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This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

This document specifies dimensional, functional and visual requirements for Automotive grade coaxial cable. This material will be designated AG for general-purpose automotive applications or AG LL for low loss applications. It is the responsibility of the user of this cable to verify the suitability of the selected product (based on dimensional, mechanical, electrical and environmental requirements) for its intended application. It is the responsibility of the supplier to retain and maintain records as evidence of compliance to the requirements detailed in this standard.

This document specifies dimensional, functional and visual requirements for Automotive grade coaxial cable. This material will be designated AG for general-purpose automotive applications or AG LL for low loss applications. It is the responsibility of the user of this cable to verify the suitability of the selected product (based on dimensional, mechanical, electrical and environmental requirements) for its intended application. It is the responsibility of the supplier to retain and maintain records as evidence of compliance to the requirements detailed in this standard.

SAE/USCAR-45 defines test methods and performance requirements for ultrasonically-welded wire-to-wire splices for automotive applications. Face-to-face, butt splice, and center strip configurations per Figure 1 can be tested. The tests defined in this specification subject samples on test to stresses that simulate a lifetime of exposure for a road vehicle. Stresses called out in this specification include thermal shock, temperature/humidity cycling and mechanical stress from different directions.

This radio frequency (RF) connector interface specification is suited for unsealed automobile applications up to 2 GHz. Dimensional requirements are specified in this document to ensure interchangeability. This RF connector interface specification is intended for in-line, board mount, device mount, straight or angled applications. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.

This radio frequency (RF) connector interface specification is suited for unsealed automobile applications up to 2 GHz. Dimensional requirements are specified in this document to ensure interchangeability. This RF connector interface specification is intended for in-line, board mount, device mount, straight or angled applications. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.

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 150000 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, such as coaxial cable crimps, unless a USCAR-21 test is specifically referenced in the test specification for that wire type. This specification is based on accepted levels of environmental exposure for automotive applications.

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.

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

This specification defines test methods and performance criteria for evaluating ultrasonically welded wire-to-terminal metallurgical bonds. The examples used are specific to the linear weld type of process equipment. USCAR-38 is not applicable for “Splice Welding”. The specification is applicable to wire-on-pad configurations with a typical weld shown in Figure 1. This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures called-out in this specification include Thermal Shock, Temperature Humidity Cycling and mechanical abuse. This test specification is intended to evaluate the strength and performance of the interface between wires to an electrical terminal. Validation of the performance of the Terminal is a separate task and can be accomplished using a component validation test such as SAE/USCAR-2, which evaluates whether the entire connection system is acceptable.

This document gives general guidelines to be used during the connector design stage. Various guidelines may not apply in all situations. Therefore, sound engineering judgment must be used in their application. Consider these guidelines as the basis for connector and wiring DFMEA’s. Items in this document are grouped by DFMEA functional requirements. Groups are as follows: A Electrical Continuity B Electrical Isolation/Sealing C Device Assembly D Harness Assembly E Vehicle Assembly F Materials G Serviceability H Environmental Requirements I High Voltage (≥ 60V) Application Requirements

This document gives specific and measurable design criteria to be applied at a design review prior to tooling. The specification is formatted as a checklist to aid in its use. The requirements do not apply in all situations so engineering judgment must be used. This is a specification for design criteria; applicable performance specifications (USCAR-2, etc.) must still be performed. Items in this document are grouped by component as follows: A Terminals B Secondary Terminal Locks C Connectors D Connector Locks E Secondary Connector Locks (Connector Position Assurance, CPA) F Connector Seals G Serviceability H High Voltage (≥60V) Application Requirements I Drawing and General Requirements

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 for coaxial cable connection systems (hereafter referred to as RF connectors) in road vehicle applications. The intent of this specification is to qualify RF connectors that operate at frequencies greater than 200 MHz. This specification does not apply to single conductor wire or twisted pair connection systems. The RF connection system will be qualified for specific coaxial cable; the qualified coaxial cable and frequency range of interest must be listed on the connector drawing. Changing coaxial cable necessitates re-qualification. This specification is a supplement to the SAE/USCAR-2 Performance Standard for Automotive Electrical Connector Systems and all requirements herein must be met in addition to all requirements of SAE/USCAR-2, unless otherwise specified.

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 for coaxial cable connection systems (hereafter referred to as RF connectors) in road vehicle applications. The intent of this specification is to qualify RF connectors that operate at frequencies greater than 200 MHz. This specification does not apply to single conductor wire or twisted pair connection systems. The RF connection system will be qualified for a specific coaxial cable; the qualified coaxial cable and frequency range of interest must be listed on the connector drawing. Changing coaxial cable necessitates re-qualification.

This document is a supplement to DIN 72594 and is intended to give recommended usages for one and two way connectors and dimensional requirements for 2-way connectors which are not currently specified by DIN. The radio frequency (RF) connector interface specified herein is suited for unsealed automobile applications up to 3 GHz and is intended for in-line, board mount, device mount, straight or angled applications. Dimensional requirements are specified in this document to ensure interchangeability. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.

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.