QC/T 417.2-2001Road vehicles - Connectors for on-board electrical wiring harnesses - Part 2: Test methods and general performance requirements (motorcycles) (English PDF)

3.1 Locking device

A device in the connector which maintains its mating portion in a mechanically automatically locked state and which is manually opened.

4.1 General

4.1.1 Test conditions

All tests shall be carried out at room temperature (23 ± 5) °C and a relative humidity of 45% ~ 75%, unless otherwise specified.

Each test (see Table 1) shall start from a new specimen. The preparation of specimen shall comply with the relevant standards.

The connector shall be tested together with its mating portion. The connector shall be crimped to the corresponding wire. The wire used shall comply with the provisions of JB/T 8139. The specifications of all the wires used shall be recorded in the test report.

Various test methods and test samples shall affect each other. For example, in a high temperature chamber, the test samples shall be kept at a distance from each other and cannot be in contact with each other.

4.1.2 Test sequence

The test sequence for each of the specimen groups in Table 1 is represented by Xs from top to bottom.

The tests in specimen groups A, B, C, D, E, F, G, H, I apply to unsealed connectors.

The tests in specimen groups A, B, C, D, E, F, G, H, I apply to sealed connectors and splash-proof connectors.

Each specimen group shall have at least 20 sets of specimens of single-wire

For hybrid type multi-wire connectors, each type shall have at least 20 pairs of connector specimens to be tested. Each specimen group shall use the new specimen for testing.

Unless otherwise specified in the test method, at least 4 pair of connectors need to be measured in each set of multi-wire connectors. For single-wire, 2-wire, 3- direction of the connector. Maintain stability for s.

4.5.1.2 Locking of connector

After the 11th insertion as specified in 4.3.1.2, apply a force of N in the pullout direction of connector. Maintain stability for s.

4.5.2 Requirements

4.5.2.1 For the connector whose shell is locked, apply a static tension of N in the pullout direction of the connector. Maintain it for s without falling off or being damaged.

4.5.2.2 For the connector whose connection piece is locked, apply a static tension of N in the pullout direction of the connector. Maintain it for s without falling off or being damaged.

4.6 Insertion force of connector into shell

4.6.1 Test

When measuring the insertion force of the connector into the shell cavity, use the test fixture to position the connection piece along the insertion direction.

The position shall be as close as possible to the insulation reel of wire.

Use a constant speed within the range of 50 mm/min ~ 150 mm/min to insert it into the shell. The rate of application shall be recorded in the test report.

4.6.2 Requirements

After the connector is crimped to the wire as required, insert it into the shell cavity. If the nominal cross-section of the conductor of the wire as crimped by the connector is not more than 1 mm², the insertion force is at most 15 N. If the nominal cross-section of the conductor of the wire as crimped by the connector is more than 1 mm², the insertion force is at most 30 N.

4.7 Retaining force of connector in shell

4.7.1 Test

Use an appropriate test device to test the retaining force of the connector. In front of or behind the connector, apply a constant force axially and maintain it for s. The applied force shall be recorded in the test report.

4.7.2 Requirements

Insert each connector into the shell cavity. After inserting it in place, apply a constant tension of 60 N along the axial direction of the crimped connection between the connector and wire. Maintain it for s. The connector must not be removed from the shell or damaged.

Depending on the insertion/pullout force, material, design requirements, it may also require a higher retaining force.

For the sealed connector, the force as applied by the seal shall be included.

4.8 Contact resistance (voltage drop)

4.8.1 Test

4.8.1.1 Measurement at millivolt levels

The test voltage shall not exceed 20 mV of DC or AC peak voltage. The test current shall not exceed 50 mA.

As shown in Figure 2 and Figure 3, measure the contact resistance. The resistance of the associated conductor shall be subtracted from the measured value.

4.8.1.2 Measurement at specified test current

Measurements shall be made at a current intensity of 5 A/mm2 after reaching heat balance, unless otherwise specified.

If the wire used for testing is soldered to the measuring point, it shall not affect the connection of the connector.

4.8.2 Requirements

Each pair of connectors shall be inserted into the position. After the initial insertion, the contact resistance is up to 5 mohm. After 10 insertion/pullout, current cycle, temperature/humidity cycle, vibration, salt spray test, the maximum contact resistance is 10 mohm, or otherwise 150% of the initially measured value, as selected by the user.

4.9 Water-tightness

If agreed by the manufacturer and the user, for the connectors of some special purposes, the test voltage may be reduced to DC 100 V. The applied voltage shall be recorded in the test report.

When a stable reading occurs, record the insulation resistance. However, after the temperature/humidity cycle test, the unsealed and splash-proof connectors shall be placed in the conditions as specified in 4.1.1 for 24 h, before measuring the insulation resistance.

4.12.2 Requirements

According to the test sequence of Table 1, before and after the test, make determination according to 4.12.1. The insulation resistance between the connectors that are not connected in the connector as well as between the connector and the shell shall be more than 100 Mohm.

4.13 Insulation dielectric strength

4.13.1 Test

Between the connectors which are not connected in the connector as well as between the connector and the metal foil which wrap the shell, apply the AC 1000 V (50 Hz or 60 Hz) voltage or DC 1600 V voltage for 1 min. For the purposes of safety, the metal foil shall be grounded.

4.13.2 Requirements

When tested according to 4.13.1, there shall be no breakdown or sparking.

4.14 Temperature-rise

4.14.1 Test

Use the mating connector of the simulated or actual wire-wire connection (see Figure 2) or device connection (see Figure 3) to carry out the temperature-rise test.

Crimp the specimen to a wire whose nominal cross-section of conductor is not more than 2.5 mm² and length is 200 mm ± 5 mm. For cables whose conductor has a nominal cross-section of more than 2.5 mm², the length shall be 500 mm ± 2 mm.

During the test, take care to protect the sample. Prevent ventilation and manual cooling, for example, the cooling due to thermocouples.

The connector to be measured shall be able to reach the highest stable temperature. A typical measurement surface is as shown in Figure 10.

4.16.2 Requirements

After the test according to 4.16.1, it shall follow the sequence of Table 1 to carry out the subsequent tests.

4.17 Current cycle

4.17.1 Test

Use the specimen as specified in 4.14.1 to carry out the current cycle test.

According to the type of the mating connector used, based on the requirements of Table 6, specify the specification of the crimped wire of the connector and the test current.

Put the specimen into the test equipment. The temperature is as specified in Table 8. Carry out 500 cycles of tests. Each cycle consists of 45 min of power- on and 15 min of power-off.

Note: Avoid the specimen from ventilation and manual cooling.

4.18 Aging

4.18.1 Test

Put the connector in the test equipment for 100 h. The test temperature is as specified in Table 5.

Note: If using another method, that is, the test temperature as specified in Table 8, the test time needs to be increased to 500 h.

4.18.2 Requirements

Number of lines of connector Conversion factor Category Test temperature, °C (±2 °C)

7.17.2 Requirements

After the test according to 4.17.1, it shall follow the sequence of Table 1 to carry out the subsequent tests. […]