QC/T 417-2021Electrical wire harness assemblies for motorcycles and mopeds (English PDF)

3.1 Electrical wire harness assemblies

Components for wires, in-line connectors and equipment connectors used to connect motorcycle electrical components. The wire harness includes main stems, laterals, embranchment points, junctures and terminals of wires.

3.2 Connector

An assembly consisting of terminals, housings and accessories used to achieve electrical connections.

3.3 Housing

Non-metallic parts used to secure and protect terminals.

3.4 Cable attachment

Durable connection between cable and terminal (e.g., crimp, pierce connection, soldering, etc.).

3.5 Polarization feature

A device or structure on a connector that prevents incorrect connections from occurring.

Visual and/or mechanical and/or photosensitive devices to prevent connectors of the same family with the same number of terminals and different coding from being connected.

3.6 Connector cavity number

A visible, regular number on the connector that marks the cavity location.

3.7 In-line connector

A connector that forms an electrical connection between cables.

4.1 Basic requirements

4.1.1 The wire harness shall be manufactured according to product drawings or technical documents approved through the prescribed procedures and shall comply with the provisions of this document.

4.2 Size requirements

The length of the main stem and protective casing shall not be less than 100 mm and shall be a multiple of 10. For example, it shall be 100 mm, 110 mm or 120 mm, etc.

The length of the lateral shall not be less than 30 mm.

4.3 Appearance requirements

4.3.1 The surface of the connector shell shall be free of cracks and obvious deformation. The surface of the terminal shall be free of rust, burrs, breaks or cracks. The mating part of the mating connector shall have no deformation that affects the connection performance.

4.3.3 According to the test sequence in Table 6, after testing all sample groups, the connector shall have no defects such as expansion, corrosion, discoloration, contact plating wear, physical deformation, cracking, and water accumulation that affect the performance.

4.5 Pull-off force of crimp connectors

The pull-off force of the crimp connector shall not be less than the requirements in Table 4 (when multiple wires are crimped to a single terminal, each wire shall comply with the requirements in Table 3 respectively).

4.6 Locking device strength

For connectors with shell locking type and terminal locking type, a static pulling force is applied in the pull-out direction of the connector, without falling off or being damaged.

4.8 Terminal retention in shell body

After each terminal is inserted into the shell cavity and plugged into place, a constant force of 60 N (100 N if the nominal cross-sectional area of the high-voltage connector wire conductor is greater than 8 mm2) is applied in the axial direction of the connection between the terminal and the wire. Terminals must not be removed from the shell or damaged.

4.9 Contact resistance (voltage drop)

Each pair of terminals shall plug into place. The maximum contact resistance after initial plugging is 5 mohm. After 10 times of plugging and unplugging, current cycling, temperature and humidity cycling, vibration and salt spray tests, the maximum contact resistance is 10 mohm, or 150% of the initial measurement value, selected by the user.

4.13 Insulation resistance

The insulation resistance measured in accordance with 5.13 shall be at least 100 Mohm.

However, after the temperature/humidity cycle test and before measuring the insulation resistance, unsealed connectors and splash-proof connectors shall be maintained at an ambient temperature of 23°C ±5°C and a relative humidity of 45%~75% for 3 h.

4.24 Chemical fluid

After conducting the test in accordance with the provisions of 5.24, the test shall be completed in the order of Table 6.

5.1 Preparation before test

5.1.1 Sample pretreatment

Before starting all tests, the samples shall be kept at room temperature of 23°C±5°C and relative humidity of 45%~75% for 24 h.

5.1.3 Allowable error of test conditions

Unless otherwise stated, the allowable error of test conditions is expressed as a percentage of the nominal value, see Table 7.

5.1.4 Test sequence

5.1.4.1 The test sequence for each specimen group shall be carried out in accordance with Table 6 (sequence from top to bottom). The test items in specimen groups A, B, C, D, E, F, G, H, I, K and L are applicable to non-sealed connectors. The test items in specimen groups A, B, C, D, E, F, G, H, I, M and N are applicable to sealed connectors and splash-proof connectors.

5.1.4.2 Each specimen group shall have at least 20 sets of single-wire connector specimens, or 10 sets of 2-wire, 7 sets of 3-wire, or 5 sets of 4-wire connector specimens, etc.

5.2 Size inspection

Use a universal measuring tool to check dimensions.

5.3 Visual inspection

Perform a visual inspection of all connectors and terminals. Inspectors shall have normal vision and normal color discrimination abilities. Under natural light or equivalent lighting conditions (40 W × 2 fluorescent lamp) from 8:00 to 16:00, conduct a visual inspection at a distance of about 40 cm from the sample. The results shall meet the requirements of 4.3.

5.5 Pull-off force of crimp connectors

5.5.1 Use appropriate test equipment. The test is carried out at a constant speed in the range of 50 mm/min~150 mm/min. The applied speed shall be recorded in the test report. If the terminal has an electrical conductor insulation drum, it shall be made mechanically ineffective. When multiple conductors are crimped to a single terminal, the force specified in Table 4 is applied individually to each conductor.

5.7 Insertion force of terminal into housing

When testing the insertion force of a terminal into a housing cavity using conductors of the smallest and largest sizes that can be connected, use a test fixture to position the terminal according to the insertion direction.

5.13 Insulation resistance

5.13.1 A DC 500V voltage is applied between all adjacent but not connected terminals in the connector, and between the terminals and the metal foil covering the shell, at a relative humidity of 45% to 75%.

5.14 Insulation dielectric strength

Between all adjacent but not connected terminals in the connector, between the terminals and the metal foil covering the housing, apply AC 1000 V (root mean square value) under the condition of a relative humidity of 45%~75% (50Hz or 60Hz) voltage or DC 1600V voltage for 1 min.