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Figure 1: Terminal Conditioning 3. GMw 3. Figure Unmated Connector Seal Test 4. Table 9: Locked Connector Disengage Force 4. Figure Base Curve. Figure Derating CUnv nnn 4. Table Maximum Resistance Values. A Table Cyelic Humiity Requirements. Random Vibration Cycle. Not applicable 62 Acronyms, Abbreviations, and Symbols. Note: In the event of conflct between the English and domestic language, the English language shall take precedence.
Define test and validation requirements including test sequences for electrical connection systems. Not applicable. B B omw3t72 ooo omw, B , Ghaw omwi 2. The test facilities and equipment shall be in good working order and shall have a vali calibration label. Alternative test facilties and equipment may also be used. Test equipment shall be capable of measuring the physical and electrical parameters as specified All meters and gauges used in measurements of the test sample shall be capable of measuring to one significant digit less than the specified value.
Electrical connectors used for testing shall be manufactured according to the values and the tolerances that are shown on the drawings or the releases. Materials shall conform to ail pectcations shown on the respective crawings.
Specific sample quantity requirements are detalled in each tost procaduro, Sea test sequences in Section 4. Terminal Attachment. Not applicabie. The following conditioning shall be performed as defined on connectors and terminals prior to the test procedures specified in this specification: 1. Attach wires of appropriate gauge size to terminals.
Insert terminated leads into the specific connector housings undergoing testing, if required,. For tests that do not require connector housings, mate and unmate the fomalo terminal with the corresponding male terminal 10 times being careful not to cause overstress to the contact spring, 4, For tests on connectionvterminal assembles, male and unmate the connectors with terminals 10 times with the corresponding connector or header interface, except when performing Section 4.
Insert the test pin and apply a force of 0. Note: A terminal shall be stressed in only one direction, thus for another axis stress another terminal. Thus it takes four separate terminals to stress in each of the four directions, 4 terminals, each in one direction only Figure 1: Terminal Conditioning f.
Deviations from the requirements ofthis standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc.
Assure parts used for testing are free of damage and obvious defects. Normal lighting, photographic equipment, a device with at least 10x magnification 3s required.
All test samples shall be conditioned per 3. Visually examine each test specimen before testing andior Conditioning. The test specimens shall not exhibit any evidence of deterioration, cracks andlor other deformities that could affect performance, function andior appearance.
A control sample shall be retained Photographs andlor video recordings of the samples being tested shall be taken. There shall be no corrosion, discoloration, cracks, etc. Swelling or physical distortion shall not exceed the tolerances specified on the part drawing. This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use.
In some cases, a shorter test can be agreed to between the responsiole GM department and the supplier. The sample connectors shall be fully assembled with terminals, cables, and seals. Terminals with crimped on wire seals shall be fully sssembled with cables and seals The supplier shall inform the GM Connector Design Release Engineer DRE of al adjustments, modifications.
Each sequence and its specific results shall be reported. Any failures shall be documented and include the requirement that was not met. Additional documentation may be attached 0.
Raw test data shall be provided when requested. Such deviations shall be specified on component drawings, test certificates, reports, etc. Unless stated otherwise, Table 1 shall define the test environment parameters and tolerances to be used forall validation testing.
Electrical connectors are classified by temperature class, vibration class, seating class and mating force cass. Table 2 defines the general temperature classes for electrical connection systems within the vehicle. Speatestion 4. When Target Life is expected to exceed this, the classification shall be labeled as the multiple of this tracitional target life, Le.
Uniess otherwise specified, connectors will be validated to Target Life. Table 4 defines the general sealing classes for electrical connections systems within the vehicle. The supplier shall follow all of the procedures defined under each test section. The supplier shall folow the test sequences defined in Section 4. This test is used to determine the susceptibility to stress-corrosion of any portion of terminals made from un-plated copper-zine alloys.
Finished terminals crimped to wires. Three 3 minimum. Clean contacts or material to be tested by degreasing in suitable alkaline cleaner or organic solvent. Dry the paris thoroughly. Suspend the cleaned test samples at a height of 80 mm above the surface of the ammonia solution and seal the test vessel Expose the samples for 24 1 hours. Note: Deviations from the continuous time requirement shall be noted on the test report.
If itis necessary to interrupt the test, test samples may be removed from the vessel and stored in de-lonized water for up to 16 hours, dried and then re-exposed to the ammonia medium for the remainder of the time required 5.
Observe and note any cracks, The surface shall be free of cracks. The purpose of this procedure is to verily cable attachment integrity and conformance to performance requirements. Use the appropriate cable seal as applicable. Terminal crimps forall wire sizes specified for the terminal shall be completed, Cable Terminals Welds and Welded Splices for all wire sizes specified for the terminal shall be completed.
Quantify the force required to insert male terminal into a female terminal 4. Male and female torminals with attached wire leads. Ten 10 terminal pairs, minimum, Secure terminals to bs tested onto fixtures. Record peak force and graph force versus distance from initial terminal to terminal contact to the fully engaged position.
The purpose of this testis to quantify the force required to insert a terminal with an attached wire lead into an appropriate connector body.
Test Samples. Minimum of 10 terminals and an appropriate number of connector bodies. Note: Terminated leads shall be constructed from the smallest and largest wire size specified for the respective terminals as listed below. Mount the connector with the TPA in the Open position into a fixture. Record peak force and graph force versus distance from intial contact of terminal to connector body to final engaged positon. Mount a connector with a fully seated TPA into a fixture.
Take spacial care when securing the terminated lead so that the lead fixture does not interfere with fil terminal insertion during the test 3. Record peak force and graph force versus distance from initial contact of terminal to connector body to final engaged position. TPA in Open Position. For terminals with less than 1. For terminals with 1. For terminals with greater than 1. Quantiy the force required to remove a terminated lead from the connector body. Terminals crimped to the maximum wire size specified for the respective terminal and compatible connectors.
Fifty 60 terminated leads and a sutficient number of connectors to support the 50 terminals. Note: All cavities of a connector shall be tested, Note the pull-out value and fallure mode.
Record peak force required to pull the terminal out of the connector cavity. If the conductor breaks or pulls out ofthe terminal before the terminal pulls out ofthe cavity, record this force and note the failure mode. The pull test shall be performed immediately following removal of the connectors from the temperaturelhumidity chamber. The terminal extraction force shall meet the requirements specified in Table 6.
GMW 3191 PDF