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QC/T 417-2001 consists of the following five parts under the general title Connector used in automobile wire harness and electrical device:
——Part 1: Definition, test method and requirement;
——Part 2: Type and dimension of the male terminal;
——Part 3: Type, dimension and special requirement of the ring terminal;
——Part 4: Type, dimension and special requirement of the device connector (male);
——Part 5: Type, dimension and special requirement of the device connector (female);
This is Part 1 of QC/T 417-2001.
This standard is developed in accordance with the rules given in GB/T 1.1-2009 Directives for standardization - Part 1: Structure and drafting of standards.
This standard is revised from QC/T 417.1-2001 Connector used in automobile wire harness - Part 1: Definition, test method and requirement, with respect to which, the following main changes have been made:
——the name is changed from Connector used in automobile wire harness to Connector used in automobile wire harness and electrical device, the scope of application is extended, and high-voltage connector requirements are added;
——in normative references (Clause 2), GB/T 25085, QC/T 29106 and GB 12981 are added, while GB 2423.5-1995, GB 4208-1993, JB/T 8139-1995, JT 225-1996, QC/T 413-1999 and ZB E39004-1988 are deleted;
——7 terms, i.e., “housing", "in-line connector" "device connector (male)", " device connector (female )", "terminal position assurance (TPA)" "primary lock reinforcement (PLR)” and "connector position assurance (CPA)”, are added in terms and definitions (Clause 3);
——7 terms, i.e., "plug", "socket", " locking socket", " lockpin", " reference point", "connection" and " multi-line connection", are deleted in terms and definitions (Clause 3);
——in terms and definitions (Clause 3), "wire attachment" is changed to "cable attachment", "connector clip" to "terminal", "plug connector" to "connector", "plug connector positioning" to "polarization feature" and " plug connector number" to "connector cavity number";
——15 tests, i.e., "bending resistance of terminal", "retention force of ferrule", "insulation resistance of shield", “coupling and separating force of power-assisted connector", "insertion force and withdrawal force of TPA", " insertion force and withdrawal force of CPA", "sound of proper connector insertion", " terminal hole strength", "polarization feature of terminal and terminal hole", "mechanical strength of fixed structure", "mechanical strength of power-assisted mechanism", "retention force of sealing piece (unfitted connector)", "retention force of sealing piece (fitted connector )", "retention force of pin at plate end” and "air tightness", are added in tests and requirements (Clause 4);
——3 tests, i.e., "tensile strength of conductor accessories", "temperature rise” and "flowing gas corrosion test", are deleted in tests and requirements (Clause 4);
——the connected resistance value in the voltage drop test is revised;
——the time for current cycle test is changed from 500h to 1008h (or negotiated by the supplier and the demander);
——in the test on insertion force, thrust and retention force of terminal to housing, requirements for thrust are added, and the retention force value is revised;
——in the test on coupling and separating force of connector (non-power-assisted), requirements for coupling and separating force of non-power-assisted connector are added, and the strength value of lock-up device is revised;
——the time for thermal aging test is changed from 100h to 1008h (or as agreed by the supplier and the demander);
——the original informative in Annexes A and B are deleted while normative Annexes A and B and informative Annex C are added.
This standard is formulated by reference to ISO 8092.2:2005 and USCAR-2 (Revision 6).
This standard is not involved with patents.
This standard was proposed by and is under the jurisdiction of the National Technical Committee of Auto Standardization (SAC/TC 114).
Connector used in automobile wire harness and electrical device
Part 1: Definition, test method and requirement
1 Scope
This standard specifies the definition, requirement and specific test method for a connector used for automotive.
This standard is applicable to the low-voltage (not higher than 60V) and high-voltage (higher than 60V but not higher than 600V) connectors used in automotive wire harnesses and electrical device, including in-line connectors and device connectors.
2 Normative References
The following referenced documents are indispensable for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB 252 General diesel fuels
GB 484 Gasoline for motor vehicles
GB 5337 Nomenclature and terminology for automotive electrical equipment, lighting and instrumentation
GB 11118.1 Hydraulic Fluids of Mineral Oil Type and Synthetic Hydrocarbon Type
GB 11121 Gasoline engine oils
GB 12981 Motor vehicle brake fluids
GB/T 2423.17 Environmental testing for electric and electronic products - Part 2: Test method - Test Ka: Salt mist
GB/T 25085 Road vehicles - 60V and 600V single-core cables
QC/T 29106 Technical Specification of Automobile Wire Harness
3 Terms and definitions
For the purposes of this standard, the terms and definitions given in GB 5337 and the following apply.
3.1
connector
assembly consisting a terminal, a housing and accessories, which may realize electrical connection
3.2
housing
non-metallic piece fixing and protecting the terminal
3.3
terminal
metal piece realizing electrical connection, including the male terminal for plugging (Figure 1) , female terminal (Figure 2) and wire joint (Figure 3) for forming electrical connection with a fastener
1——conductor crimping; 2——cable; 3——cable attachment; 4——insulating support or sealing piece handle; 5——pre-insulated connection; 6——connecting trough; 7——connecting trough or insulating support (if there is no 8); 8——insulating support
Figure 1 Male terminal
1——conductor crimping; 2——cable; 3——cable attachment; 4——insulating support or sealing piece handle; 5——puncture connection; 6——connecting trough; 7——connecting trough or insulating support (if there is no 8); 8——insulating support
Figure 2 Female terminal
1——conductor crimping; 2——cable; 3——cable attachment; 4—— insulating support
Figure 3 Cable joint
3.4
cable attachment
durable attachment between a cable and a terminal, such as crimping, pre-insulated connection, soldering, etc.
3.5
polarization feature
device or feature on a connector that preventing fault connection
3.6
connector cavity number
visible and regular number on a connector, indicating the cavity
3.7
in-line connector
connector forming an electrical connection between cables
3.8
device connector (male)
connector at the output terminal, connecting the interior of a device
3.9
device connector (female)
connector at the input terminal (harness terminal), connecting the device connector (male)
3.10
terminal position assurance (TPA)
mechanism ensuring the proper installation of a terminal and providing terminal locking force
3.11
primary lock reinforcement (PLR)
mechanism ensuring that the primary position assurance of terminal remains in correct position
3.12
connector position assurance (CPA)
additional position assurance on the position assurance of a connector
4 Tests and requirements
4.1 Sample pretreatment
Before starting all tests, the samples shall be placed in an environment at ambient temperature of (23±5)℃ and relative humidity of 45%~75% for 24h.
4.1.1 Test requirements.
All tests shall be conducted in an environment at ambient temperature of (23±5)℃. All cavities of connector shall be tested.
The cable shall meet the requirements of GB/T 25085 or negotiated by the supplier and the demander. The cable used shall be recorded in the test report.
All tests and test samples cannot affect each other. For example, test samples in a high-temperature chamber shall be kept at a certain distance from each other and cannot be in contact with each other and stacked.
Lubricating oil or other additives shall not be coated on the surfaces of male terminal and female terminal throughout the test, except for the lubricant left in the production process.
4.1.2 Default test error.
The default test error is expressed as a percentage of nominal value (see Table 1).
Table 1 Default test error
Temperature ±3℃
Voltage ±5%
Current ±5%
Resistance ±5%
Length ±5%
Time ±5%
Force ±5%
Frequency ±5%
Flow rate ±5%
Relative humidity ±5% (where controlled)
Speed ±5%
Sound ±5%
Pressure ±5%
Vacuum degree ±5%
4.1.3 Grade classification.
Depending on the intended service environment of automobile body, the test connectors shall be provided with temperature grade (Table 2), sealing grade (Table 3), vibration grade (Table 4) and plugging cycle grade (Table 5).
Table 2 Temperature grade
Grade Working temperature range Applicable position
A -40℃~85℃ Passenger compartment (not recommended)
B -40℃~100℃ Passenger compartment
C -40℃~125℃ Engine compartment
D -40℃~150℃ Positions near engine and heating component
E -40℃~175℃ To be negotiated by the supplier and the demander
Table 3 Sealing grade
Sealing grade Application type Applicable position
S1 Not sealed Dry areas on automobile body, such as passenger compartment and luggage compartment
S2 Sealed Exposed areas on automobile body
S3 Sealed (sprayed with high-pressure water) Exposed areas on automobile body Applicable to the areas with direct spray of splash water
Table 4 Vibration grade
Vibration grade Applicable position
V1 Connector mounted on the elastic part of automobile body but not connected to the engine
V2 Connector connected to the engine but not connected to a severely vibrating component
V3 Connector installed in a severe vibration environment
V4 Installed in areas of extreme vibration as needed
V5 on wheels
Note: elastic parts refer to the parts of automobile body that are supported by suspension system. Elastic parts do not include tires, hubs, brake discs (drums) and other parts.
Table 5 Plugging cycle grade
Plugging cycle grade Number of times for plugging Typical application
M1 10 In-line connector and plate end connector are not frequently disassembled during maintenance and service. Such connectors are in fixed connection and not expected to be disassembled after the vehicle is assembled. For example, bulkhead connector. Prior to test, the connectors of Grade M1 shall be plugged for 10 times.
M2 50 In-line connector and plate end connector are frequently disassembled during maintenance and service. For example, maintenance disassembly or safety disassembly. Prior to test, the connectors of Grade M2 shall be plugged for 50 times.
M3 To be negotiated by the supplier and the demander As for in-line connector and plate end connector, the break-make is regarded as a normal function of parts. For example, charge interface, etc. Number of times for plugging is recorded in the test report.
4.1.4 Preparation of terminal sample
Terminals with cable attachment shall be adopted during all tests. Cable crimping shall meet the requirements of QC/T 29106 and sample dimension shall meet the requirements of engineering drawings approved according to specified procedures, unless otherwise specified.
4.1.5 Low-voltage connector test sequence (Table 6).
Table 6 Low-voltage connector test sequence
Clauses Test item Test group
A B C D E F G H I J K
4.1 Sample pretreatment 1a 1 1 1 1 1 1 1 1 1 1
4.2 Appearance 2,4 2,4 2,5 2,4 2,7 2,4 2,5 2,5 2,5 2,4 2,4
4.3 Plugging cycle 3
4.4 Insertion force and withdrawal force between terminals 3
4.5 Bending resistance of terminal 3
4.9 Current cycling 4
4.11 Insertion force, thrust and retention force of terminal to housing 3
4.12 Coupling force and separating force and lock-up device strength of connector (non-power-assisted) 5
4.13 Coupling force and separating force and lock-up device strength of power-assisted connector 5
4.14 Polarization feature of connector 3
4.15 Insertion force and withdrawal force of TPA (including PLR) 3
4.16 Insertion force and withdrawal force of CPA 4
4.18 Sound of proper connector insertion 3
4.19 Drop 4
4.20 Terminal hole strength 3
4.21 Polarization feature of terminal and terminal hole 4
4.22 Polarization feature of terminal and terminal hole 4
4.23 Mechanical strength of power-assisted mechanism 3
4.24 Retention force of sealing piece (unfitted connector) 3
4.25 Retention force of sealing piece (fitted connector) 6
4.26 Retention force of pin at plate end 3
Table 6 Low-voltage connector test sequence (continued)
Clauses Test item Test group
L M N O P Q R Sb T U V Wb X Y Z
4.1 Sample pretreatment 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
4.2 Appearance 2,8 2,8 2,10 2,8 2,8 2,8 2,8 2,9 2,10 2,9 2,12 2,9 2,10 2,9 2,12
4.3 Plugging cycle 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
4.7 Microcurrent connecting resistance 4,6 4,6 4,6 4,6 4,6
4.8 Voltage drop 7 7 7 7 7
4.11 Insertion force, thrust and retention of terminal to housing 11 9 9 10 11 10 13 10 11 10 13
4.17 Vibration/mechanical shock 5
4.27 Insulation resistance 8 4,6 4,6 4,7 4,8 4,7 4,10 4,7 4,8 4,7 4,10
4.28.1 Insulating dielectric strength (low-voltage connector) 9 7 7 8 9 8 11 8 9 8 11
4.29 Thermal shock 5
4.30 Temperature/humidity cycling 5 5 6 5 6
4.31 Thermal aging 5 5 6 5 6
4.32 Resistance to chemical solution 5
4.33 Watertightness 6 7 6 7
4.34 Air tightness 5,7 5,9 5,7 5,9
4.35 Spray with high-pressure water 6 8 6 8
4.36.1 Salt mist test (low-voltage connector) 5
4.37 Dust prevention test 5
Notes:
a The Arabic numerals in the table indicate test steps.
b For tests S, T, U and V, only one is conducted; for tests W, X, Y and Z, only one is conducted.
4.1.6 High-voltage connector test sequence (Table 7).
Table 7 High-voltage connector test sequence
Clauses Test item Test group
A B C D E F G H I J K
4.1 Sample pretreatment 1a 1 1 1 1 1 1 1 1 1 1
4.2 Appearance 2,4 2,4 2,4 2,5 2,4 2,4 2,4 2,4 2,5 2,5 2,4
4.4 Insertion force and withdrawal force between terminals 3
4.5 Bending resistance of terminal 3
4.6 Retention force of ferrule (high-voltage connector) 4
4.9 Current cycling 3
4.10 Insulation resistance of shield (high-voltage connector) 3
4.11 Insertion force, thrust and retention force of terminal to housing 3
4.12 Coupling force and separating force and lock-up device strength of connector (non-power-assisted) 3
4.13 Coupling force and separating force and lock-up device strength of power-assisted connector 3
4.14 Polarization feature of connector 3
4.15 Insertion force and withdrawal force of TPA (including PLR) 3
4.16 Insertion force and withdrawal force of CPA 4
4.18 Sound of proper connector insertion 3
4.19 Drop 4
4.20 Terminal hole strength 3
4.22 Mechanical strength of fixed structure 4
4.26 Retention force of pin at plate end 3
Table 7 High-voltage connector test sequence (continued)
Clauses Test item Test group
L M N O P Q Rb S T U
4.1 Sample pretreatment 1 1 1 1 1 1 1 1 1 1
4.2 Appearance 2,7 2,8 2,9 2,8 2,5 2,6 2,9 2,11 2,9 2,10
4.3 Plugging cycle 3 3 3 3 3 3 3 3
4.8 Voltage drop 6 5 5 5
4.11 Insertion force, thrust and retention force of terminal to housing 8 10
4.17 Vibration/mechanical shock 4
4.27 Insulation resistance 5 6 6 6 4 4 5,7 5,8 5,7 5,8
4.28.2 Insulating dielectric strength (high-voltage connector) 7 7 7 5 8 9 8 9
4.29 Thermal shock 4
4.30 Temperature/humidity cycling 4 4 6
4.31 Thermal aging 4 4 6
4.32 Resistance to chemical solution 3
4.33 Watertightness 6 6
4.34 Airtightness 4,7 4,7
4.36.2 Salt mist test (high-voltage connector) 3
Notes:
a The Arabic numerals in the table indicate test steps.
b For tests R, S, T and U, only one is conducted.
4.2 Appearance
4.2.1 Devices.
Camera, video tape recorder and magnifier (if necessary).
4.2.2 Method.
The test sequence is as follows:
1) Prior to test, visually inspect the test sample to record manufacturing and material defects such as crack, discoloration, burrs, etc. Photograph and record the test sample or prepare a sample (not for test) for each test group for comparison with the sample after test.
2) After test, visually inspect each sample tested and record all observed changes, compare the sample after test with the untested sample, photograph or record in Step 1) above, and record all differences in the test report.
4.2.3 Requirements.
Samples shall be free of defects affecting product function, such as expansion, corrosion, discoloration, contact plating wear, physical deformation, cracking, etc.
4.3 Plugging cycle
4.3.1 Device.
To be negotiated by the supplier and the demander
4.3.2 Method.
The plugging cycle for connector or terminal is completed according to Table 5. Where only the terminal is subject to plugging cycle, the plugging cycle shall be performed along the center line of terminal during the test.
4.3.3 Requirements.
No damage affecting subsequent tests.
4.4 Insertion force and withdrawal force between terminals
4.4.1 Device.
Plug tester.
4.4.2 Method.
The test sequence is as follows:
1) Prepare 10 pairs of terminals and number them respectively.
2) Fix 1 pair of terminals to the fixture and make sure that the plug is conducted along the center line of the terminal.
3) Insert the terminal at a constant speed of 50mm/min and record the peak force (the first insertion force) required to insert in place.
4) Separate the terminals at a constant speed of 50mm/min and record the peak force (the first withdrawal force) required for complete separation.
5) Repeat Steps 3) and 4) according to the number of times for plugging as specified in Table 5, and record the last withdrawal force.
6) Conduct Steps 2)~5) for each pair of terminals.
4.4.3 Requirements.
The appearance shall meet the requirements of 4.2, and the metal substrate at contact position shall not be exposed. Insertion force and withdrawal force shall meet the requirements of product design document or be negotiated by the supplier and the demander.
4.5 Bending resistance of terminal
4.5.1 Devices.
Special fixture and force tester with peak reading characteristics.
4.5.2 Method.
This test is not applicable to the case where cable attachment is 90° to the insertion direction of terminal.
The test sequence is as follows:
1) Determine the type of test terminal as shown in Figure 4.
Foreword i
1 Scope
2 Normative References
3 Terms and definitions
4 Tests and requirements
Annex A (Normative) Test method for current carrying capacity of terminal
Annex B (Normative) Power spectral density (PSD) or acceleration and frequency
Annex C (Informative) Type and dimension of connector fixing structure
