SAE-J1742-2005.pdf

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1、 SURFACE VEHICLE RECOMMENDED PRACTICE (R) Connections for High Voltage On-Board Road Vehicle Electrical Wiring Harnesses Test Methods and General Performance Requirements SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineer

2、ing sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be

3、reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2005 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, r

4、ecording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS: http:/www.sae.org Issued 1998-03 Revised 2005-12 Superseding J1742 MAR199

5、8 J1742 REV. DEC2005 TABLE OF CONTENTS 1. Scope.2 1.1 Rationale3 2. References.3 2.1 Document Hierarchy 3 2.2 Part Drawing 3 2.3 Product Design Specification.3 2.4 Test Request/Order3 2.5 Other Referenced Documents.4 2.6 Related Publications 4 3. Definitions and Abbreviations 4 3.1 Definitions.4 3.2

6、 Abbreviations .5 4. General Requirements.5 4.1 Equipment5 5. Test and Acceptance Requirements5 5.1 General.5 5.2 Terminal - Mechanical Tests6 5.3 Terminal - Electrical Tests .7 5.4 Connector - Mechanical Tests.12 5.5 Connector - Electrical Tests.13 5.6 Connector Environmental Tests.15 5.7 Special T

7、ests15 5.8 Severe Duty Tests16 5.9 Test Sequence.16 Appendix A Tests Recommended for New Tooling, Tool Transfer, or Material Change21 Appendix B Tests for New/Existing Terminal or Connector Designs23 Appendix C Design Notes24 SAE J1742 Revised DEC2005 - 2 - NOTENo electrical connector, terminal, or

8、related component may be represented as having met SAE specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts. If testing is performed by a

9、nother source, it does not relieve the primary supplier of responsibility for documentation of all test results and for verification that all samples tested met all applicable Acceptance Criteria. See Section 4. 1. Scope Procedures included within this specification are intended to cover performance

10、 testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in high power (20 V to 600 V and/or 80 amps) road vehicle applications. These procedures are applicable only to terminals used f

11、or In-Line, Header, and Device Connectors and for cable sizes up to 120 mm 2 (4/0). In cases where power levels are mixed in the same connector, (i.e. sensing or normal 14.5 volt system circuits with High Power Contacts) the High Power Contacts must pass J1742 requirements, and all other contacts mu

12、st pass SAE J2223-2 requirements. The connection system (housing and high power contacts) shall meet J1742 requirements. The requirements and procedures in this document are not intended for connections internal to electrical/electronic modules or complete subassemblies. This document does not conta

13、in a test for EMI/EMC since these parameters must be tested as a combination of cable and connector. These are considered system level requirements. Determination of the need and type of test must be considered at that level. See Appendix C, Design Notes for further information. IMPORTANT NOTICE: In

14、 any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicl

15、e application. By way only of example, this includes products that may be subjected to temperatures beyond the extremes of Class 5 in Table 2 of SAE J2223-2, or may be subjected to shock or vibration in the un-sprung portions of a vehicle, such as the wheel hub. Products certified by their supplier

16、as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for

17、 what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and for authorizing any deviations to the equipment, procedures and/or acceptance requirements contained in this specification. Any such deviation must b

18、e documented and included in the final test report and on the part print. The following are examples of appropriate print notations: Example 1: Test value per SAE J2223-2, Revision 1, paragraph 5.4.2 Connector Mating/Un-mating Force mating force value = 85 N. Example 2: SAE J2223-2, Revision 1, para

19、graph 5.4.9 Cavity Damage Susceptibility not applicable to this design. SAE J1742 Revised DEC2005 - 3 - Agreement to waive or alter test procedures and Acceptance Criteria must be made between customer and supplier. Guidance as to the recommended tests for selected purposes is given in the charts in

20、 Appendix A and B. In the absence of contrary direction from the Authorized Person in the test request/order, all electrical connectors and their associated terminals and other components are required to meet all applicable portions of this document with the following exception: Specific tests that

21、are not required or additional test requirements as specified in any document in the hierarchy of Section 2. 1.1 Rationale Numerous technological advances have been made since the original document was issued. USCAR and SAE have also cooperated on the development of more refined connector test metho

22、ds and acceptance criteria. These changes are reflected in this revision of J1742. 2. References 2.1 Document Hierarchy In the event there is a conflict between performance specifications, part drawings, and other related standards or specifications, the requirements shall be prioritized as follows:

23、 1 st Applicable FMVSS requirements and other applicable state and Federal requirements 2 nd Applicable part drawings 3 rd Applicable product design specification(s) 4 th Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) 5 th Applicable SAE performance specifications 6

24、th Other applicable standards and specifications 2.2 Part Drawing See SAE J2223-2 for part drawing information. 2.3 Product Design Specification See SAE J2223-2 for Product Design Specification information. 2.4 Test Request/Order Refer to SAE J2223-2 for Test Request information. SAE J1742 Revised D

25、EC2005 - 4 - 2.5 Other Referenced Documents 2.5.1 SAE PUBLICATIONS Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J2223-2Connections for On-Board Road Vehicle Electrical Wiring Harnesses SAE J1127Battery Cable SAE J1128Low Tension Primary Cable SAE/USCAR-23Road Vehicle60

26、V and 600 V Single Core (ISO/Metric) CablesDimensions, Test Methods and Requirements 2.6 Related Publications The following publications are provided for information purposes only and are not a required part of this document. 2.6.1 SAE PUBLICATIONS Available from SAE, 400 Commonwealth Drive, Warrend

27、ale, PA 15096-0001. SAE J1654High Voltage Primary Cable SAE J1673Recommended Practice for High Voltage Wiring Assemblies 3. Definitions and Abbreviations 3.1 Definitions Terms defined in the definitions or abbreviations sections are capitalized (i.e. Room Temperature, PLR, etc.) See SAE J2223-2 for

28、additional definitions applicable to this document. 3.1.1 BREAKDOWN The failure of the dielectric of an insulation under the effect of an excessive electric field and/or by physical or chemical deterioration of the dielectric material. 3.1.2 CONNECTOR A component which terminates conductors for the

29、purpose of providing connection and disconnection to a suitable mating component. Connectors are designed to be connected and disconnected in the de-energized state unless otherwise specified. See Appendix C. 3.1.3 CONNECTOR HOUSING The part of a connector into which the insert and contacts are asse

30、mbled. 3.1.4 CONTACT Conductive element in a component that mates with a corresponding element to form an electrical path. -,-,- SAE J1742 Revised DEC2005 - 5 - 3.1.5 HIGH POWER CONNECTOR Any connector containing one or more High Power Contacts. Connectors fitting this description shall meet the req

31、uirements of SAE J1742. 3.1.6 HIGH POWER CONTACT Terminal assembly contained within a connector that operates at between 20 V and 600 V and/or 80A for any portion of their duty cycle. 3.1.7 RATED VOLTAGE Voltage level at which a device is designed to operate. 3.1.8 HIGH POWER CONTACT Any connector c

32、ontact designed to carry 20 Volts (AC rms or DC) and/or 80 amps. 3.2 Abbreviations See SAE J2223-2 for abbreviations. 4. General Requirements See SAE J2223-2 for General Requirements. 4.1 Equipment Equipment is required per J2223-2. In addition, the items found in Table 1 are required for testing Hi

33、gh Voltage Connection Systems. TABLE 1EQUIPMENT Item Description Requirements 1 High Potential Tester with load meter AC 1000 V rms (50-60 Hz or DC 1600 V 5. Test and Acceptance Requirements 5.1 General See SAE J2223-2 for General Test and Acceptance Requirements. All sections of J2223-2 apply to th

34、e testing and validation of high Power connections systems except as noted in this document. Certain additional testing as described herein shall also be conducted. 5.1.1 CIRCUIT CONTINUITY MONITORING Where Continuity Monitoring is required, follow the Circuit Continuity Monitoring procedures in SAE

35、 J2223-2. No Circuit Continuity Monitoring is required during any conditioning procedure for contacts operating above 20 volts. SAE J1742 Revised DEC2005 - 6 - 5.2 Terminal - Mechanical Tests 5.2.1 TERMINAL-TO-TERMINAL ENGAGE/DISENGAGE FORCE Conduct the Terminal-to-Terminal Engage/Disengage Force pe

36、r SAE J2223-2. 5.2.2 TERMINAL BEND RESISTANCE Conduct the Terminal Bend Resistance Test per SAE J2223-2. 5.2.3 TERMINAL TO CONDUCTOR ATTACHMENT (CRIMP) PULL-OUT FORCE 5.2.3.1 Purpose This procedure details a standard method to measure the retention capability of crimped connections. NOTEPull-out for

37、ce test shall not be used to determine electrical performance of the crimp application. It is used only to determine the mechanical limits of the crimp application for handling purposes 5.2.3.2 Equipment 1. Measuring device capable of measuring crimp heights and widths. 2. De-crimping tool, or other

38、 suitable means of opening insulation crimps without damaging the cable conductor. (Note: it is acceptable to make the samples with the insulation crimp not crimped to avoid this step.) 3. Force Tester. 4. Cable strippers, long-nose pliers and/or side cutters. 5.2.4 PROCEDURE 1. A minimum of 20 samp

39、les is required to be tested for each production crimp height. Data shall be obtained and recorded for minimum, maximum, and nominal production crimp heights. 2. Samples shall be applied to appropriate cable with overall length no less than 150 mm. 3. Pull-out force test shall be performed on leads

40、with the insulation crimp wings open (not crimped). 4. Pull-out force test shall be performed on taut leads (i.e., remove slack in cable before performing pull- out test to prevent incorrect test results due to “jerking”). 5. Measure and record the conductor crimp and insulation crimp heights and wi

41、dths in millimeters for each sample. 6. If the insulation crimp is not already open, open the insulation crimp with the de-crimper or other suitable tool so that the pull-out force will reflect only the conductor crimp connection. 7. Visually inspect the de-crimped area to ensure that none of the co

42、nductor strands have been damaged. Do not use any samples that have damaged conductor strands. 8. Measure and record pull-out forces in Newtons for each sample. 9. Apply an axial force at a rate between 50 and 250 mm/min (100 mm/min is recommended). 10. For double, triple, or multiple crimp setups w

43、ith conductor sizes within one conductor size step, pull the smallest conductor. (e.g. for a .35/.50 double, pull the .35 mm 2 wire). -,-,- SAE J1742 Revised DEC2005 - 7 - 11. For double, triple, or multiple crimp setups with conductor sizes more than one step apart, one of the smallest and one of t

44、he largest gage size cables must be tested. (e.g. for a .50/1.0 double, pull both wires individually, for a .50/1.0/2.0 triple, pull the .50 mm 2 and the 2.0 mm2 wires, for a .50/.50/2.0 triple, pull one of the .50 mm 2 and the 2.0 mm2 wires.) In this case, 20 samples per wire size tested will be re

45、quired. 12. Report any observations from visual examination. 5.2.5 ACCEPTANCE CRITERIA 1. The minimum pull-out forces for cables up to 8.0 mm 2 are specified in Table 2. The pull-out forces for unlisted conductor sizes can be defined by linear interpolation, (i.e. read out from plotted values in Tab

46、le 2). 2. For cable sizes 8.0 mm 2, the minimum pull-out value is 600 N. TABLE 2PULL-OUT FORCE REQUIREMENTS Approx. (mm 2) AWG Minimum Pull-out Force (N) Reference MinimumCable Break Strength (N) 0.22 24 40 0.35 22 50 (Annealed Core) 58 0.35 22 70 (Hard Drawn Core) 0.5 20 75 91 0.8 18 90 136 1.0 16

47、120 202 1.5 150 2.0 14 180 331 2.5 210 3.0 12 240 521 4.0 265 5.0 10 290 833 6.0 320 8.0 8 350 5.3 Terminal - Electrical Tests 5.3.1 VOLTAGE DROP 5.3.1.1 Purpose This test determines the voltage drop associated with the electrical resistance of the conductor crimp(s) and contact interface regions at

48、 nominal current conditions. This voltage drop is then used to calculate the Total Connection Resistance. For terminals rated 80 amps, refer to SAE J2223-2 for completion of the Voltage Drop test. -,-,- SAE J1742 Revised DEC2005 - 8 - 5.3.1.2 Equipment Digital Multimeter (DMM) AC or DC Power Supply

49、(Voltage and current as required) Current shunts 5.3.1.3 Procedure 1. Voltage Drop readings are taken at the maximum current rating of the terminal and cable combination as determined in Section 5.3.2, Maximum Current Test. Adjust the power supply to provide the required test current. Record the test current used. More than one terminal pair may be tested in series. Refer to Figure