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ELECTRICAL WIRING COMPONENT APPLICATION PARTNERSHIP

USCAR Connector Test Specifications

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  • Click here for: USCAR-2 Performance Specification for Automotive Electrical Connector Systems

    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.  Click USCAR-2 to go to the ordering site.

  • Click here for: USCAR-12 Electrical Connector Design Criteria

    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. Click USCAR-12 to go to the ordering site.

  • Click here for: USCAR-17 Performance Specification for Automotive RF Connector Systems

    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. Click USCAR-17 to go to the ordering site.

  • Click here for: USCAR-18 - Supplement to USCAR-17  (RF applications and dimensional requirements)

    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. Click USCAR-18 to go to the ordering site.

  • Click here for: USCAR-19 - Coaxial Cable Connector Interface - Square Outer Conductor

    This specification describes an alternate style of coaxial connector. A technical review in June 2014 determined that no future updates will be made to this design. It has been used successfully but not in high enough volume to justify ongoing support. STABILIZED NOTICE --This document has been declared "Stabilized" by the EWCAP (Electrical Wiring Components Application Partnership) and will no longer be subjected to periodic reviews for currency. Users are responsible for verifying references and continued suitability of technical requirements. Newer technology may exist. Click USCAR-19 to go to the ordering site.

  • Click here for: USCAR-20 - Field Correlated Life Test Supplement to SAE/USCAR-2

    This test specification details the procedure for testing the performance of electrical connections to a test sequence (FCLT - Field Correlated Life Test) that has been correlated to automotive vehicle conditions. The correlation applies to crimps and interfaces used in automotive applications and has been established with thousands of samples and millions of product and vehicle environmental measurements. The testing is performed with mated connector assemblies. In general, testing of connections at two base temperatures, 85°C and 125°C, through two cycles of the FCLT has been shown to correlate to at least 150,000 miles (240,000 kilometers).  The current version of USCAR-2 no longer refers to USCAR-20 so implementation will require engineering review. Click USCAR-20 to go to the ordering site.

  • Click here for: USCAR-21 - Performance Specification for Cable-To-Terminal Electrical Crimps

    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. Click USCAR-21 to go to the ordering site.  Also, USCAR members have agreed to a preferred report format for USCAR-21 testing. Click USCAR-21 Crimp Report to download the template for this standard format (requires Microsoft Excel).

  • Click here for: USCAR-25 - Ergonomics Specifications for Electrical Connections

    This document describes the deign relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurance devices (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. Click USCAR-25 to go to the ordering site.

  • Click here for: USCAR-29 - Automotive Grade Coaxial Cable Performance Specification

    This document specifies dimensional, functional and visual requirements for automotive grade coaxial cable.  Click USCAR-29 to go to the ordering site.

  • Click here for: USCAR-30 - Performance Specification for Automotive Universal Serial Bus (USB) Connection Systems

    Procedures in this specification describe performance testing of USB connectors for road vehicle applications. These procedures are only applicable to the USB connector and its cable. Click USCAR-30 to go to the ordering site.

     

  • Click here for: USCAR-37 - High Voltage Connector Performance Supplement to SAE/USCAR-2

    Procedures included within this specification supplement are, when used in conjunction with SAE/USCAR 2, 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 high voltage (60~600V) road vehicle applications. These procedures are applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. Click USCAR-37 to go to the ordering site.

  • Click here for: USCAR-38 - Performance Specification for Ultrasonically welded wire terminations

    Procedures included within this specification supplement are, when used in conjunction with SAE/USCAR 2, 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 high voltage (60~600V) road vehicle applications. These procedures are applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. Click USCAR-38 to go to the ordering site.

  • Click here for: USCAR-44 - Performance Specification for Wire Harness Retainer Clips

    This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. Click USCAR-44 to go to the ordering site.

Note: Unpublished updates and clarifications to the specifications listed are available here