 16 4.2.9 Terminal Position Assurance (TPA). . 17 Table 8: TPA Removal Force Table
9、18 4.2.10 Lever and Slide Open Position Retention. 18 Figure 4: Retention of Slide in the Open Position . 19 4.2.11 Mechanical Assist Integrity. 19 Figure 5: Side Force Strength . 20 4.2.12 Connector Mounting Feature Mechanical Strength. . 20 Figure 6: Connector Mounting Fixture Strength Example . 2
10、1 Figure 7: Connector Mounting Fixture Strength Test Setup, 3-Dimensional View . 21 Figure 8: Connector Mounting Fixture Strength Test Setup, End View 22 Figure 9: Connector Mounting Fixture Strength Test Setup, Side View . 22 4.2.13 Connector Audible Feedback. 22 4.2.14 Connector Lock Mechanical Ov
11、erstress. 23 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Reserved June 2012 Pag
12、e 3 of 79 4.2.15 Connector Position Assurance (CPA). 23 4.2.16 Connector Seal Retention - Mated Connector. . 24 4.2.17 Connector Seal Retention - Unmated Connector. 24 Figure 10: Unmated Connector Seal Test 25 4.2.18 Locked Connector Disengagement Force. . 25 Table 9: Locked Connector Disengage Forc
13、e 25 4.2.19 Unlocked Connector Disengagement Force. 25 4.2.20 Connector Polarization (Coding) Feature Effectiveness. 26 4.2.21 Mechanical Shock. 27 Figure 11: Series Circuit Monitoring 28 Figure 12: Vibration Mounting Fixture . 29 Table 10: Mechanical Shock . 29 Figure 13: Continuity Loss 30 Figure
14、14: Continuity Loss for SIR Connectors . 30 4.3 Electrical Tests. . 30 4.3.1 Maximum Current Rating. . 30 Figure 15: Draft-Free Enclosure 31 Figure 16: Base Curve 32 Figure 17: Derating Curve . 33 4.3.2 Dry Circuit Resistance. . 33 Figure 18: In-Line Circuit Lead Location . 34 Table 11: Maximum Resi
15、stance Values 34 4.3.3 Voltage Drop. 35 Figure 19 - Terminal Insertion . 35 Figure 20: Current Resistance Test Setup 36 Figure 21: Typical Connection Resistance Millivolt Lead Locations . 36 4.3.4 1008-Hour Current Cycling. 37 4.3.5 Isolation Resistance. . 38 4.3.6 Dielectric Strength. 38 4.4 Enviro
16、nmental Tests. . 39 4.4.1 Thermal Aging. 39 4.4.2 Thermal Shock. . 40 4.4.3 Humid Heat Cyclic (HHC). 41 Table 12: Cyclic Humidity Requirements 41 Figure 22: Cyclic Humidity Profile . 42 Table 13: Cyclic Humidity Profile 43 4.4.4 Humid Heat Constant (HHCO). 43 Table 14: Constant Humidity Requirements
17、 . 44 4.4.5 Heavy Duty Test. 44 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Res
18、erved June 2012 Page 4 of 79 4.4.6 Flammability. . 45 4.4.7 Corrosion. . 45 4.4.8 Vibration with Thermal Cycling. 46 Figure 23: Thermal Cycle 47 Table 15: Thermal Cycle Requirements . 47 Figure 24: Body (Sprung Masses) Random Vibration Schedule 47 Table 16: Body (Sprung Masses) Random Vibration Sche
19、dule . 48 Figure 25: Engine Mounted Sinusoidal Vibration Cycle (based on ISO 16750-3) 48 Table 17: Engine Mounted Sinusoidal Vibration Cycle (based on ISO 16750-3) . 48 Figure 26: Engine Mounted Random Vibration Cycle (based on ISO 16750-3) . 49 Table 18: Engine Mounted Random Vibration Cycle (based
20、 on ISO 16750-3) 49 Figure 27: Wheel Random Vibration Cycle . 50 Table 19: Wheel Random Vibration Cycle 50 Figure 28: Severe Applications Sinusoidal Vibration (based on ISO 16750-3) 51 Table 20: Severe Sinusoidal Vibration (based on ISO 16750-3) 51 Figure 29: Severe Random Vibration Cycle (based on
21、ISO 16750-3) 52 Table 21: Severe Random Vibration Cycle (Severe Applications; based on ISO 16750-3) . 52 Table 22: Generic Vibration Profiles for Transmissions (12 to 20 000) Hz . 53 4.4.9 Water Submersion. . 53 Figure 30: Water Submersion Setup . 54 4.4.10 Pressure/Vacuum Leak. . 54 4.4.11 High Pre
22、ssure Spray. 56 Figure 31: Nozzle and Jet Dimensions . 57 Table 23: Spray Pattern 57 Figure 32: High Pressure Spray Test Arrangement 58 4.4.12 Fluid Resistance. 58 Table 24: Fluids . 60 4.5 Miscellaneous Tests. . 60 4.5.1 Resistance of Short Circuit Devices. 60 Figure 33: Electrical Resistance of Sh
23、orting Bars . 61 4.5.2 Terminal Push-out Force. . 61 Table 25: Push-out Force 62 4.6 Further Requirements. . 62 4.6.1 Test Sequences 62 Table 26: Terminal Mechanical Tests . 63 Table 27: Terminal Electrical Tests . 64 Table 27: Terminal Electrical Tests (continued) 65 Table 28: Connector Mechanical
24、Tests 66 Table 28: Connector Mechanical Tests (continued) . 67 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 Genera
25、l Motors Company All Rights Reserved June 2012 Page 5 of 79 Table 28: Connector Mechanical Tests (continued) . 68 Table 28: Connector Mechanical Tests (continued) . 69 Table 29: Sealed Connector Environmental Tests . 70 Table 29: Sealed Connector Environmental Tests (continued) 71 Table 30: Unsealed
26、 Connector Environmental Tests . 72 Table 31: Connector Validation Test Matrix 73 5 Provisions for Shipping 75 6 Notes 75 6.1 Glossary. Not applicable 75 6.2 Acronyms, Abbreviations, and Symbols. . 75 7 Additional Paragraphs 76 7.1 All parts or systems supplied to this standard . 76 8 Coding System
27、. 76 9 Release and Revisions 76 Appendix A 77 Data Sheet A1: Electrical Connection System Test Summary 77 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEER
28、ING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 6 of 79 1 Introduction Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take p
29、recedence. 1.1 Scope. This standard defines the requirements, functional tests, and durability tests for low voltage automotive single and multiple-pole electrical connectors, terminals, and related components. Procedures included within this specification are intended to cover performance testing a
30、t all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems. 1.2 Mission/Theme. Define test and validation requirements including test sequences for electrical connection systems. 1.3 Classification
31、. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM IRM-902 EN 590 ISO/TS16949 USCAR23 ASTM IRM-903 EN 60068-2-6 SAE J1127 USCAR25 ASTM Reference Fuel C EN 60068-2-64 SAE J1128 USCAR38 ASTM Ser
32、vice Fluid 104 IEC 60068-2-38 SAE RM66-04 Citgo #33123 IEC 60068-2-78 USCAR21 2.2 GM Standards/Specifications. B 040 0900 B 040 2012 GMW3172 B 040 1065 L 000 0102 GMW3232 B 040 1073 GMW3059 GMW14914 2.3 Additional References. ISO/TS16949 Certification 3 Test Preparation and Evaluation 3.1 Resources.
33、 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. (As required by ISO/TS16949.) 3.1.2 Alternatives. Alternative test facilities and equipment may also be used. However, all measuring variables as specified in this standard
34、shall be determined correctly with respect to their physical definition. 3.1.3 Facilities. All facilities and test equipment shall be ISO/TS16949 certified. 3.1.4 Equipment. Test equipment shall be capable of measuring the physical and electrical parameters as specified. All meters and gauges used i
35、n measurements of the test sample shall be capable of measuring to one significant digit less than the specified value. 3.1.5 Test Vehicle/Test Piece. Electrical connectors used for testing shall be manufactured according to the values and the tolerances that are shown on the drawings or the release
36、s. Materials shall conform to all specifications shown on the respective drawings. Specific sample quantity requirements are detailed in each test procedure. See test sequences in Section 4.6 to determine which tests are required. Should a test failure occur, consult with the responsible GM engineer
37、 to determine if the test is to be continued to gain additional product experience or if testing shall be terminated. 3.1.5.1 Terminal Attachment. Terminals shall be affixed to the cable using production intent processes per USCAR21 mechanical crimp or USCAR38 ultrasonic weld specifications. Copyrig
38、ht General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 7 of 79 3.1.5.2 Di
39、sposition of Samples. Test samples shall be retained for examination and further analysis and shall not be disposed of without permission of the responsible GM connector and validation engineers. 3.1.6 Test Time. Not applicable. 3.1.7 Test Required Information. Not applicable. 3.1.8 Personnel/Skills
40、. Not applicable. 3.2 Preparation. 3.2.1 Conditioning. The following conditioning shall be performed as defined on connectors and terminals prior to the test procedures specified in this specification: a. Attach wires of appropriate gauge size to terminals. b. Insert terminated leads into the specif
41、ic connector housings undergoing testing, if required. c. For tests that do not require connector housings, mate and unmate the female terminal with the corresponding male terminal 10 times being careful not to cause overstress to the contact spring. d. For tests on connection/terminal assemblies, m
42、ate and unmate the connectors with terminals 10 times with the corresponding connector or header interface, except when performing Section 4.2.8, which requires unmated virgin test samples. e. For tests on connection/terminal assemblies with terminals sizes 2.8 mm and smaller, stress terminals by in
43、serting a male terminal or equivalent test pin into the female terminal. The male terminal or test pin shall correspond in size to the female terminal being tested. Insert the test pin and apply a force of 0.5 N in each direction as shown in Figure 1 for 10 seconds. Note: A terminal shall be stresse
44、d in only one direction, thus for another axis stress another terminal. Thus it takes four separate terminals to stress in each of the four directions. Figure 1: Terminal Conditioning f. Connector housings without terminals shall be aged for a minimum of 24 hours at (+40 3) C and a relative humidity
45、 of 95% to 98% prior to performing any connector mechanical testing. g. Store test samples at an ambient temperature of (+23 5) C for at least 24 hours prior to performing any electrical testing regardless of connector housing material. 3.3 Conditions. X mm (10mm) 5N4 terminals, each in one directio
46、n only Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Copyright 2012 General Motors Company All Rights Reserved June 2012 Page 8 of
47、 79 3.3.1 Environmental Conditions. Not applicable. 3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.4 Instructions. 3.4.1 Visual Examination. 3.4.1.1 P
48、urpose. Assure parts used for testing are free of damage and obvious defects. 3.4.1.2 Equipment. Normal lighting, photographic equipment, a device with at least 10 magnification as required. 3.4.1.3 Sample Preparation. All test samples shall be conditioned per 3.2.1. 3.4.1.4 Procedure. Not applicabl
49、e. 3.4.1.5 Pre-Test Visual Examination. Visually examine each test specimen before testing and/or conditioning. The test specimens shall not exhibit any evidence of deterioration, cracks and/or other deformities that could affect performance, function and/or appearance. A control sample shall be retained. Photographs and/or video recordings of the samples being te
