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1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243 TO PLACE A DOCU
3、MENT ORDER: (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http:/www.sae.org Copyright 1998 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 STANDARD Submitted for recognition as an American National Sta
4、ndard J2223-2 REV. DEC1998 Issued1994-02 Revised1998-12 Superseding J2223/2 FEB94 (R) Connections for On-Board Road Vehicle Electrical Wiring Harnesses Part 2: Tests and General Performance Requirements This document is technically equivalent to ISO 8092/2. ForewordThis Document been changed from a
5、Draft Technical Report to a Standard. Also it has been changed to comply with the new SAE Technical Standards Board Format. Definitions have been changed to Section 3. All other section numbers have changed accordingly. SAE J2223 consists of the following parts: SAE J2223-1Connections for On-Board R
6、oad Vehicle Electrical Wiring HarnessesPart 1: Single-Pole ConnectorsFlat Blade TerminalsDimensional Characteristics and Specific Requirements SAE J2223-2Connections for On-Board Road Vehicle Electrical Wiring HarnessesPart 2: Tests and General Performance Requirements SAE J2223-3Connections for On-
7、Board Road Vehicle Electrical Wiring HarnessesPart 3: Multipole ConnectorsFlat Blade TerminalsDimensional Characteristics and Specific Requirements 1.ScopeThis SAE Standard defines tests methods and general performance requirements of single-pole and multipole connectors for on-board electrical wiri
8、ng harnesses of road vehicles. These requirements are not intended for connections internal to electronic devices. This document applies to connectors designed to be disconnected after mounting in the vehicle in the case of repair and/or maintenance. 2.References 2.1Applicable PublicationsThe follow
9、ing publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J1128Low Tension Primary Cable SAE J1213/1G
10、lossary of Vehicle Networks for Multiplexing and Data Communications SAE J1213/2Glossary of Reliability Terminology Associated with Automotive Electronics SAE J1560Low Tension Thin Wall Primary Cable SAE J2183Unscreened Low Tension Cable (DRAFT) SAE J2223-2 Revised DEC1998 -2- SAE J2223-1Connections
11、 for On-Board Road Vehicle Electrical Wiring HarnessesPart 1: Single-Pole ConnectorsFlat Blade TerminalsDimensional Characteristics and Specific Requirements SAE J2223-3Connections for On-Board Road Vehicle Electrical Wiring HarnessesPart 3: Multipole ConnectorsFlat Blade TerminalsDimensional Charac
12、teristics and Specific Requirements 2.1.2ASTM PUBLICATIONAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM B 117Method of Salt Spray (Fog) Testing 2.1.3IEC PUBLICATIONAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. IEC-Publication 50International E
13、lectrotechnical Vocabulary - Chapter 581, Electromechanical compo- nents for electronic equipment 2.1.4ISO PUBLICATIONAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. ISO 8092/2Connections for on-board road vehicle electrical wiring harnessesPart 2: Test methods and general perform
14、ance requirements 2.2Related PublicationsThe following publications are for information purposes only and are not a required part of this document. 2.2.1IEC PUBLICATIONAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. IEC-Publication 529Classification of degrees of protection by enc
15、losures 2.2.2ISO PUBLICATIONSAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. ISO 6722-3Road vehiclesUnscreened low tension cablesPart 3: Conductor sizes and dimensions of thick insulated cables ISO 6722-4Road vehiclesUnscreened low tension cablesPart 4: Conductor sizes and dimensi
16、ons of thin insulated cables ISO 9227:1990Corrosion tests in artificial atmospheresSalt spray tests 3.DefinitionsSee SAE J1213 and IEC 50 chapter 581. For the purpose of SAE J2223, the following definitions apply. 3.1Flat Blades and ReceptaclesFlat Blades and receptacles are terminals (or contacts),
17、 see Figures 1 and 2. FIGURE 1MALE TERMINAL SAE J2223-2 Revised DEC1998 -3- FIGURE 2FEMALE TERMINAL 3.1.1BLADEThat part of an electrical terminal which is pushed into a female terminal, forming an electrical connection. 3.1.2FEMALE TERMINALThat part of an electrical connector which receives the blad
18、e, forming an electrical connection. 3.1.3POSITIVE LOCKING FEMALE TERMINALFemale terminal with automatic positive locking and manual unlocking device engaging the blade hole. 3.2DetentHole in the blade, which engages a raised portion of the female terminal, thus providing a latch for the mating part
19、s. 3.3Reference PointSpecially marked point used when making electrical test measurements. 3.4Typical Examples of ConnectionsA to D of Figure 3 show typical examples of connections. SAE J2223-2 Revised DEC1998 -4- FIGURE 3TYPICAL EXAMPLES OF CONNECTIONS SAE J2223-2 Revised DEC1998 -5- 3.5Multipole C
20、onnectionsFigure 4 shows multipole connections and their parts. Two connector halves mated form a connection. FIGURE 4MULTIPOLE CONNECTORS/CONNECTIONS 3.6DefinitionsDefinitions of wording changes from ISO-8092/2. (See Table 1.) TABLE 1WORDING CHANGES ISOSAE TabFlat Blade HousingConnector ConnectorTe
21、rminal Single Cable SealIndividual Cable Seal SAE J2223-2 Revised DEC1998 -6- 4.Test Procedures and Performance Requirements 4.1General 4.1.1TEST METHODS AND GENERAL SPECIFICATIONSAll test procedures shall be carried out at an ambient temperature of 23 C 5 C and a relative humidity between 45% and 7
22、5%, unless otherwise stated. Each test sequence (see Figure 5) shall be started with unused test samples manufactured to conform to the dimensions specified in the applicable part of this document. Female connectors for positive locking terminals shall be tested with blades with holes to permit lock
23、ing. Crimped connections shall be fixed to the cable with a crimping tool used in accordance with the manufacturers recommendations. Cables shall be according to SAE J2183, SAE J1560, or SAE J1128 or equivalent. The cable(s) used shall be noted in the test report. Care shall be taken that test sampl
24、es do not influence each other, e.g., in a heat chamber. 4.1.2GENERAL PERFORMANCE REQUIREMENTSConnectors and/or contacts that allow connections for multiple positions, e.g., nonoriented, 90 degree or 180 degree orienting, shall meet requirements in all intended positions. Electrical connectors of ot
25、her types, for example, circuit board and flexible circuits, shall also meet the following requirements. Particular requirements are under consideration. 4.1.3TEST SEQUENCESFor each test sample group in Table 1, a test sequence is indicated by Xs from top to bottom. For unsealed connectors, apply te
26、sts as in the test sample groups A, B, C, D, E, F, H, I. NOTETest sample group G is for sealed connectors. For sealed connectors, apply tests as in the test sample groups A, B, C, D, E, G, H, I. NOTETest sample group F is for unsealed connectors only. Each test sample group shall contain at least: a
27、.20 test samples in the case of single-pole connectors b.10 test samples in the case of 2-pole connectors c.7 test samples in the case of 3-pole connectors d.5 test samples in the case of 4-pole connectors e.In connectors with mixed types of contacts a minimum of 20 contacts of each type shall be te
28、sted All test samples shall be used for all tests in a test sample group. Each connector shall have the full complement of contacts fitted, unless otherwise specified in the test method. Measurements shall be taken on a minimum of four contacts per connector unless otherwise specified in the test me
29、thods. For 1-, 2-, and 3-pole connectors, all contacts shall be measured. SAE J2223-2 Revised DEC1998 -7- FIGURE 5TEST SEQUENCES AND PERFORMANCE REQUIREMENTS 4.2Visual Examination 4.2.1TEST METHODThe visual examination shall be carried out with naked eye (normal strength of vision, normal color perc
30、eption) at the most favorable viewing distance, and with suitable illumination. SAE J2223-2 Revised DEC1998 -8- 4.2.2PERFORMANCEVisual examination as detailed in 4.2.1 shall allow identification, appearance, workmanship and finish of the item to be checked against the relevant specification. If the
31、connector has a cable insulation support, the insulation grip shall not cut through the insulation and shall firmly enclose the cable. Both insulation and the cable conductor shall be visible between the conductor crimp and the insulation support on the tab and the female connector (see Figure 6), e
32、xcept insulation displacement connections. FIGURE 6CONDUCTOR AND INSULATION CRIMP Conductors shall protrude from the conductor crimp but shall not interfere with the mating part. All wire strands of the conductor shall be enclosed by the conductor attachment. There shall be no damaged wire strand(s)
33、. During visual examination, after tests as in the test sample groups A to I, special care shall be taken to ensure that as a minimum requirement no cracking, discoloration, deformation, and no water ingress (test sample group G only) is in evidence. 4.3Connection and Disconnection 4.3.1TEST METHODC
34、onnection and disconnection of connectors shall be performed as intended or as specified in the particular specification of the product. The rate for connection and disconnection shall be a constant speed between 50 and 150 mm/min. The applied speed shall be noted in the test report. The connector s
35、hall be subjected to test 4.3.1.1 or 4.3.1.2 as appropriate. 4.3.1.1Female Terminals (Without Positive Locking)The terminals shall be subjected to 10 connections and disconnections. The force necessary shall be measured at: a.First connection b.First disconnection c.10th disconnection SAE J2223-2 Re
36、vised DEC1998 -9- 4.3.1.2Positive Locking Female ConnectorEleven cycles of connection and disconnection shall be performed as follows: a.The first 10 cycles shall be performed operating the locking device at each cycle in accordance to the manufacturers instruction and normal use. b.The eleventh cyc
37、le shall be performed with the locking device engaged for the locking device strength test as in 4.5.2.2. The force necessary shall be measured at: a.First connection b.First disconnection c.10th disconnection 4.3.2PERFORMANCE REQUIREMENTSSingle-pole connectors, as tested in 4.3.1, shall conform to
38、the requirements specified in the applicable part of this document. For multipole connectors, the connection and disconnection forces, as tested in 4.3.1, shall be as in the particular specification of the user, supplier, or of a standard. 4.4Tensile Strength of the Cable Attachment 4.4.1TEST METHOD
39、The tensile strength of the cable attachment shall be tested by using suitable test apparatus at a constant speed within the range of 50 to 150 mm/min. The applied speed shall be noted in the test report. Each test sample shall be attached to the corresponding cable(s) as specified by the connector
40、manufacturer. If the connector has a cable insulation support it shall be rendered mechanically ineffective. When more than one cable is attached, the force according to Table 2 shall be applied to each cable by using separate samples. 4.4.2PERFORMANCE REQUIREMENTSThe tensile strength of the crimped
41、 connection, as tested in 4.4.1, shall withstand the minimum values specified in Table 2. Other types of cable attachment are under consideration. 4.5Connector Disengage Force 4.5.1LOCKING DEVICE STRENGTHThe purpose of this test is to check the ability of a locked connector to withstand a specific a
42、nd static actual load. Single-pole connectors and multipole connectors shall be subjected to test 4.5.2.1 or 4.5.2.2 as appropriate. TABLE 2MINIMUM TENSILE STRENGTH OF CRIMPED CONNECTIONS Nominal cross-sectional area of cable (mm2) 0.220.350.50.751.01.52.02.53.04.05.06.010.0 Minimum tensile strength
43、 (N) 40507090115155195235260320360400600 NOTEThe minimum tensile strength of connections for cables with nonspecified nominal cross-sectional areas shall be determined by interpolation. SAE J2223-2 Revised DEC1998 -10- 4.5.2TEST METHOD 4.5.2.1Single-Pole Connectors and Multipole Connectors with Lock
44、ing Devices Being Part of Their Housings (Without Positive Locking Female Connector)The procedure shall be carried out with the connector: a.Empty b.Full complement of contacts fitted A fixture (fixtures) shall be made which can be secured to the connector halves to be tested. The securing of this (
45、these) shall not distort either half of the connector during testing. The housing shall be mounted on the fixture(s) with the locking device engaged. The force shall be applied to the fixture in the disconnection direction and held constant for 10 s 2 s. 4.5.2.2Single-Pole Connectors and Multipole C
46、onnectors with Positive Locking Female ConnectorsAfter the 11th connection specified in 4.3.1.2, the force shall be applied on the test sample with the locking device engaged in the disconnection direction and held constant for 10 s 2 s. 4.5.3PERFORMANCE REQUIREMENTSSingle-pole connectors with locki
47、ng devices tested as in 4.5.1 shall conform to the requirements specified in the applicable part of this document. The locking device of multipole connectors tested as in 4.5.1 shall withstand a force of 100 N 2 N. 4.6Contact Insertion Force 4.6.1TEST METHODThe insertion force of the contact into th
48、e cavity shall be tested by using the minimum and maximum size of cable which can be attached, and be applied in the insertion direction via a test fixture, to be positioned as close as possible to the cable attachment. Care shall be taken that the contact under test is locked as provided for. The r
49、ate for insertion shall be a constant speed between 50 and 150 mm/min. The applied speed shall be noted in the test report. 4.6.2PERFORMANCE REQUIREMENTSThe contact insertion force, tested as in 4.5.1, shall be a maximum of 15 N for contacts, having cables attached with a nominal cross-sectional area of up to and including 1 mm2. For contacts with a cable having larger nominal cross-sectional areas, the force shall be a maximum of 30 N. In the case of sealed connectors or splash-proof connectors,