1、什么是什么是“USCAR”2USCAR：United States Council for Automotive Research LLC 美国汽车研究协会 http:/www.uscar.org/guest/index.php 什么是什么是“USCAR-21”3USCAR-21：Performance Specification for Cable-to-Terminal Electrical Crimps 端子压接的性能规范 发布日期：May 2002 最新版次：2008-1041、This specification defines basic test methods and requ
2、irements for solder-less crimped connections.本规范规定了无焊锡端子端压的基本试验方法和要求2、New or revised terminals shall be designed to meet this specification.新的或修改的端子在设计上须符合此规格。3、All grip applications shall meet this specification.Deviations must be approved by the customer engineering 所有新端压申请须符合此规格。偏差必须达到客户工程师的批准Usc
3、ar-21适用范围适用范围 51、SAE/USCAR-2：Performance Specification for Automotive Electrical Connector Systems 汽车电气插头系统SAE/USCAR-2性能规范2、SAE/USCAR-20：Field Correlated Life Test Supplement to SAE/USCAR-2 SAE/USCAR-20场相关寿命试验补充到 SAE/USCAR-2 参考文件参考文件61.1.1：The Crimp connection performance is characterized by:端压连接性能的
4、特点是：Mechanical performance is measured by terminal to conductor Pull-Out Force.机械性能是测量电线对端子的固著力 Electrical performance is measured by terminal-to-conductor Crimp Resistance.电气性能测量端子与电线端压部位的压接电阻。1.11.1：端压参数介绍：端压参数介绍71.1.2：The geometry of a conductor crimp is characterized by:导体压接几何形状的特点是：Conductor cr
5、imp height(CCH)前足高度 Conductor crimp width(CCW)前足宽度 Insulation crimp height(ICH)后足高度 Insulation crimp width(ICW)后足宽度 Burr(anvil flash)dimension on the base of the conductor grip 前足毛边尺寸 Step between the core and insulation tools 压接模具前后角的台 Crimp tooling geometry 端压模片的几何形状 Cut-off 连锁部 Bell mouth(flare)R
6、角 End of conductor 导体末端 End of Insulation 绝缘皮末端1.11.1：端压参数介绍：端压参数介绍 (续续1 1）81.11.1：端压参数介绍：端压参数介绍 (续续2 2）91.11.1：端压参数介绍：端压参数介绍 (续续3 3）10Default Tolerances,expressed as a percentage of the nominal value unless otherwise indicated:默认公差，是用书面公差的百分比来表示的，除非另有說明：Temperature=3 D.C溫度=3 o C Voltage=5%电压=5%Curr
7、ent=5%电流=5%Resistance=5%电阻=5%Length=5%长度=5%Time=5%时间=5%Force=5%力=5%Relative Humidity=5%相对湿度=5%1.21.2：默认测试公差：默认测试公差114.1：General Testing requirements 一般的测试要求 4.1.1：Dimensional Characteristics-尺寸特性Part construction shall conform to the dimensions,shape,and detail attributes specified on the latest rev
8、ision of the applicable part drawing(s).零件结构应符合該 最新的可适用的零件图面中要求的尺寸、形状和特殊要求12All material used in each test sample shall conform to the material specifications on the latest revision of the applicable part drawing(s).每个测试样本中使用的所有材料应当都符合最新的、适用的零件图中要求的规范。1.Any engineering development,prototype,or produ
9、ction parts be submitted for test.任何的任何工程研究、原型产品、或者量产品必须提交测试2.The samples submitted for test should be identified by description,part number,and revision letter.提交测试的样品应有明确的描述、品番、和版次。4.14.1：General Testing requirements General Testing requirements 一般的测试要求一般的测试要求 4.1.2：Material Characteristics -材料特性1
10、33.For validation testing,all parts are to be in their“as furnished for vehicle assembly”condition when testing begins.For example,electrical terminals typically have residual die lubricant on them when finally assembled into a vehicle.This same condition must prevail for test samples development,pr
11、ototype,or production parts may be submitted for test.对于确认试验，所有的零件都要在与其实际使用条件相同的情况下做试验（用于汽车中的组件）。例如，端子经常在装入汽车中时会有残留的模具润滑剂。那么试验的端子应该也有相同的条件。4.Samples submitted for any test shall be prepared per Appendix E.任何提交测试的样品都应按照附录E的要求进行准备4.1：General Testing requirements 一般的测试要求 4.1.2：Material Characteristics
12、-材料特性（续1）14This test is used to document the physical appearance of test samples and to assist in the evaluation of the effects of environmental conditioning on test samples.A comparison can then be made with other test samples.Examinations in most cases can be accomplished by a person with normal o
13、r corrected vision,and normal color sensitivity,under cool white lighting.Photographs and/or videos are encouraged as a more complete means of documentation.An appropriately identified untested sample from each test group must be retained for post-test physical comparisons if photographs/videos are
14、not taken 该试验是用于检查试验样品的物理外观，也用于样品进行环境试验后的外观情况。与其它样品进行比较。在大多数情况下该项检查由一个人（正常视力或纠正视力）在白炽灯下完成即可。鼓励用相片或视频录象的形式记录检查结果。假如没有使用相片或视频录象的形式记录检查结果就需要留几个样品（需要作出标志）用于与经过试验的样品作比较。4.2：Visual Inspection 目视检查 4.2.1：Purpose 目的151.The samples should conform to the requirements of the specified conditioning and any addi
15、tional measurements that are to performed.样品应符合规定的条件和任何附加要求的测量方法。2.For purposes of comparison and especially when only subtle appearance changes are anticipated,it is desirable to submit an additional sample to serve as a control 为便于比较，尤其当预期的微妙的外观变化，它要求提交附加的样品用作控制。4.2：Visual Inspection 目视检查 4.2.2：Sa
16、mples 样品16Video/photography equipment.摄像/拍照设备4.2：Visual Inspection 目视检查 4.2.3：Equipment 设备171.Visually examine each test specimen prior to testing and/or conditioning,noting in detail any manufacturing or material defects such as cracks,bending,deformation,etc.When specified in the test request/orde
17、r,take photographs and/or video recordings of representative samples to be tested and keep a properly labeled control sample 在测试和或环境负荷之前目视检查每一个测试样品，详细的记录任何的生产或原材料的不良，如裂开、弯曲、变形等。当有要求时采取相片或视频的形式记录时样品时，需要给样品贴个适当的标签并加以管控。4.2：Visual Inspection 目视检查 4.2.3：Procedure 流程182.After testing and/or conditioning,
18、re-examine each test sample and in detail any observable changes,such as physical distortions,cracks,etc.Compare the tested and/or conditioned samples to the control samples,the videos,and/or the photographs,recording any differences in the test report.The Authorized Person will need to provide an a
19、dditional sample for this purpose.在测试后 和或测试中，再次检查每一测试样品并详细记录任何观察到的变化，如物理形的变形、裂纹等，测试后或测试中的样品与控制样品进行比较，摄像或拍照在报告中记录任何有差异的现象，授权者需要提供额外的样品。4.2：Visual Inspection 目视检查 4.2.3：Procedure 流程（续1）193.If the terminal suppliers appearance requirements are more strict than those specified below,then the terminal su
20、pplier specifications should be applied.如果端子供应商的外观要求比该规范的要求更高，则执行供应商自己规范中的外观要求。4.Return test samples to requestor after all tests are completed and all necessary data have been obtained.在所有测试完成和所有必需的数据都已经获得后，返回测试样本给申请者。4.2：Visual Inspection 目视检查 4.2.3：Procedure 流程（续2）201.General Appearance Refer to
21、Figure 4.2.5.The crimping operation should not affect the contact,locking,connector mating,or insertion functions of the terminal.These characteristics are verified as part of USCAR-2 testing.总的外观-参考图4.2.5压接操作不能影响接触，锁住，连接配合或端子的插入功能，这些特性按照USCAR-2测试进行验证4.2：Visual Inspection 目视检查 4.2.3：Acceptance Crite
22、ria 接受标准212.End of conductor The end of conductor must extend beyond the front edge of the conductor crimp.The insertion and locking functions of the terminal must not be affected by the projecting end of the conductor.Mat seals(plug through seals)must not be damaged by the core,and may require core
23、 depressors and strip length control to depress the core in front of the core wing.导体的末端必须超出芯线压线角的前端。导体的末端的突出不能影响端子的插入和锁住功能。配合的密封物不会被芯线破坏并且需要控制芯线和剥头长度，芯线在芯线压线脚的前端。（此处芯线即是导体）end of conductor4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续1）223.End of insulation The end of the insulation mu
24、st be visible in the window between the conductor crimp wings and the insulation crimp wings such that conductor is visible and should be centralized as much as possible.In no case may insulation be crimped in the conductor crimp 绝缘体的末端-绝缘体的末端必须在端子的前后足间的窗口可以以看得见，同样，在端子的前后足间的窗口必须也能看得见导体，尽可能在中间，无论如何，不
25、可以绝缘绝缘加缔加缔加缔了4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续2）234.Cut-off The cut-off length shall not exceed 0.5 mm or terminal stock thickness,whichever is greater,unless otherwise specified on the component print.连锁部的长度不能超过0.5毫米或者端子板厚的一半，取最大者，除非在零件图面上另有规定。4.2：Visual Inspection 目视检查 4.
26、2.3：Acceptance Criteria 接受标准（续3）244.Cut-off 4-1、The burr on the cut-off must not exceed 0.3 mm on terminal stock 0.8 mm unless otherwise specified on the component print.The burr must not exceed 0.6 mm on 0.8 mm stock thickness unless otherwise specified on the component print.连锁部上的毛边，在端子板厚小于或等于0.8毫
27、米时，不能超过0.3毫米；在端子板厚 大于0.8毫米时，不能超过0.6毫米；除非在零件图面上另有规定。4-2、The cut-off and burr must not affect the insertion function of the terminal into the connector.连锁部和毛边不能影响端子对连接器的插入功能4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续4）255.Bellmouth(Flare、R）喇叭口、R形 5-1、Single Stage Conductor Crimp：The co
28、nductor crimp may also have a Bellmouth(flare)on the front edge of the conductor crimp,nearest the terminal body.前前R在需要时可以在需要时可以有有4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续5）The conductor crimp(d.)shall produce a Bellmouth(flare)on the side of the grip nearest the insulation crimp.必
29、须要有必须要有后后R RBellmouth(flare)on the insulation crimp(e.)should not exceed the insulation crimp tolerances.后足后足上的上的R型不应超出后足端压的公差型不应超出后足端压的公差26Bellmouth(flare)not required on second stage.第二第二个台阶不需要个台阶不需要R R型型4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续6）5.Bellmouth(Flare、R）喇叭口、R形 5-2、Tw
30、o Stage Conductor Crimp：276.Conductor Crimp All individual strands must be enclosed in the crimp.Crimps with strands lying outside the crimp or broken off before the crimp,are not permitted.所有的芯线都必须被压接在前足里面，芯线外露或在端压芯线外露或在端压前芯前芯线断裂是不允许线断裂是不允许的的 4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标
31、准（续6）287.Insulation Crimp 后足 7.1：The purpose of an insulation grip is to add strain relief to the crimped conductor.This moves the stress riser between the crimped and un-crimped wire strands out into the un-crimped portion of the wire core 后足的目的是增加对芯线压线脚的应变消除，7.2：The crimped Insulation grip must co
32、ntact the surface of the insulated cable in at least 3 locations around the circumference of the cable(three point contact).Total contact is also acceptable.端子的后足至少要有3点与绝缘体接触，后足完全与绝缘体接触式可以接受的4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续7）297.Insulation Crimp 后足（续1）7.3：The crimped Insul
33、ation grip dimensions are reference dimensions.后足的端压尺寸是只是参考尺寸。7.4：The crimped Insulation grip must not interfere with any subsequent operations.端压的后足不能影响后续的任何操作。7.5：The crimped Insulation grip must not interfere with seating of a terminal into a plastic connector cavity 端压的后足不能对端子插入到连接器孔位产生任何影响。4.2：
34、Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续8）304.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续9）7.Insulation Crimp 后足（续2）7.6：The crimped insulation grip must not damage the cable(see Paragraph 4.3.5-3)后足不能讲电线损伤318.Cable Conductor Appearance prior to crimping 端压前导体的外观端压前导体的外观要
35、求要求 8.1：Strands shall not be cut,missing,excessively nicked(strand area reduction which may affect pull-out force),or elongated.芯线不可切断、少芯线、过分的伤痕（导体面积减少会影响固著力）或拉伸的。8.2：Insulation shall not be stuck or imbedded in strands.绝缘体不可与导体粘住或浸入到导体里4.2：Visual Inspection 目视检查 4.2.3：Acceptance Criteria 接受标准（续9）32
36、Cross-sectional analysis is used as a diagnostic aid in determining why a grip passes or fails a portion of this test.Failure to pass an electrical test may be due to uneven strand dispersion,inadequate wing closure,voids,wings bottoming out,etc 截面分析作为压接检验的一部分。没有通过电气性能试验可能是由于芯线散股，压线脚没有充分包住，空芯线，底部开裂等
37、造成。4.3：Cross-Section Analysis 截面分析 4.3.1：Purpose 目的33At least one specimen for each crimp height shall be evaluated.shall be obtained and recorded for minimum,maximum and nominal production crimp heights.每个压接高度至少有一个样品用于分析。必须获得最大压接高度，最小压接高度和基本压接高度的数据并记录 即即：至少：至少3个样品，压规上限规格、个样品，压规上限规格、压规压规中间规格、压规下限规格各
38、中间规格、压规下限规格各1个个4.3：Cross-Section Analysis 截面分析 4.3.2：Sample Size 样品数量34Various specialized equipment exists for cross-sectioning samples.The choice of equipment is up to the supplier,but should be capable of sectioning the crimp with minimal disturbance to the terminal and cable stranding.有很多专业的设备可以
39、做截面分析，设备的选择由供应商自己负责，但是获取截面分析时需不能影响端子和芯线。4.3：Cross-Section Analysis 截面分析 4.3.3：Equipment 测试设备351.Cross-section and photograph each sample for analysis 获取截面并拍照下来用于分析2.Cross-section analysis shall be performed on all conductor crimp applications at each crimp height setting(nominal,min.and max.toleranc
40、e).对所有导体的压接高度（正常、最小和最大公差）进行分析 即即：至少：至少3个样品，压规上限规格、个样品，压规上限规格、压规压规中间规格、压规下限规格各中间规格、压规下限规格各1个个 4.3：Cross-Section Analysis 截面分析 4.3.4：Procedure 步骤363.Cross-sections shall be performed between the serrations,as near to the mid-point of the core crimp as possible.截取截面的位置，应尽可能在端子前足的中间中间部位部位4.3：Cross-Secti
41、on Analysis 截面分析 4.3.4：Procedure 步骤（续1）中间部位，大约1/2处374.Compare the samples to the acceptance criteria of paragraph 4.3.5 Acceptance Criteria 与4.3.5可接受的标准进行比较4.3：Cross-Section Analysis 截面分析 4.3.4：Procedure 步骤（续2）385.Matters needing attention 注意事项 截面截取的时候，不可有倾斜，必须垂直于压接的X轴和Y轴：X4.3：Cross-Section Analysis
42、 截面分析 4.3.4：Procedure 步骤（续3）391.Cross-section views of crimped conductor grips 前足的接受标准 Crimped Conductor Grip attributes considered ideal认为理想的前足压接截面 Symmetric 对称 Compaction of all strands(no round strands)所有芯线都要被压缩 Wings touch only conductor 前足的爪子仅仅接触到芯线 Terminal stock free of cracks/breaks 端子没有裂痕、开
43、裂 Core wings Locked(No Gap)at top of crimp 前足两爪之间没有间隙4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准40Symmetric 对称X1=X2X1X2X4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续1）1.Cross-section views of crimped conductor grips 前足的接受标准（续1）41Crimped Conductor Grip attributes
44、 considered acceptable but not ideal.下面的可以接受但不理想4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续2）1.Cross-section views of crimped conductor grips 前足的接受标准（续2）42Crimped Conductor grip attributes considered unacceptable下面你的压接是认为不可接受的（一）Open wings with conductor exposed or folded down i
45、nto core but not touching(not locked)前足两爪之间露电线，且没有闭合4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续3）1.Cross-section views of crimped conductor grips 前足的接受标准（续3）43No strand compaction芯线没有被压缩4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续4）Crimped Conductor grip attr
46、ibutes considered unacceptable下面你的压接是认为不可接受的（二）1.Cross-section views of crimped conductor grips 前足的接受标准（续4）44Terminal stock cracked/broken端子内部有裂痕或断裂4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续5）Crimped Conductor grip attributes considered unacceptable下面你的压接是认为不可接受的（三）1.Cross-sect
47、ion views of crimped conductor grips 前足的接受标准（续5）45One or both wings(grips)penetrate(“crash”)to the terminal floor or wall端子前足爪部其中的一个或两个接触到端子内壁4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续6）Crimped Conductor grip attributes considered unacceptable下面你的压接是认为不可接受的（四）1.Cross-section vi
48、ews of crimped conductor grips 前足的接受标准（续6）46One or both wing(grip)details do not capture strands端子前足爪部的一个或两个没有抓住芯线4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续7）Crimped Conductor grip attributes considered unacceptable下面你的压接是认为不可接受的（五）1.Cross-section views of crimped conductor gri
49、ps 前足的接受标准（续7）47One or both wings folded back端子前足爪部的一个或两个向外翻折4.3：Cross-Section Analysis 截面分析 4.3.5：Acceptance Criteria 接受标准（续8）Crimped Conductor grip attributes considered unacceptable下面你的压接是认为不可接受的（六）1.Cross-section views of crimped conductor grips 前足的接受标准（续8）48Note:With OEM customer approval,the a
50、bove attributes listed as unacceptable may be considered acceptable if it can be shown that all other requirements of this specification are met and past production experience has shown them to be functional in the intended application.注释：如果经过OEM顾客的批准，碰到以下情况可以对上述的一些不能接受的压接作出让步接收：该压接虽然没有符合接受标准，但是符合本规
