SAE USCAR-21

The research data, analysis, conclusion, opinions and other contents of this document are solely the product of the authors. Neither the Society of Automotive Engineers, Inc. (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.

5. VALIDATION REQUIREMENTS FOR CRIMPED TERMINALS - SUMMARY (31)

5.1 Validation Test Requirements (31)

5.2 Special Applications and Exclusions (31)

5.3 Other Crimp Validation Methods (31)

APPENDIX A: CRIMP DESIGN RECOMMENDATIONS (34)

APPENDIX B: DEFINITIONS (37)

APPENDIX C: GLOSSARY OF TERMS (39)

APPENDIX D: MATERIAL RESISTANCE TABLES (41)

APPENDIX E: CRIMP DEVELOPMENT AND GEOMETRY (43)

APPENDIX F: REVISIONS (46)

1. SCOPE

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.

1. This specification defines basic test methods and requirements for solder-less crimped

connections. Some sections of this document may also be applicable to other terminal attachment methods such as sonic or electrical welding or soldering. In these cases,

applicability of the procedures in this document shall be determined by the Responsible Engineer.

2. Crimp applications validated to this specification supercede any crimp information on Ford,

GM, or DaimlerChrysler component prints. The terminal supplier has the primary

responsibility for testing and selection of crimp tooling and to 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.

3. New or revised terminals shall be designed to meet this specification.

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.

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.

6. Procedures included within this specification are intended to cover performance testing and

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 125°C maximum. The OEM customer must approve use of these test procedures for use at

voltages and temperatures beyond these limits.

7. These procedures are applicable only to terminals used for in-line, header, edge board, and

device connector systems.

1.1 Crimping Parameters

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.

1.1.2 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

2. REFERENCED DOCUMENTS

SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems

SAE/USCAR-20 Field Correlated Life Test Supplement to SAE/USCAR-2

2.1 Document Hierarchy

In the event there is a conflict between performance specification, 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

2.2 Test Request/Order

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.

2.3 Materials and Processes Specifications

Suppliers are expected to adhere to the appropriate Materials and Process 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.

2.4 Other Referenced Documents

?SAE J1128: Low Tension Primary Cable

?JISC 3406: Low Tension Primary Cable

?ISO/DIS 6722 Low Tension Primary Cable

?AIAG:Measurement Systems Analysis Reference Manual

?SAE/USCAR-2 Performance Specification for Automotive Electrical Connector Systems ?SAE/USCAR-20 Field Correlated Life Test Supplement to SAE/USCAR-2

3. GENERAL REQUIREMENTS

3.1 Record Retention

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 ISO and AIAG policies and practices.

3.2 Sample Documentation

All test samples shall be identified in accordance with the requirements of ISO and the AIAG PPAP.

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. Any alternative sample size and/or methodologies must be approved by the Authorized Person.

3.4 Default Test Tolerances

Default Tolerances, expressed as a percentage of the nominal value unless otherwise indicated:

A. Temperature = ± 3 o C

B. Voltage = ± 5%

C. Current = ± 5%

D. Resistance = ± 5%

E. Length = ± 5%

F. Time = ± 5%

G. Force = ± 5%

H. Relative Humidity = ± 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

3.6 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.

4.1.2 Material Characteristics

All material used in each test sample shall conform to the material specifications on the latest revision of the applicable part drawing(s).

1. Any engineering development, prototype, or production parts may be submitted for test.

2. The samples submitted for test should be identified by description, part number, and

revision letter.

3. 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.

4. Samples submitted for any test shall be prepared per Appendix E.

4.2 Visual Inspection

4.2.1 Purpose

This 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 or corrected vision, and normal color sensitivity, under cool white fluorescent 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/video’s are not taken.

4.2.2 Samples

1. The samples should conform to the requirements of the specified conditioning and any

additional measurements that are to be performed.

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.

4.2.3 Equipment

Video/photography equipment.

required here.

d

6. 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.

7. Insulation Crimp

a. The purpose of the insulation crimp is to add strain relief to the conductor crimp.

b. The Insulation Crimp must contact the surface of the insulated cable in at least 3

locations around the circumference of the Crimp (three point contact).

c. The Insulation Crimp dimensions are reference dimensions.

d. The Insulation Crimp must not interfere with any subsequent operations.

e. The Insulation Crimp must not interfere with seating of a terminal into a plastic

connector cavity

f. The Insulation Crimp must not damage the cable (see Paragraph 4.3.5-3)

8. Cable Conductor Appearance prior to crimping

a. Strands shall not be cut, missing, excessively nicked (strand area reduction which may

affect pull-out force), or elongated.

b. Insulation shall not be stuck or imbedded in strands.

9. Individual Cable Seal

Note: This specification does not include any requirements for seal sliding force due to the large number of variables. It is necessary that individual cable seals be properly seated in plastic connectors to function.

a. The seal must be firmly secured by the insulation crimp.

b. The seal must show no signs of damage.

c. The end of the seal neck must be visible in the area between the insulation crimp and

the conductor crimp.

d. The cable insulation must be visible under the seal.

4.3 Cross-Section Analysis

4.3.1 Purpose

Cross-sectional analysis is used as a diagnostic aid in determining why a crimp 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.

4.3.2 Sample Size

At least one sample for each crimp height to be evaluated. Data shall be obtained and recorded for minimum, maximum and nominal production crimp heights.

4.3.3 Equipment

Various 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.

4.3.4 Procedure

1. Cross-section and photograph each sample for analysis

2. Cross-section analysis shall be performed on all conductor crimp applications at each crimp

height setting (nominal, min. and max. tolerance).

3. Cross-sections shall be performed between the serrations, as near to the mid-point of the

core crimp as possible.

4. Compare the samples to the acceptance criteria of paragraph 4.3.

5.

Acceptance Criteria

4.3.5 Acceptance Criteria

Acceptance criteria for the cross-sectioned samples are described below.

1. Cross-section views of conductor crimp

Conductor crimp attributes considered undesirable

0.1 mm max.

Some examples of non-standard insulation crimps include ”tee-pee” (“tear drop”), ”square”, and ”tall B”.

Cable Seals

Individual cable seal

Conductor Crimp Pull-Out Force

4.4.3 Samples

1. A minimum of 20 samples 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.

4.4.4 Procedure

1. Pull-out force test shall be performed on leads with the insulation crimp wings open (not

crimped).

2. 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”).

3. Refer to Appendix E, 6-8. Measure and record the conductor crimp and insulation crimp

heights and widths in millimeters for each sample.

4. 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.

5. Visually inspect the de-crimped area to ensure that none of the conductor strands have

been damaged. Do not use any samples that have damaged conductor strands.

6. Measure and record pull-out forces in Newtons for each sample.

7. Apply an axial force at a rate between 50 and 250 mm/minute (100 mm/min. is

recommended).

8. For double, triple, or multiple crimp setups with conductor sizes within one step, pull the

smallest conductor. (e.g. for a .35/.50 double, pull the .35mm2 wire)

9. For double, triple, or multiple crimp setups with conductor sizes more than one step apart,

one of the smallest and one of the 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 .50mm2 and the

2.0 mm2 wires, for a .50/.50/2.0 triple, pull one of the .50 mm2 and the 2.0 mm2 wires.) In

this case, 20 samples per wire size tested will be required.

4.5 Electrical Performance Tests

4.5.1 Current Cycling of Electrical Terminations (ECC)

4.5.1.1 Purpose

Current cycling is an accelerated aging test that emphasizes the effect of expansion and contraction of terminal interfaces and conductor crimps as a result of thermal cycling. This test is optional (see table 5.1). The Accelerated Environmental Test (paragraph 4.5.2) may be done in place of this test for Power applications. (see table 5.1)

4.5.1.2 Samples

1. Any engineering development, prototype, or production terminal – particularly those

intended for high current or “Power” applications – may be submitted for test.

2. Test data will be collected on 10 samples of each crimp height. Data shall be obtained and

recorded for minimum, maximum and nominal production crimp heights.

3. In cases where mating terminals are available, apply these to the opposite ends of the test

sample cables. These should be a minimum cut length of 150mm. The terminal crimps on the mating terminals may be soldered. Samples are then connected to form a continuous series circuit.

4. Test sample terminals that have no mating terminals should be applied to one end only of

the test cable (a minimum cut length of 150 mm). The opposite stripped ends of the

samples are then soldered to box or blade of the next sample to form a continuous series circuit.

5. Doubles should be terminated with the test terminal on one end only. A mating terminal may

be applied (with the crimp soldered) to the other end of the largest size cable. When

identical size cables are doubled, cables should be randomly tested.

4.5.1.3 Equipment

1. Power supply – AC or DC current regulated capable of supplying the test current.

2. Cycle timer.

3. Ammeter or current shunt/voltmeter

4. Voltmeter.

5. Voltage sense lead – solid conductor .32 mm or smaller in diameter.