PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMP
端子压接的性能规范
1. SCOPE范围
IMPORTANT NOTICE: In 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 vehicle application. Products certified by their supplier 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 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 to authorizing any deviations to the equipment or procedures contained in this specification. Any such deviation must be documented and included in the final test report.
重要提示：在任何汽车应用中，对于本规范没有涉及到的情况，产品必须通过相应的特殊试验，该试验的试验条件应该模仿汽车在实际使用中的条件。对于通过了该规范中要求的试验的产品，使用时也不能应用于超过该试验条件的场合。权威人士是最终有权指出他或她的产品需要做哪些试验并且这些试验有哪些目的的人。对于解决该规范中出现的任何试验问题，对于与该规范中包含的试验设备和试验程序相违背的情况，他或她仍然是有最终决定权的人。试验中出现的任何不符合性都必须作记录，并记录在最终试验报告中。
1. This specification defines basic test methods and requirements for solder-less crimped connections.
1.在该规范中定义了关于纯压接连接（没有焊接）的基本试验方法和试验要求。
2. Crimp applications validated to this specification supercede any crimp information on Ford, GM, or DaimlerChrysler component prints. It is preferred that the terminal supplier do testing and selection of crimp tooling and supply detailed crimp information or make crimp tooling available to the wiring assembly supplier actually doing the production
crimping. If the wiring supplier deviates from this information or it is not available, then the responsibility for testing to this specification or getting approval from the customer with appropriate test data showing that the crimp will function in it’s intended circuit lies with the wiring harness supplier.
2.该生效的压接规范代替了Ford,GM, or DaimlerChrysler的任何压接信息。端子供应商做试验和选择压接工具和提供详细的压接信息，或需要端子压接的供应商制作压接工具。假如与该规范违背或不适用，那么该规范的试验或关于证明符合预期压接功能的试验数据得到顾客的批准的责任将由线束供应商承担。
3. New or revised terminals shall be designed to meet this specification. 3.新设计或修改的端子设计需要符合该规范。
4. All new crimp applications shall meet this specification. New crimp applications are defined as terminal/wire crimp combinations not previously specified on Ford, GM, or DaimlerChrysler vehicle wiring harness assemblies. Existing crimp applications may be carried over if approved by the customer engineering department.
4.所有新的压接应用需要符合该规范。新的压接应用定义为端子/导线的压接连接，不是以前在Ford, GM、DaimlerChrysler汽车应用中规定的线束装配。如果顾客的工程部门批准，现存的压接应用可以继续使用。
5. Electrical tests in this specification have been proven by past experience to ensure that crimps will meet the requirements in SAE/USCAR-2 and SAE/USCAR-20 by including
Thermal Shock, Temperature Humidity, and Power Current Cycling. Testing and
electrical acceptance criteria will detect defects in crimp tooling geometry, plating quality, inadequate strand distribution in the grip, or cable stranding. Crimp applications that have passed SAE/USCAR-2 and SAE/USCAR-20 normally have only passed the nominal crimp height and usually only with the largest gauge size. Therefore, crimps within the production crimp height range may not necessarily pass this test.
5.该规范中的电性能试验已经由过去的经验证明能确保压接符合SAE/USCAR-2和
SAE/USCAR-20规范要求，其中包含了热冲击、温度循环和电流循环试验。电性能试验和电性能试验接收标准，该接收标准涉及了检测压接工具的几何缺陷，镀层的质量，不合理的压线角（包括没有充分包住线芯或电缆线芯，所包芯线两边不对称）、芯线断股。已经通过SAE/USCAR-2和SAE/USCAR-20规范的压接情况通常只是通过名义压接高度并且通常只用最大线规压接。所以对于那些在此压接高度范围内的情况没有必要做试验。
6. Procedures included within this specification are intended to cover performance testing at development of electrical terminal crimps that are part of the electrical connection
systems in low voltage (0 - 48 VDC) road vehicle applications at ambient temperatures of
maximum. The OEM customer must approve use of these test procedures for use
at voltages and temperatures beyond these limits.
6.该规范中包含的程序覆盖了端子压接开发过程中需要思考的性能试验，端子压接是电连接系统的一部分，该电连接系统应用在电压是0 - 48 VDC，最高环境温度是的汽车中。对于超过该电压和该环境温度的情况，如果要使用该规范中的试验程序，需得到OEM顾客的批准。
7. These procedures are applicable only to terminals used for in-line, header, edge board, and device connector systems.
7.该程序只是适用于以下应用情况中的端子：in-line, header, edge board, and device connector systems.
1.1 Crimping Parameters 1.1压接参数
1.1.1 The Crimp connection performance is characterized by:
Mechanical performance is measured by terminal to conductor Pull-Out Force. Electrical performance is measured by terminal-to-conductor Crimp Resistance. 1.1.1压接连接的性能由以下方法来判断：
机械性能通过测试端子与导线的拉脱力来判断； 电性能通过测量端子与导线的压接电阻来判断。
1.1.2 The geometry of a conductor crimp is characterized by: Conductor crimp height (CCH) Conductor crimp width (CCW) Insulation crimp height (ICH) Insulation crimp width (ICW) Cut-off
End of conductor End of insulation Bellmouth (flare)
Burr (anvil flash) dimension on the base of the conductor crimp Step between the core and insulation tools Crimp tooling geometry
1.1.2压接的几何尺寸由以下方法判断： 导体压接高度(CCH) 导体压接宽度(CCW)
绝缘体压接高度(ICH) 绝缘体压接宽度(ICW)
料带切断截面（料带分离处） 导体末端 绝缘体末端 喇叭口（张开）
导体压接处低部的毛刺尺寸
导体压线脚和绝缘体压线脚之间的台阶（即压接模具前后角的台阶） 压接工具的几何尺寸
2. REFERENCED DOCUMENTS 2.参考文件
2.1 Document Hierarchy
In the event there is a conflict between performance standards, part drawings, and other related standards or specifications, the requirements shall be prioritized as follows: 1st-Applicable FMVSS requirements and other applicable state and Federal requirements.
2nd-Applicable part drawings
3rd - Applicable product design specification(s).
4th-Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) 5th-Applicable USCAR/EWCAP performance specifications 6th-Other applicable standards and specifications 2.1文件层次
假如性能标准，零件图和其它相关的标准或规范有冲突则按照以下顺序执行： 1st- 适用的FMVSS（联邦汽车安全标准）和国家法律法规和联邦要求 2nd-适用的零件图
3rd-适用的产品设计规范
4th- Automotive Industry Action Group (AIAG)、PPAP 5th-适用的USCAR/EWCAP性能规范 6th-其它适用的标准和规范 2.2 Test Request/Order 2.2试验要求/规则
2.2.1 Samples, Test Type and Special Tests
The laboratory test request/order shall provide location and documentation of test samples, identify the type of test to be performed (development, validation, special
purpose, etc.) and describe any special tests that are not a part of this specification. Any required revisions to, or deviations from any tests in this specification must include detailed instructions for each change. 2.2.1样品，试验类型和特殊试验
实验室试验要求/规则要提供试验样品的场所和文件，识别试验的类型（开发，确认，特殊目的等）并且描述该规范没有提到的特殊试验。对于任何与该规范的修订或违背的情况要求作出详细的说明、记录。
2.3 Materials And Processes Standards
Suppliers are expected to adhere to the appropriate Materials and Process Standards that are referenced in this specification and any associated drawings and reference
documents. Unless otherwise specified or required by law, suppliers are expected to use the most recent versions of any applicable drawings, reference documents, and standards.
2.3材料和过程标准
供应商要符合该规范提到的材料和过程标准，要符合任何相关的图纸和参考文件。除非法律另外说明和要求，否则供应商应该要使用相应图纸，参考文件和标准的最新版本。 2.4 Other Referenced Documents ence Manual -2 Performance Specification for Automotive Electrical Connector Systems -20 Field Correlated Life Test Supplement to SAE/USCAR-2 2.4其它参考文件 低压电线电缆 低压电线电缆 低压电线电缆 测量系统参考手册
AE/USCAR-2 汽车电连接系统性能规范 -20 补充SAE/USCAR-2的寿命试验 3. GENERAL REQUIREMENTS 3.总体要求
3.1 Record Retention 3.1保存记录
The supplier shall maintain a central file for the storage of laboratory reports and calibration records. Such record storage must be in accordance with established QS-9000 and AIAG policies and practices. 供应商应该保存试验报告和校准记录。这些保存情况必须符合QS-9000 and AIAG的体系要求。
3.2 Sample Documentation
All test samples shall be identified in accordance with the requirements of QS-9000 and the AIAG PPAP. 3.2样品记录
所有的样品必须符合QS-9000 and the AIAG PPAP的要求进行标识。 3.3 Sample Size
Minimum sample sizes are given for each test in this specification. A greater number of samples may be required by the test request/order. However, no part or device may be represented as having met this specification unless the minimum sample size has been tested and all samples of the group tested have met the applicable Acceptance Criteria for that test. It is never permissible to test a larger group, then select the minimum sample size from among those that passed and represent that this specification has been met. 3.3样品数量
该规范中的每一个试验都规定了最小样品数量。如果试验要求/规则需要，允许使用更多的样品。除非数量符合最小样品数量要求并且所选的样品都符合接收标准才证明该样品符合规范要求。若只是部分样品符合或没有达到要求的数量就不能证明该样品符合规范。决不允许选择较多的样品数量，然后从中选择符合要求的样品。若是这样，即使满足规定的最小数量要求，也不能证明该样品符合本试验规范。 3.4 Default Test Tolerances
Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated:
A. Temperature = ± 3 C B. Voltage = ± 2%
C. Current = ± 1% D. Resistance = ± 1% E. Length = ± 1% F. Time = ± 5% G. Force = ± 5% H. Distance = ± 1%
I. Relative Humidity = ± 5% 3.4默认的试验公差
除非另外说明，否则默认的试验公差以基本值的百分比来描述。 A. 温度 = ± 3 C B. 电压 = ± 2% C. 电流 = ± 1% D. 电阻 = ± 1% E. 长度 = ± 1% F. 时间 = ± 5% G. 力 = ± 5% H. 距离 = ± 1% I. 相对湿度 = ± 5%
3.5 Test Default Conditions
When specific test conditions are not given either in the product design specification, the test request/order or elsewhere in this specification, the following basic conditions shall apply:
A. Room Temperature = 23 ± 5o C B. Relative Humidity = Ambient C. Voltage = 14.0 ± 0.1 VDC 3.5默认的试验条件
如果在产品设计规范、试验要求/规则、该规范的其它地方没有提到试验条件，则按照如下的基本条件做试验： A. 室温 = 23 ± 5 C
B. 相对湿度 = 环境湿度 C. 电压 = 14.0 ± 0.1 VDC 3.6 Equipment
Neither the list shown in Table 3.6, nor the list in each test section is all-inclusive. It is meant to highlight specialized equipment or devices with particular accuracy
requirements. Many other items of customary laboratory equipment and supplies will also be required. 3.6设备
既没有在表格3.6中描述，也没有在试验段落中描述的设备都包含在内。对于高亮度显示的设备或仪器表明有特殊精度要求。其它一些通常用到的设备仪器或物品也可能需要。