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Standard

WIRING COMPONENT DESIGN GUIDELINES

2009-07-10

HISTORICAL

USCAR12-3

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

Standard

WIRING COMPONENT DESIGN GUIDELINES

1999-07-01

HISTORICAL

USCAR12

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 Non-functional Drawing Requirements B Electrical Continuity C Electrical Isolation/Sealing D Device Assembly E Harness Assembly F Vehicle Assembly G Serviceability

Standard

WIRING COMPONENT DESIGN GUIDELINES

2001-12-01

HISTORICAL

USCAR12-2

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 Non-functional Drawing Requirements B Electrical Continuity C Electrical Isolation/Sealing D Device Assembly E Harness Assembly F Vehicle Assembly G Serviceability

Standard

USCAR-17 SUPPLEMENT

2016-07-21

HISTORICAL

USCAR18-4

This document is a supplement to SAE/USCAR 17 and is intended to give recommended usages for one and two-way RF connectors and dimensional requirements for 2-way RF connectors and hybrid (RF & DC power) connectors which are not currently specified elsewhere. The radio frequency (RF) connector interface specified herein is suited for unsealed and sealed automobile applications up to 6 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. Compliance with the dimensional requirements of this specification will not guarantee interoperability between different suppliers mating connectors. It is the supplier responsibility to ensure RF performance requirements are met with other suppliers mating connectors. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.

Standard

Torque-Tension Testing and Evaluation of Fastener Finishes

1998-12-30

HISTORICAL

USCAR11

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

TORQUE-TENSION TESTING AND EVALUATION OF FASTENER FINISHES

2020-11-19

CURRENT

USCAR11-2

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

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

TEST PROCEDURE FOR ELECTRICAL GROUND ATTACHMENTS

2022-02-25

HISTORICAL

USCAR26

This test procedure is intended to evaluate and/or validate electrical ground schemes for use on the body or chassis. There are two classes based on the expected environmental conditions. Exposed Grounds can be located anywhere in the vehicle (except on the powertrain) and is the class for which most schemes should be tested. Unexposed Grounds can only be used in the passenger compartment or trunk and as such are special cases. This procedure as written is not intended for testing powertrain grounds where high temperatures and vibration levels may be encountered. These situations may require modifications to this procedure and are left to the Responsible Engineer to determine. This specification does not specifically address validation of terminal to wire electrical crimps. Crimps are tested to SAE/USCAR-21

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

Specification for Testing Automotive Light Bulb Sockets

2006-08-08

HISTORICAL

USCAR15-2

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

Specification For Testing Automotive Miniature Bulb Socket/Circuit Plate Assemblies

2004-01-30

HISTORICAL

USCAR15

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. Tests marked ‘Yearly’ in the following Test Schedule Table shall be run annually. Each test shall be run on 10 samples minimum; tests may be grouped, as supplier prefers, to reduce sample quantity or facilitate scheduling. Production process control data collected at a shorter interval per an approved control plan, may substituted if approved by customer’s responsible engineer and purchasing representative.

Standard

Specification For Testing Automotive Miniature Bulb Socket/Circuit Plate Assemblies

2004-12-10

HISTORICAL

USCAR15-1

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 following test sequences shall be run annually: Test Sequence #2 (Run only the tests listed below, in the following order.) ○ Bulb Insertion/Removal Force ○ Voltage Drop ○ Vibration ○ Bulb Insertion/Removal Force ○ Bulb Wobble Test Sequence #8 Test Sequence #9 Test Sequence #10

Standard

Shipping Caps, Torque Caps, and Body Plugs Ergonomic Design Criteria

2015-03-30

CURRENT

USCAR43

This document describes the design and assembly force guidelines for conventional shipping caps, torque caps, and body plugs. All possible design 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

STANDARD FOR IN-TANK ELECTRIC FUEL PUMPS

1999-08-15

HISTORICAL

USCAR13

This standard covers the operational characteristics, environment, durability procedures, and test procedures for in-tank electric fuel pumps for automotive gasoline applications. Specific performance and test criteria used in conjunction with this procedure are specified on the pump drawing. Particular sections of this document may be required for all applications. This standard is intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking, and in-process controls, and should in no way adversely influence other inspection operations.

Standard

STANDARD FOR D.C. BRUSH MOTOR – HVAC BLOWERS

1999-02-01

HISTORICAL

USCAR6

This standard sets forth the performance and durability requirements for 12-volt, D.C. brush-type electric motors used for automobile Heating, Ventilation, and Air Conditioning (HVAC) blowers and outlines Production Validation and Continuing Conformance testing.

Standard

STANDARD FOR D.C. BRUSH MOTOR - HVAC BLOWERS

2020-11-19

CURRENT

USCAR6-1

This standard sets forth the performance and durability requirements for 12-volt, D.C. brush-type electric motors used for automobile Heating, Ventilation, and Air Conditioning (HVAC) blowers and outlines Production Validation and Continuing Conformance testing.

Standard

STANDARD FOR CIGAR LIGHTERS & POWER OUTLETS

1998-09-01

HISTORICAL

USCAR4

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

SPECIFICATION FOR TESTING GAS DISCHARGE LIGHT SOURCE SUBSYSTEM

2007-10-08

HISTORICAL

USCAR27

This specification is a general level subsystem light source specification that establishes test requirements of a Gas Discharge Light Source (GDLS) subsystem for use on passenger vehicles. The completed test data to this test specification is intended to be provided to the OEM by the Tier one lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved GDLS experiences a design, manufacturing or component change. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. The subsystem is defined as the ballast, igniter and light source and shall be tested as a subsystem and considered one test sample for the entire test sequence. A failure of any component in the test sample shall constitute a failure of the entire sample. Substitution or replacement of only the light source shall be allowed during testing.

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE MINIATURE BULBS

2022-03-15

CURRENT

USCAR3-4

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

SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEMBLIES

2022-03-15

CURRENT

USCAR34

The procedures contained in this specification cover the laboratory testing of Exterior Lamps for use in automotive road illumination. The following tests are intended to be run under the following conditions. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. If other manufacture’s components are intended to be approved for use in the lamp assembly, then those possible combinations of components shall be considered a new lamp assembly and shall also be tested.