Modification Record of Product Specification

Transcription

1 Modification Record of Product Specification No, DSP Product Name SRV Connector Systems Rev. No, Note Reason Place Date Engineer R0 Initial Release DEC A.M.

2 Page 1/17 PRODUCT SPECIFICATION Customer: Title Subject: SRV Connector System No. DSP Revised: 000 Date Issued: Date Revised: Issued by: Detroit Engineering Center This is our exclusive property. It is not to be copied, reprinted or disclosed to a third party, not used for manufacturing, without our written consent, and has to be returned to us. Prepared by: Checked by: Reviewed by: Approved by: A.M. J.S. S.F. P.C. AEC-068 REV. 1 6/30/08

3 Page 2/17 Table of Contents 1. Scope Part Name, Part Number, Part Construction & Drawing Number Material and Surface Finish Characteristics Performance Visual Examination (GMW3191, Section 4.1) Isolation Resistance (GMW3191, Section 4.19) Connector Performance Test Terminal to Connector Engagement Force (GMW3191, Section 4.7) Terminal from Connector Body Extraction Force (GMW3191, Section 4.9) Connector to Connector Engagement Force (GMW3191, Section 4.11) Terminal Position Assurance (TPA) (GMW3191, Section 4.12) Connector Mounting Feature (GMW3191, Section ) CPA Lock and Unlock Force (GMW3192 Section ) Locked Connector Disengagement Force (GMW3191, Section 4.13) Unlocked Connector Disengagement Force (GMW3191, Section 4.14) Connector Polarization Feature Effectiveness (GMW 3191, Section 4.15) Thermal Aging (GMW3191, Section 4.21) Thermal shock (GMW 3191, Section 4.22) Temperature / Humidity Cycling (GMW3191, Section 4.23) Heavy Duty (GMW3191, Section 4.24) Mechanical Shock (GMW3191, Section 4.27) Vibration with Thermal Cycling (GMW3191, Section 4.28) Fluid Resistance (GMW3191, Section 4.32) Appendix... 16

4 Page 3/17 1. Scope This document specifies product specification and performance information of SRV connector complied with the standard below. TEST STANDARD: GM Worldwide Engineering Standard, GMW 3191 Connector Test and Validation Specification (December 2007 release), Table 29: Connector Validation Test Matrix, New Sealed Connector, GMW3191 Approved Terminal System Temperature Class: Vibration Class: Sealing Class: Mating Class Class 3 (-40 C ~ 125 C) Class 1 (on body or chassis) Class 3 (High pressure spray expected) Class 2 ( 45N) 2. Part Name, Part Number, Part Construction & Drawing Number Part construction shall be in accordance with referenced drawing. Table 1: Part Name, Part Number, Drawing Number No. Part Name Part Number Drawing Number Male Connector Assembly SRVWSB-( )-( )( ) KRD-AD702 Male Housing SRVWS-05-A( ) Male TPA SRVS-B05-R Male Connector Female Connector CPA SRVSC-D05-R Male Back Cover SRVCR-( )( )-( ) Retainer Clip SRVS-C05-( )S Ring Seal SRVP-RS05-M Male Matte Seal SRVR-MS05-M Female Connector Assembly SRVPB-( )( )-( ) KRD-AD703 Female Housing SRVP-( )05-( ) Female TPA SRVS-A05-R Female Back Cover SRVCP-( )( )-( ) Female Matte Seal SRVP-MS05-M TE MCON 1.2 Female (Note1) or equivalent Terminals TE MCON 1.2 Male (Note1) or equivalent Note 1: Refer to TE Connectivity for details.

5 Page 4/17 3. Material and Surface Finish Table 2: Materials and Surface Finish Part Name Assembles with Key Code A Material Finish Flame Class Light Gray UL-94-HB 1. Male Housing B PBT GF15 Natural UL-94-HB C Brown UL-94-HB D Black UL-94-HB SRV Male Connector 2. Male TPA Any PBT GF15 Red UL-94-HB 3. CPA Any PBT GF15 Red UL-94-HB A Light Gray UL-94-HB 4. Male Back Cover B PBT GF15 Natural UL-94-HB C Brown UL-94-HB D Black UL-94-HB 5. Retainer Clip Any PBT GF15 Natural UL-94-HB 6. Ring Seal Any Silicone Green 7. Male Matte Seal Any Silicone Green SRV Female Connector A Light Gray UL-94-HB 8. Female Housing B PBT GF15 Natural UL-94-HB C Brown UL-94-HB D Black UL-94-HB 9. Female TPA Any PBT GF15 Red UL-94-HB A Light Gray UL-94-HB 10. Female Back Cover B PBT GF15 Natural UL-94-HB C Brown UL-94-HB D Black UL-94-HB 11. Female Matte Seal Any Silicone Green

6 Page 5/17 4. Characteristics Table 3: Specifications Item Current Rating (Note 1) Voltage Rating Temperature Range (Note 2) Storage Temperature Range (Note 3) Specification 7A DC max 14V DC -40 C to +125 C Temperature (-5 ~ 40 ) Humidity (40 ~ 60% R.H.) Isolation Resistance 100MΩ min Dielectric Withstanding Voltage 1,000V/minute AC Applicable Wire (Note4) Conductor Size (0.35 mm mm 2 ) Max Insulation Diameter Φ1.9mm Note 1. The temperature should be 23±5 when a single electrode is applied to a single cavity. Note 2. The temperature range includes the temperature rise when an electrical current is applied. Note 3. If a connector is packed in a box for shipment, keep it out of direct sunlight and store it in a room where there shall be no shock, condensation, or other harmful elements. If a connector is stored at a low temperature, bring to room temperature and ensure there is no condensation before. Note 4. For more details contact Terminal Supplier 5. Performance Performance should satisfy the acceptance criteria of each test specified with GMW3191, Table 29. All evaluation tests shall comply with the default test tolerances and conditions unless specified otherwise. Default Test Tolerances: Temperature: ± 3 C Voltage: ± 1 % Current: ± 1 % Resistance: ± 1 % Length: ± 1 % Time: ± 5 % Force: ± 5 % Frequency: ± 5 % Distance: ± 1 % Flow Rate: ± 5 % Relative Velocity: (50 ±10) mm/min Default Test Conditions: Room Temperature: Relative Humidity: 23 ± 5 C Ambient

7 Page 6/ Visual Examination (GMW3191, Section 4.1) No defects such as cracks, deformation, flash, and tarnish shall be noticed on the SRV Male and Female Connector assemblies Isolation Resistance (GMW3191, Section 4.19) Contact with the foil. Apply 500 VDC between the adjacent cavities of the mated connector and record the resistance. Apply 500 VDC between the terminals and the foil and record the resistance. : Isolation resistance of all adjacent pairs of terminals Isolation resistance between terminals and the metal foils > 100 MΩ > 100 MΩ Dielectric Strength (GMW3191, Section 4.20) Test Method: Wrap metal foil around the mated connector housing ensuring no wires or terminals are making contact with the foil. Apply 1000 V(AC) at 60 Hz or 1600V(DC) between the terminal and the foil and across the adjacent cavity for 60 seconds minimum. Record any current leakage. : No Dielectric breakdown during the test Samples: 10 populated mated connector pairs / test 5.2 Connector Performance Test Terminal to Connector Engagement Force (GMW3191, Section 4.7) Test method: TPA in Open Position: Insert the terminal into the connector with the TPA in the open position at a uniform rate of 50 ± 10 mm/min until the terminal is fully engaged in the connector. Record the force required to fully engage the terminal. TPA in Fully Seated Position: Insert the terminal into the connector with the TPA in the closed position at a uniform rate of 50 ± 10 mm/min until the terminal is fully engaged in the connector. Record the force required to fully engage the terminal. : TPA in Open Position TPA in Fully Seated Position 15 N 30 N

8 Page 7/ Terminal from Connector Body Extraction Force (GMW3191, Section 4.9) Test method: Dry Conditioned without TPA: Populate the connector with 10 terminals without the TPA. Apply a pulling force at a uniform rate of 50 ± 10 mm/min to the terminal until the terminal is removed from the connector. Record the peak force required to disengage the terminal. Dry Conditioned with TPA: Populate the connector with 10 terminals with the TPA. Apply a pulling force at a uniform rate of 50 ± 10 mm/min to the terminal until the terminal is removed from the connector. Record the peak force required to disengage the terminal. Moisture Conditioned with TPA: Populate the connector with 10 terminals with the TPA. Place the samples into an environmental chamber set to 40 C at 95%-98% Humidity for 6 hours. Remove the samples and apply a pulling force at a uniform rate of 50 ± 10 mm/min to the terminal until the terminal is removed from the connector. Record the peak force required to disengage the terminal. Thermal Aged with TPA: Populate the connector with 10 terminals with the TPA. Place the samples into an environmental chamber set to 155 C for 1008 hours. Remove samples and apply a pulling force at a uniform rate of 50 ± 10 mm/min to the terminal until the terminal is removed from the connector. Record the peak force required to disengage the terminal. Temperature Humidity with TPA: Populate the connector with 10 terminals with the TPA. Place the samples into an environmental chamber set for Temperature Humidity Cycling for 240 hours. Remove samples and apply a pulling force at a uniform rate of 50 ± 10 mm/min to the terminal until the terminal is removed from the connector. Record the peak force required to disengage the terminal. : Dry Conditioned without TPA Dry Conditioned with TPA Moisture Conditioned with TPA Thermal Aged with TPA Temperature Humidity with TPA 30 N 60 N 60 N 50 N 50 N Connector to Connector Engagement Force (GMW3191, Section 4.11) Test Method: Fill all the cavities of the connector with terminals. Apply a force at a uniform rate of 50 ± 10 mm/min until connectors mate. Record the force required to mate the connectors in their final engaged position. : Connector Mating Force 45 N

9 Page 8/ Terminal Position Assurance (TPA) (GMW3191, Section 4.12) Test Method: Pre Lock Force: Pull the TPA from the connector at a uniform rate of 50 ± 10mm/min until 20N is applied. Closing Force with Properly Assembled Terminals: With all wires and terminals installed correctly, insert the TPA at a uniform rate of 50 ± 10 mm/min. Record the force required to insert the TPA into its final engaged position. Closing Force with Improperly Assembled Terminals: With all but one wire and terminal installed correctly, insert the TPA at a uniform rate of 50 ± 10 mm/min. Record the force required to insert the TPA into its final engaged position. : Closed TPA Locking Force: Pull the TPA from the connector at a uniform rate of 50 ± 10 mm/min until 25N is applied. TPA Pre-lock Force TPA Closing Force w/ Properly Assembled Terminals TPA Closing Force w/ Improperly Assembled Terminals Closed TPA Locking Force 20 N 30 N 60 N 25 N Connector Mounting Feature (GMW3191, Section ) Test Method: With the connector assembly attached to a mounting bracket, apply forces in the directions as indicated below in an effort to defeat the mounting feature. The force shall be applied at a uniform rate of 50 mm/min. Test a minimum of 5 connectors for each direction

10 Page 9/17 : F1, F2, F3, F4 & F5 > 50 N F6 >100 N CPA Lock and Unlock Force (GMW3192 Section ) Test Method: CPA Lock force: Mate a pair of connectors and close the CPA at a uniform rate of 50±10mm/min. Record the force required to fully close the CPA. CPA Unlock force: Open the CPA at a uniform rate of 50±10mm/min. Record the force required to fully open the CPA CPA Closing Force on Unmated Connectors: Using unmated connectors, closed the CPA at a uniform rate of 50±10mm/min. Record the force required to fully close the CPA CPA Extraction Force: Using unmated connectors, open the CPA at a uniform rate of 50±10mm/min. Record the force required to fully open the CPA. : CPA Locking Force 22 N CPA Unlocking Force 20 N 40 CPA Closing Force on Unmated Connectors > 80 N CPA Extraction Force > 80 N Locked Connector Disengagement Force (GMW3191, Section 4.13) Test Method: : Place a mated connector pair without wires, TPA s or CPA s in an appropriate fixture. Ensure the primary locking feature is engaged. Attempt to disengage the connectors at a uniform rate of 50 mm/min ± 10. Record the forces to disengage the connectors. Disengagement Force > 80N

11 Page 10/ Unlocked Connector Disengagement Force (GMW3191, Section 4.14) Test Method: Extraction forces with wires. Disable or physically remove the connector primary locks. Populate the connector with all the applicable wires TPA s and seals. Mate the connectors. Place the mated connector pair in an appropriate fixture. Attempt to disengage the connectors at a uniform rate of 50±10 mm/min. Record the force to disengage the primary locking feature. Primary lock disengagement: Assemble a connector with the primary locking force feature engaged. Place the mated connector in an appropriate fixture. Apply force in an attempt to disengage the primary lock. Record the force to disengage the primary locking feature. s: Extraction Force w/ Wires Primary Lock Disengagement < 100 N Connector Polarization Feature Effectiveness (GMW 3191, Section 4.15) Test Method: Assemble a connector pair with wires. Place the male connector in appropriate fixture. Mount the female in the same axis as the male. Rotate the female 90. Attempt to mate the connector using a force 3X s the maximum mating force measured during the Connector to Connector Mating Force. Under no circumstances shall electrical contact be made under applied of 150N. Using additional samples test the following orientations: 180, 270, and existing coding. s: N

12 Page 11/ Thermal Aging (GMW3191, Section 4.21) : Test Method: Place 4 sets of connectors in an environmental chamber using the following conditions Temperature 125 Period 1008 hours Take Dry Circuits Resistance measurements on the 1 st of connectors. Take Isolations Resistance and Dielectric Measurements on the 2 nd set of connectors Terminal Size mω Max Thermal shock (GMW 3191, Section 4.22) Test Method: Place 4 sets of connectors in a thermal shock chamber using the following conditions 1cycle consist of: -40 C for 30 minutes 125 C for 30 minutes Total Cycles: 300 Half of the 1 st set shall be monitored for continuity during the test. Take dry circuit resistance measurements on the 1 st set of connectors. Take isolation resistance and dielectric measurements on the 2 nd set of connectors. : Terminal Size mω Max Isolation Resistance > 100 MΩ Pressure No bubbles Vacuum No Fluid Ingress Submersion No Leakage High Pressure Spray No Fluid Ingress Dielectric Strength No Dielectric Breakdown Continuity No Loss > 7Ω > 1µs

13 Page 12/ Temperature / Humidity Cycling (GMW3191, Section 4.23) Test Method: Place 4 sets of Connectors in an environmental Chamber. Using the appropriate temperature class for the connector system, run the following profile: : Repeat the profile 10 times. Remove the samples and take Dry Circuit Resistance measurements on the 1 st set of connectors. Take isolation resistance and Dielectric measurements on the 2 nd set of connectors. Terminal Size mω Max Isolation Resistance > 100 MΩ Pressure No bubbles Vacuum No Fluid Ingress Submersion No Leakage High Pressure Spray No Fluid Ingress Dielectric Strength No Dielectric Breakdown Continuity No Loss > 7Ω > 1µs

14 Page 13/ Heavy Duty (GMW3191, Section 4.24) Test Method: Place a connector with terminals inserted into 6 adjacent cavities with thermocouples attached. Connect all terminals in series. Place the connector in thermal shock chamber using the following conditions: 1 cycle consist of: -40 C for two hours with no current 80 C for five hours with de-rated current Total Cycles: 5 Terminals shall be powered with 12 ADC Let samples rest at room temperature for 24 hours. Take dry Circuit Resistance measurements : Terminal Size 1.5 Temperature Rise 8.0 mω Max 50 C Mechanical Shock (GMW3191, Section 4.27) Test Method: Assemble and mate connectors with all of the appropriate wires, TPA s, & CPA s. Wire half of the connectors in series. Place fully assembled connectors on a vibration table using the method specified in GMW3191. Run the following profiles: Test No. 1 2 Acceleration [g] Nominal Shock Duration [ms] Nominal Shock Shape Half sine Number of shock per axis (positive and negative) 132 x 6 = x 6 = 18 Half of the first set shall be monitored for continuity during the test. Take Dry circuit resistance measurements. : None. Samples are evaluated with Thermal Cycling. Samples: 10 connector pairs / test

15 Page 14/ Vibration with Thermal Cycling (GMW3191, Section 4.28) : Test Method: Using the same samples, fixtures and mounting methods from Mechanical Shock, place the samples into an Agree style chamber capable of running the following profiles: Frequency (Hz) PSD (m/s²)²/ Hz) ASD (G²/Hz) Time (minutes) Temperature ( C) Period hours for each. X, Y & Z coordinate axis Half of the 1 st shall be monitored for continuity during the test. Take dry circuit resistance measurements Terminal Size mω Max

16 Page 15/ Fluid Resistance (GMW3191, Section 4.32) Test Method: Heat fluid to the specified temperature listed on the table below. Place 2 connectors in the fluid and let them soak for one hour. Remove the samples and let them sit at a room temperature for 7 days. Perform pre and post isolation Resistance test. Inspect the samples for internal fluid residue. Fluid Temperature ( C) Brake Fluid L / SAE RM Oil B / ASTM IRM Gasoline GME L0003 / ASTM Ref. Fuel C +25 Engine Coolant B / ASTM Service Fluid Automatic Transmission Fluid B / Citgo # Windshield Washer Solvent Commercial +25 Power Steering Fluid B / ASTM IRM Diesel Fluid En 590 / 90 % IRM % T-Xylene +25 E85 Ethanol Fuel 85 % Ethanol + 15 % GME L0003 / 85 % Ethanol + 15% ASTM Ref. Fuel C +25 : Isolation Resistance Terminal Extraction Visual Inspection > 100 mω > 50 N No Fluid Ingress

17 Page 16/17 Appendix Appendix Figure 1: Connector Electrical Tests Sequence

18 Appendix Figure 2: Sealed Connector Environmental Tests Page 17/17