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The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United
States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the
contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes.
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Revised 2020-02
PERFORMANCE SPECIFICATION
FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS
Notice about interim revisions: Updates may be made as “interim revisions.” Interim revisions are available at:
https://ewcap.uscarteams.org/revisions.html
.
TABLE OF CONTENTS
1.
SCOPE ....................................................................................................................................................... 4
2. TEST SEQUENCE ..................................................................................................................................... 4
3. REFERENCED DOCUMENTS .................................................................................................................. 4
3.1 Document Hierarchy .................................................................................................................................. 4
3.2 Part Drawing .............................................................................................................................................. 5
3.3 Product Design Specification ..................................................................................................................... 5
3.4 Test Request/Order .................................................................................................................................... 5
3.4.1 Samples, Test Type, and Special Tests .................................................................................................... 5
3.4.2 Test Request/Order Instructions ................................................................................................................ 5
3.4.3 Performance and Durability Test Instructions ............................................................................................ 5
3.5 Documents Mentioned in This Specification .............................................................................................. 5
4. GENERAL REQUIREMENTS .................................................................................................................... 6
4.1 Record Retention ....................................................................................................................................... 6
4.2 Sample Documentation .............................................................................................................................. 6
4.3 Sample Size ............................................................................................................................................... 6
4.4 Test Conditions and Tolerances ................................................................................................................ 6
4.5 Equipment .................................................................................................................................................. 7
4.6 Measurement Resolution ........................................................................................................................... 7
4.7 Test Repeatability and Calibration ............................................................................................................. 7
4.8 Conformance Determination ...................................................................................................................... 7
4.9 Disposition of Samples............................................................................................................................... 8
4.10 Part Endurance .......................................................................................................................................... 8
5. TEST and ACCEPTANCE REQUIREMENTS ........................................................................................... 8
5.1 General....................................................................................................................................................... 8
5.1.1 Performance Requirements ....................................................................................................................... 8
5.1.2 Dimensional Characteristics ...................................................................................................................... 8
5.1.3 Material Characteristics.............................................................................................................................. 8
5.1.4 Classifications ............................................................................................................................................ 8
5.1.5 Testing Headers and Direct Connect Components ................................................................................. 10
5.1.6 Terminal Sample Preparation .................................................................................................................. 11
5.1.7 Connector and/or Terminal Cycling ......................................................................................................... 11
5.1.8 Visual Inspection ...................................................................................................................................... 11
5.1.9 Circuit Continuity Monitoring .................................................................................................................... 12
5.1.10 Mat Seal Sample Preparation .................................................................................................................. 14
5.2 Terminal Mechanical Tests ...................................................................................................................... 15
5.2.1 Terminal to Terminal Engage/Disengage Force ...................................................................................... 15
5.2.2 Terminal Bend Resistance ....................................................................................................................... 16
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