SAE USCAR2-7 Performance Specifications for Automotive Electrical Connection Systems

The procedures described in the standard "SAE USCAR2-7 Performance specifications for automotive electrical connection systems" developed by the Society of Automotive Engineers (SAE) are intended to cover performance testing of electrical terminals, connectors, and components that comprise electrical connection systems for low voltage (0 to 20 Volts DC) on-road vehicle applications during all phases of development, manufacturing, and field analysis. These procedures apply only to terminals used for in-line, header, and device connector systems. This standard does not apply to edge panel connector systems, twist-lock connector systems, minimum 20 Volt AC or DC, or ring terminals.

No electrical connector, terminal or related component can be claimed to meet USCAR standards unless compliance with all applicable requirements of this standard has been verified and documented. All necessary verification and documentation must be performed by the supplier of the part or parts. If testing is performed by another source, this does not relieve the primary supplier of the responsibility for documentation of all test results and verification that all tested samples meet all applicable acceptance criteria.

If products tested to this standard are subjected to conditions beyond those described in this document, they must undergo specific tests simulating the actual conditions that will be encountered before they can be considered acceptable for actual vehicle applications. The authorized person has the final authority on what tests are to be performed on his or her parts and the purpose for which those tests are necessary. He or she also has the final authority to resolve all questions regarding testing to this standard and to authorize any variations from the equipment or procedures contained in this specification. Any such deviations must be documented and included in the final test report. Guidance on recommended tests for selected purposes is included in the standard appendices (Annex C and Annex D).

The tests in each section shall be performed in the order given unless otherwise specified in the test request/order. Construction details for selected test fixtures and equipment are described in this standard. For the purposes of this standard, there are only two types of electrical connectors: sealed and unsealed.

The general requirements in this standard are given as follows:

• Record keeping: The supplier must maintain a central file for the storage of laboratory reports and calibration records. Such record storage must comply with ISO TS16949.
• Sample documentation: All test samples must be described in accordance with the requirements of the ISO TS16949 standard.
• Sample size: Minimum sample sizes are given for each test in this standard. A larger number of samples may be required by the test request/order. However, no part or device can be demonstrated to meet this specification unless the minimum sample size has been tested and all samples of the tested batch meet the acceptance criteria applicable to that test. It is never acceptable to test a larger batch, then select the minimum sample size from those that pass, and demonstrate that this specification has been met.
• Test conditions and tolerances: Unless otherwise stated, the default tolerances expressed as a percentage of the nominal value are given in a table within the standard. Unless otherwise stated, the following basic conditions apply: room temperature, 23 degrees plus/minus 5 degrees, relative humidity, uncontrolled as in laboratory conditions, voltage, 14,0 plus/minus 0,1 Volts DC.
• Equipment: the lists provided in the standard are not all-inclusive. They are designed to highlight specific equipment or devices with specific accuracy requirements.
• Measurement resolution: Measuring devices and measuring instruments used in measuring test samples must be able to measure with a resolution better than one decimal place than the specified value.
• Test repeatability and calibration: All equipment used for test sample evaluation must be calibrated and maintained according to the requirements of the ISO TS16949 standard.
• Determination of compliance: Compliance shall be determined based on the specified requirements of the test conducted. All samples shall meet the requirements regardless of sample age, test cycles or test temperature.
• Purge of samples: If a premature non-compliance occurs during a test, the authorized person should be contacted to determine whether the test should be continued to gain additional product experience or whether the test should be suspended or terminated.
• Component durability: Successful completion of the requirements of this standard is intended to demonstrate that the design and construction of the tested components and fastener systems are capable of operating for 200 thousand miles in the intended vehicle environment and application.

Major tests performed under this standard include:

• Terminal mechanical tests
• Terminal - Electrical tests
• Fastener - Mechanical tests
• Connector - Electrical tests
• Binder environmental tests
• Tests for titles
• Heavy duty tests

Among the numerous testing, measurement, analysis and evaluation studies that our organization has carried out for businesses in various sectors, it also provides testing services defined in the “SAE USCAR2-7 Performance specifications for automotive electrical connection systems” standard with its trained and expert staff and advanced technological equipment.