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Standard

Ergonomics Specification for Electrical Connections

2016-02-15

HISTORICAL

USCAR25-2

This document describes the design relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). The minimum values associated with this design guide need to be evaluated against other critical characteristics that impact quality, efficiency and other traits of assembly feasibility. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department.

Standard

Ergonomic Guidelines for Small Lot Delivery Operations

2015-03-10

CURRENT

USCAR42

This document describes the design, assessment methods and physical requirements associated with material handling systems. This would include, but not limited to manual dollies, small lot systems and kitting. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the shelf” design, always consult the responsible Ergonomics Department.

Standard

PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS

2014-11-01

HISTORICAL

USCAR21-3

This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150,000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned. This specification is based on accepted levels of environmental exposure for automotive applications.

Standard

Standard for Cigar Lighters & Power Outlets

2014-03-31

CURRENT

USCAR4-1

This standard is intended to cover cigar or cigarette lighters as well as power outlets based on the form and dimensions of the cigar lighter. This standard is a full performance specification, it includes dimensional and operational parameters as well as performance characteristics which must be met when submitting a cigar lighter assembly or power outlet assembly for production approval. This standard constitutes an acceptance specification for a surface mounted, front-loaded cigar lighter or power outlet.

Standard

USCAR INFLATOR TECHNICAL REQUIREMENTS AND VALIDATION

2013-04-30

HISTORICAL

USCAR24-2

This specification establishes the performance, and validation requirements for the inflator assembly used in airbag modules. Seatbelt Pretensioners are covered as a reference only.

Standard

Performance Specification for Automotive Electrical Connector Systems

2013-02-01

HISTORICAL

USCAR2-6

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 – 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet-type terminals. No electrical connector, terminal, or related component may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts.

Standard

SALT SPRAY TESTING AND EVALUATION OF FASTENER FINISHES

2012-07-30

HISTORICAL

USCAR1-2

This procedure is used to test and evaluate the resistance of fastener surface finishes to laboratory salt spray testing.

Standard

DEEMBRITTLEMENT VERIFICATION TEST

2012-07-30

HISTORICAL

USCAR7-1

This standard outlines test methods and practices which can detect embrittlement of steel parts. It is a process control or referee verification test. The risk of embrittlement of steel is minimized by using best practices in the finishing/coating process. One such practice is described in SAE/USCAR-5, Avoidance of Hydrogen Embrittlement of Steel.

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LIGHT BULB SOCKETS

2010-01-15

HISTORICAL

USCAR15-3

This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire wedge base sockets, circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs: New design Design, material or process change made to an existing device, which could affect the outcome of the test. The test sequence shown in Appendix F shall be run annually. (NOTE: Production process control data collected at a shorter interval per an approved control plan, may be substituted if approved by customer’s responsible engineer and purchasing representative.)

Standard

Performance Specification for Ultrasonically Welded Wire/Cable Termination

2009-12-18

HISTORICAL

USCAR38

IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE MINIATURE BULBS

2009-12-01

HISTORICAL

USCAR3-3

The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling applications. The following tests shall be run whenever the following occurs: New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test. The completion of one calendar year as noted in the following Test Schedule Table. Process control data is acceptable.

Standard

PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS

2008-10-20

HISTORICAL

USCAR21-2

In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.

Standard

ELECTRICAL CONNECTOR ASSEMBLY ERGONOMIC DESIGN CRITERIA

2008-09-26

HISTORICAL

USCAR25-1

This document describes the design, assembly force, and packaging guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department. Refer to SAE/USCAR-12 Wiring Component Design Guidelines for additional guidelines.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2007-10-08

HISTORICAL

USCAR2-5

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet type terminals.

Standard

TORQUE-TENSION TESTING AND EVALUATION OF FASTENER FINISHES

2007-03-01

HISTORICAL

USCAR11-1

This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.

Standard

Initiator Technical Requirements and Validation

2005-06-06

CURRENT

USCAR28

This specification establishes the design, performance, and validation requirements for the initiator assembly used in airbag modules, seatbelt pretensioners and/or any other Electro-Explosive Devices (EED).

Standard

Performance Specification for Automotive RF Connector Systems

2004-11-30

HISTORICAL

USCAR17-2

Standard

USCAR INFLATOR TECHNICAL REQUIREMENTS AND VALIDATION

2004-06-24

HISTORICAL

USCAR24

This specification establishes the performance, and validation requirements for the inflator assembly used in airbag modules. Pretensioners are covered only in respect to their effluents as included in Section 3.2.3, Effluents and their autoignition performance as included in Section 3.2.5, Autoignition, High Temperature Oven Performance/Autoignition of Heat Aged Inflators

Standard

FIELD CORRELATED LIFE TEST SUPPLEMENT TO SAE/USCAR-2

2004-06-23

HISTORICAL

USCAR20-1

This life test for underhood/passenger/trunk connector systems may be used in place of Section 5.9.6, Connection System Electrical Table of SAE/USCAR-2. All other requirements of SAE/USCAR-2 remain applicable even when this test is used. Refer to SAE/USCAR-2 and Connector/Terminal Supplier for appropriate power rating and current cycle Testing.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2004-05-25

HISTORICAL

USCAR2-4

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, > 20 VAC or DC, or to eyelet type terminals.