5.压接端子的确认要求—摘要 5.1 Validation Test Requirements 5.1确认试验要求 Test 试验 Requirement Paragraph Number. Design Validation (Yes/No) Minimum Conformance to Tolerance 要求 章节号 设计确认 Y Y 最小符合性偏差 100% 100% Cable/Terminal/Crimp Tooling Identification Appendix E traceable to Performance Testing 附件E 用于性能试验的导线、端子、压接工具的标识 Compaction (Verified in production by Terminal, Cable, and crimp tool dimensions usually controlled by specific part numbers and traceable to validation testing.) 压缩状态（在生产中通过端子、导线、压接工具尺寸进行验证，由物料号和追踪性标识对确认试验进行控制） Appearance - end of conductor - end of insulation - cut off - bellmouth - conductor crimp - insulation crimp - individual cable seal -conductor crimp lock (top) - terminal bend and twist due to crimping 外观 导体末端 绝缘体末端 料带切断截面（料带分离处） 喇叭口（张开） 芯线压线脚 绝缘体压线脚 电缆线/导线密封 芯线压线脚两卷边闭合 由于压接端子弯曲和扭曲 Crimp geometry - Conductor and insulation crimp height and width (CCH, CCW, ICH, ICW) - cross-section requirements Appendix E, 附件E 1-2 4.2.5 4.2.5-2 4.2.5-3 4.2.5-4 4.2.5-5 4.2.5-6 4.2.5-7 4.2.5-9 4.2.5-5 Appendix E 附件E Y Y Y Y Y Y Y Y N 100% Appendix E, 附件E 7-9 4.3 Y 100% 压接几何尺寸 -导体和绝缘体压线脚高度和宽度（CCH, CCW, ICH, ICW） -截面要求 Mechanical performance - Pull out force (Final OEM’s quality assurance approval form process validation may be 4.4 Y -3s>Limit required.) 机械性能 -拉脱力（可能需要最终OEM质量保证批准形式过程确认） Electrical performance For Power Applications: - Electrical testing Current Cycling – (ECC) or accelerated environmental testing (ENV) 电性能 对于端子应用于强电流或电源电路中的情况（要做以下试验）： —电流循环试验(ECC) —加速环境老化试验(ENV) For Low Energy Applications: - Accelerated Environmental testing (ENV) 对于端子应用于低功率电路中的情况（要做以下试验）： —加速环境老化试验(ENV) For Low Impedance Applications: Validation should be done on bare copper wire to optimize crimp parameters (Production on Tinned Wire is optional) - Accelerated Environmental testing 对于端子应用于低阻抗的情况（要做以下试验）： 4.5 4.5.1 or 4.5.2（选择其中一种方法做试验） Y 100% 4.5.2 Y 100% 4.5.2 Y 100% 对于压接裸铜丝的情况一定要对压接参数最优化进行确认（对于镀锡铜线可选做） —加速环境老化试验(ENV) 表5.1 用于确认的试验
5.1.1 The validation requirements listed in Table 5.1 shall be conducted to demonstrate tha the design intent is met.
5.1.1表中所列的确认要求必须执行，以便证明设计满足要求
5.1.2 The requirements should be conducted in the order shown in Table 5.1, to avoid unnecessary testing.
5.1.2必须按照表5.1的顺序进行试验，以便避免没有必要的试验。 5.2 Special Applications And Exclusions 5.2特殊试验和另外情况
5.2.1 Special applications and variances from this specification require customer
approval. Solder, sonic weld, or other processes that have proven to create an electrically stable application may be excluded from some or all of the crimp validation testing based on experience and/or sound engineering judgment. Pull-out force testing and cross-sections [ PTX ] are required for all validations.
5.2.1对于特殊试验和与本规范不一样的地方，需要得到顾客的批准。基于经验和/或合理的
工程判断，焊接，超声波焊接或其它一些过程（这些过程建立了稳定的电性能）被排除在该部分或全部压接确认试验之外。
所有的确认试验都必须进行拉脱力试验和截面分析 5.3 Other Crimp Validation Methods 5.3其它压接确认方法
5.3.1 Reference [REF] - The application is the \already validated to meet the circuit and/or customer requirements.
5.3.1参考[REF] –端子/导线压接与其它端子/导线压接相同且已经证明满足电路和/或顾客要求的情况相同（参考类似的应用，进行压接设计开发） 5.3.2 “Same as\ - terminal stock thickness - material (alloy and temper) - the same terminal plating
- the same terminal conductor wing dimensions and features [serrations, etc.] - the same conductor core cross sectional area 5.3.2“相同”的定义是： -端子料厚相同
-端子材料相同（合金和热处理） -相同端子镀层
-芯线压线脚的尺寸和特征相同 -相同的导体截面面积
-相同的导体基本材料和镀层 -压接模具内部尺寸相同
“类似”的定义（讨论）：在压线脚、导线尺寸相同，压线脚特征相同，基体材料相同而其它不同定义为类似。
比如，我们已经进行以下的确认试验：将裸铜丝的导线与端子压接。
那么下次遇到以下情况：其他与上述情况都相同，只是导线的导体是镀锡导体。
那么只需要进行工程判断（利用裸铜丝的导线与端子压接的确认试验进行判断），不需要进行确认试验了（需要得到顾客批准）
利用“类似”进行工程判断有以下前提：我们已经知道这次的导线与端子压接肯定比前次好。如镀锡导体比裸铜丝好。
5.3.3 Cables with the same conductor core construction, but differences in the insulation may be considered the “same” for conductor crimp validation purposes. The Insulation Crimp must be reviewed against the cross section requirements for final validation.
5.3.3两导线/电缆线，如果芯线结构相同，但线皮不同，则在芯线压接确认时，这两种情况是相同的，可以只做一次。但是在最后确认时，要确认绝缘体压线脚的截面要符合要求。 5.3.4 Customer Waiver Letter [ CWL ] - The customer has authorized the use of the terminal crimp as specified in a waiver letter.
5.3.4 [ CWL ]：顾客弃权书。顾客不对你提供给他的关于确认试验的文件的批准，只要求你提供合格的产品给他，而不需要其中的过程文件。出了问题完全由供方承担。 5.3.5 Engineering Judgment [ ENJ ] – Engineering Judgment may be used in lieu of validation testing based upon past experience, knowledge, and/or testing. The basis of this judgment shall be documented. Engineering judgment shall not be used to accept applications that have failed crimp validation testing. All cases where Engineering Judgment is used must be reviewed and approved by the OEM customer.
5.3.5工程判断[ ENJ ] –基于以往的经验，知识和/或试验，工程判断可能用于确认试验。这些判断需要记录下来。工程判断不能用于接受没有通过压接确认试验的情况（即确认试验
不通过，而工程判断可以，这种情况样品还是判断为不合格）。在任何情况下，工程判断必须经过OEM顾客评审和批准。
APPENDIX A
附件A
CRIMP DESIGN RECOMMENDATIONS 压接设计（推荐）
A. Recommended Terminal Wing/Cable Loading for new terminal designs or revisions to meet the performance requirements of this specification is shown in Table A.
A. 新端子设计和端子更改之后端子压线脚/导线压接推荐满足该规范表A中的性能标准。（推荐每个端子压线脚设计时能压接一定范围的导线）
Terminal Wing/Cable Loading Ranges 端子压线脚/导线压接范围 Cable Range SAE DIN 导线范围 （导体/芯线截面积） 0.20-0.22 Χ Χ 0.35-0.50 Χ Χ 0.75-1.25 Χ Χ 1.5-2.5 Χ Χ 2.0-3.0 Χ Χ 4.0-6.0 Χ Χ
TABLE A-1 - Recommended Wing/Cable Loading B. Crimp Engineering Guidelines
The following guidelines are intended only to assist in passing the requirements of this specification and are based upon previous experience from terminal suppliers: B．压接工程指导
如下的指导意见只是为了帮助供应商通过本规范的要求，该指导意见是基于以前供应商的经验作出来的。
1. The terminal supplier determines double application terminals. 1.由供应商来决定双线端子应用。
2. Core wings that have features to break oxides and minimize cable strand movement will give better electrical results. Sharp cornered serrations are preferred.
2.在芯线压线脚处，尽量地去除氧化物并且尽量地减少芯线的移动，这样会有好的电性能，推荐压线脚的两边尽量弯成角度比较小的锐角。
3. Tin or silver plating is the optimum design for 10 year/150K life. Avoid nickel, stainless steel inter-metallic (thermic tin) or gold in core wings. The design should provide for
adequate free tin at end of life. Nickel plated high temperature wire also may not pass this electrical testing and may require specific changes in acceptance criteria based upon circuit application sensitivity (i.e. O2 sensor circuits)
3.对于10年/150K寿命要求，镀锡或镀银是最适宜的。消除镍，不锈钢内部金属性或芯线压线脚的金。设计必须包含在寿命的最后阶段没有锡，镀镍耐高温导线也可能不能通过电性能试验并且基于电路的灵敏性可能需要改变接收标准（如O2传感器电路）
4. Optimum 10 year/150K life is obtained with similar alloys, tempers used for spring members and contact arms. This maintains crimp wing normal force with time and
temperature. It also provides strength to resist crimp wing relaxation due to movement and stresses applied during vehicle life.
4.用类似的合金可以得到10年/150K的寿命，对于弹簧类和接触件需要回火热处理。这些使得压线脚持续一段时间和温度后仍然保持正常的力。这样能够避免了由于在汽车实际使用时的运动和应力释放而引起压线脚的张开。
5. Wing blank width should be designed to provide for uniform strand dispersion for the gauge size recommended. This is necessary for optimum electrical strand contact, pulls, and nuisance free use of crimp force process monitors.
5.压接前压线脚宽度的设计应该确保芯线均匀分布。这个对于芯线的电连接，拉脱情况，免受压接力过程监控的损害是必要的。
6. Crimp electrical performance should be done separately from connector testing. This is done so that a low and stable milli-ohm acceptance criteria can detect the loss of strand contacts in the crimp. Crimps that meet this criteria must then be able to pass USCAR tests in connectors.
6.压接电性能试验应该要做，并且应该与连接器试验分开做 （即做两次电性能试验：一个压接电性能试验，一个连接器电性能试验）。
这试验必须做，以便一个低且稳定的毫欧姆接收标准（压接电阻接收标准）能够检测出压接引起的断芯线现象。通过该试验的压接，接下来必须能够通过USCAR的连接器试验。 7. Pull testing must only be used to determine mechanical strength. The pull standard must not be too high resulting in over compaction and poor electrical results. Usually the best electrical performance is on the tight side of the pull vs. crimp height curve (ref. Figure A-1). Insulation wings/grips must be designed to minimize insulation penetration and provide for optimum crimp processability.
7.拉脱力测试只是用来判断其机械性能的好坏。拉脱力不是越大越好，如果定的值非常高会引起过压缩并且电性能很差。最好的电性能看拉脱力VS压接高度曲线图的最下面曲线（靠近压接高度的轴）的中间一段。绝缘体压线脚的设计要注意尽量减少线皮的刺穿和提供最适宜的压接加工性能。
8. The preferred insulation crimp geometry is the traditional “F” or “B” crimp. Overlapping, diagonal cut bypassing wings, or butting wings may be used, but may be sensitive to crimp processing conditions. It is usually best to tool specific grip wings for heavy-wall, regularwall, thin-wall and/or Extra Thin Wall insulations.
8.推荐的绝缘体压线脚形状为“F” 或“B”字型。绝缘体压线脚（两翼）重叠，对角剪切或羊角等也可以接收，但这些可能受压接过程条件影响很大。最好对于厚的材料，常规材料，薄的材料，特薄材料压接成指定的形状。
9. Where possible, grip wings should be designed for European, US, and/or Asian cable constructions.
9.如果可能按照欧洲，美国和/或亚洲的电缆线/导线结构分别设计压线脚。
10. A typical mechanical/electrical vs. crimp height curve is shown in Figure A-1. 10.如下图是典型的机械性能/电性能VS压接高度的曲线图