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Performance Specification for Welded Wire-to-Wire Splices

USCAR
  • Ground Vehicle Standard
  • USCAR45
  • Current
Published 2018-06-14 by SAE International in United States

SAE/USCAR-45 defines test methods and performance requirements for ultrasonically-welded wire-to-wire splices for automotive applications. Face-to-face, butt splice, and center strip configurations per Figure 1 can be tested. The tests defined in this specification subject samples on test to stresses that simulate a lifetime of exposure for a road vehicle. Stresses called out in this specification include thermal shock, temperature/humidity cycling and mechanical stress from different directions.

Electrical Connector Design Criteria

USCAR
  • Ground Vehicle Standard
  • USCAR12-5
  • Current
Published 2017-08-17 by SAE International in United States
This document gives specific and measurable design criteria to be applied at a design review prior to tooling. The specification is formatted as a checklist to aid in its use. The requirements do not apply in all situations so engineering judgment must be used. This is a specification for design criteria; applicable performance specifications (USCAR-2, etc.) must still be performed

Road vehicles - 60 V and 600 V single core cables - Dimensions, test methods and requirements

USCAR
  • Ground Vehicle Standard
  • USCAR23-1
  • Current
Published 2017-07-13 by SAE International in United States
No Abstract Available.

Performance Specification for Automotive Wire Harness Retainer Clips

USCAR
  • Ground Vehicle Standard
  • USCAR44
  • Current
Published 2017-05-10 by SAE International in United States

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of "branches" that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal from 0.6mm to 8mm thick so this specification focuses on that range. Outside of this range requires a custom test. The procedures described in this document have been evaluated for the design types shown in Table 2.3. Use of USCAR-44 for other than a design shown in Table 2.3 may or may not produce acceptable test correlation to actual experience but USCAR has not reviewed any data. USCAR-44 can be used at all phases of development, production, and field analysis since it is a performance test and not a process validation or quality assessment. No retainer may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be provided by the supplier of the part. If testing is performed by another source, it does not relieve the primary supplier of responsibility for documentation (DVP&R) of all test results and for verification that all samples tested met all applicable acceptance criteria. This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of "branches" that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal from 0.6mm to 8mm thick so this specification focuses on that range. Outside of this range requires a custom test. The procedures described in this document have been evaluated for the design types shown in Table 2.3. Use of USCAR-44 for other than a design shown in Table 2.3 may or may not produce acceptable test correlation to actual experience but USCAR has not reviewed any data. USCAR-44 can be used at all phases of development, production, and field analysis since it is a performance test and not a process validation or quality assessment. No retainer may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be provided by the supplier of the part. If testing is performed by another source, it does not relieve the primary supplier of responsibility for documentation (DVP&R) of all test results and for verification that all samples tested met all applicable acceptance criteria.

Performance Specification for Automotive RF Connector Systems

USCAR
  • Ground Vehicle Standard
  • USCAR17-5
  • Current
Published 2016-11-30 by SAE International in United States
1.0 SCOPE 1. This document contains procedures for testing performance of SMB-style electrical terminals, connectors and components for coaxial cable connection systems intended for road vehicle applications. These are often called FAKRA II designs. This specification does not apply to the Non RF portion of a Hybrid RF connection system. 2. The intent of this specification is to qualify sealed and unsealed RF connectors that operate at frequencies from DC to 6 GHz. The characteristic impedance of the SMB/FAKRA connection system is 50 ohms however this specification does not exclude the use of these RF connectors on non-50 ohm cables or systems. 3. This specification does not apply to single conductor wire or twisted pair connection systems. 4. This specification (along with SAE/USCAR 18) is designed to provide the mechanical and electrical data required to insure that assemblies from various manufacturers will perform reliably in actual conditions. There is intermateability testing included in this specification. End users who may be concerned about intermateability are responsible to request the supplier complete this testing.

USCAR17 Supplement

USCAR
  • Ground Vehicle Standard
  • USCAR18-4
  • Current
Published 2016-07-21 by SAE International in United States

This document is a supplement to SAE/USCAR 17 and is intended to give recommended usages for one and two-way RF connectors and dimensional requirements for 2-way RF connectors and hybrid (RF & DC power) connectors which are not currently specified elsewhere. The radio frequency (RF) connector interface specified herein is suited for unsealed and sealed automobile applications up to 6 GHz and is intended for in-line, board mount, device mount, straight or angled applications. Dimensional requirements are specified in this document to ensure interchangeability. Compliance with the dimensional requirements of this specification will not guarantee interoperability between different suppliers mating connectors. It is the supplier responsibility to ensure RF performance requirements are met with other suppliers mating connectors. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.

Performance Specification for Ultrasonically welded wire terminations

USCAR
  • Ground Vehicle Standard
  • USCAR38-1
  • Current
Published 2016-04-05 by SAE International in United States
This specification defines test methods and performance criteria for evaluating ultrasonically welded wire-to-terminal metallurgical bonds. The examples used are specific to the linear weld type of process equipment. USCAR-38 is not applicable for “Splice Welding”. The specification is applicable to wire-on-pad configurations with a typical weld shown in Figure 1. This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures called-out in this specification include Thermal Shock, Temperature Humidity Cycling and mechanical abuse. This test specification is intended to evaluate the strength and performance of the interface between wires to an electrical terminal. Validation of the performance of the Terminal is a separate task and can be accomplished using a component validation test such as SAE/USCAR-2, which evaluates whether the entire connection system is acceptable.

ERGONOMICS SPECIFICATION FOR ELECTRICAL CONNECTIONS

USCAR
  • Ground Vehicle Standard
  • USCAR25-3
  • Current
Published 2016-03-10 by SAE International in United States

This document decribes the deign relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). The minimum values associated with this design guide need to be evaluated against other critical characteristics that impact quality, efficiency and other traits of assembly feasibility.

Ergonomics Specification for Electrical Connections

USCAR
  • Ground Vehicle Standard
  • USCAR25-2
  • Historical
Published 2016-02-15 by SAE International in United States
This document describes the design relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). The minimum values associated with this design guide need to be evaluated against other critical characteristics that impact quality, efficiency and other traits of assembly feasibility. All possible designs and applications could 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.
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ELECTRICAL CONNECTOR DESIGN CRITERIA

USCAR
  • Ground Vehicle Standard
  • USCAR12-4
  • Historical
Published 2016-02-12 by SAE International in United States
This document gives specific and measurable design criteria to be applied at a design review prior to tooling. The specification is formatted as a checklist to aid in its use. The requirements do not apply in all situations so engineering judgment must be used. This is a specification for design criteria; applicable performance specifications (USCAR-2, etc.) must still be performed. Items in this document are grouped by component as follows: A Terminals B Secondary Terminal Locks C Connectors D Connector Locks E Secondary Connector Locks (Connector Position Assurance, CPA) F Connector Seals G Serviceability H High Voltage (≥60V) Application Requirements I Drawing and General Requirements
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