HVSL系列型式測試大綱

Documenttype:TestPlanDocumentstateTitle,DescriptionTypetestplanofconnectorandcableassemblyRevisionLang.En/ChSheet/NUMPAGES16highvoltagewithconnectorandcableassemblytypetestplan高壓連接器及線纜型式試驗(yàn)計(jì)劃FOREWORDNote:Fundamentalmodifications,comparedwiththepreviousedition,areindicatedbyaverticallineintherightmargin.MODIFICATIONSREVISIONDATE2013.11.13LOC.DESCRIPTIONPre-releaseA2014.5.10FirstreleaseB2017.02.13UPDATEPERJILI

SCOPE適用范圍ThisTestReviewcontainstestitemsandmethodsforHVSL1000connectorandcableassembly.此測試規(guī)范定義HVSL1000高壓互鎖連接器及組裝線束的測試項(xiàng)目及測試方法REFERENCE參考文件IEC61984SafetyrequirementsandtestsEN60529Degreesofprotectionprovidedbyenclosures(IPcode)DIN40050-9Roadvehiclesdegreesofprotection(IPcode)EN60512Electromechanical

components

for

electronic

equipment

-

Basic

testing

procedures

and

measuring

methodsEN60068-2

EnvironmentaltestingLV215Electrical/ElectronicRequirementsofHVConnectorsVW80302High-VoltageConnectorsinMotorVehiclesRequirementsandTestConditionsforVOLKSWAGENSAEJ1742ConnectionsforHighVoltageOn-BoardVehicleElectricalWiringHarnesses-TestMethodsandGeneralPerformanceRequirements…TESTGROUP測試項(xiàng)目TestrequirementsandproceduresTestdescriptionRequirementProcedureT1Conditioningandinspectionofas-receivedcondition檢驗(yàn)測試條件Beforeatest,everyspecimenmustbeconditioned16hoursunderstandardtestconditions,thencheckthedimensionsaccordingtoAmphenol’sdrawings.測試前，每一樣品須在測試標(biāo)準(zhǔn)條件下放置16后，然后根據(jù)圖紙檢查尺寸。T2Visualinspection目視檢查Nodefectsoffabrication,nochangesbeforeandafterseveraltestingprocedures,mechanicalbasicfunctionaretocheck測試前后無任何不良EN60512-1-1T3Basicfunctionaltest基本功能測試Allspecimensmustgothroughthefollowinginitialmeasurementsinordertomakeitpossibletochecktheirbasicelectricfunctionsandthereforemeettherelevantbasicrequirements.ThecontactresistancemustbecompliancewithLV215specificationsandtheinsulationresistancemustbe>200Mohmsat1075Vdc;andwithstandingvoltage2700VACnoflash-overoccurred.所有測試樣品須作初始基本功能性檢驗(yàn)，測試條件同后；接觸阻抗符合LV215要求；絕緣阻抗大于200Mohms；耐2700V電壓無閃花等。EN60512-2-1EN60512-2-2EN60512-3-1MECHANICALTESTOfContactT4Materialandsurfacetest材料及表面測試Acc.toAmphenoldrawingsandspecificationstocheckthecontactmaterialandplatingthickness.根據(jù)Amphenol的圖紙及規(guī)范，檢驗(yàn)端子的材質(zhì)及表面處理的厚度及外觀。T5Contactinsertionandextractionforce端子的插入及拔出力ThecontactinsertionandextractionforcemustbecompliancewithAmphenolspecifications.端子的插入及拔力須符合Amphenol的規(guī)范（插入力最大7lbf,拔出力最小3lbf）。EN60512-8T6Durability耐久性Thecyclesofinsertionandextractionmustbemorethan50.端子須耐至少50次插拔。EN60512-8T7Crimpretentionforce壓接保持力ThecrimpretentionforcemustbecompliancewithLV215specification.端子的壓接保持力須符合LV215規(guī)范。EN60512-8T8Thermaltimeconstant(Temperaturerise)溫升Loadacontactwithnormalcurrentacc.toAmphenoldrawingsandspecifications.Themaxtemperatureriseis55℃溫升不超過55℃EN60512-5-2T9Contactresistance接觸阻抗Acc.toLV215specification.接觸阻抗符合LV215規(guī)范要求。EN60512-2-2ELECTRICALTESTOfContactT10Voltagedrop電壓降Thevoltagedropismeasuredwiththemaximumnominalcurrentcorrespondingtotheplugcontactandlinecombination.Thenvoltagedropisnotexceed80mV.壓降依據(jù)端子及其線纜的最大負(fù)載電流作測試。壓降不超過80mV.EN60512-5-2MECHANICALTESTOfconnectorhousingT11Materialandsurfaceanalysis,housing外殼材料及表面分析Injectionmoldedskinsandmoldseparationmarksmustnotimpairthehandlingorfunction.Burrsandtooloffsetonmatingsurfacesareimpermissible.縮水及分模線等無損害操作或功能；毛邊和頂針印等可接受。T12Non-reversibilitytest(Polarization)極性Testload300N,nodamageofnon-matedconnectorstoinserted非配對的連接器用300N的力不能插入EN60512-13-5T13Determiningthemaximumextractionforce外殼最大分離力Specimensetup:thespecimenswithoutsecondarylatchmechanism.Theextractionforcemustgreaterthan110N.樣品不使用次級鎖緊機(jī)構(gòu)，外殼最大分離力大于110N。EN60512-8T14Durabilityofhousinglatch外殼卡鉤的耐久Themaximumvalueis75%ofthemaximumExtractionuptoamaximumof110N.Themaximumtestforcemustbemaintainedfor15s.保持力為最大分離力的75%，最大110N，持續(xù)15秒。EN60512-15-6T15Connectorengageandseparationforce連接器的插入及分離力Theconnectorengageandseparationforcemustnotexceed100N.連接器的插入及分離力不超過100N.EN60512-13-1T16Effectivenessofsecondarylatchmechanism次級卡鉤的保持力Themaximumvalueis110N.Themaximumtestforcemustbemaintainedfor15s.保持力為最大110N，持續(xù)15秒。EN60512-8ELECTRICALTESTT17Insulationresistance絕緣阻抗Testvoltage1075VDC,theinsulationresistancemustbe>200Mohms.測試電壓1075VDC，絕緣阻抗大于200Mohms.EN60512-3-1T18Withstandvoltage耐電壓測試Acc.toLV215specification.接觸阻抗符合LV215規(guī)范要求ENVIROMENTALTESTT19Coastalclimateload鹽霧試驗(yàn)周期(氯化鈉溶液)Themaintestconsistsof8hourssprayingand16hofbreak;durationcycles:6cycles8小時(shí)氯化鈉溶液噴霧然后中止16小時(shí)再繼續(xù)，共計(jì)6個(gè)循環(huán)。EN60068-2-52T20Changeoftemperature溫度改變Cycles:20cycles;Duration3hoursat-40℃,then3hoursat140℃;-40℃~140℃循環(huán)沖擊20次；每個(gè)溫度階段維持3小時(shí)。EN60068-2-14T21Dryheat高溫試驗(yàn)Period:120H;Temperature140℃140℃120小時(shí)EN60068-2-2T22Humidheat,cyclic濕熱循環(huán)Thespecimensaretestedataconstantrelativehumidityof95%.Thetemperaturechangesfrom25℃to55℃withinacycle.Duration10cycles.相對濕度95%，溫度20℃-50℃，10個(gè)循環(huán)。EN60068-2-30T23Humidheat,constant恒定濕熱Thespecimensareagedfor10daysat40℃.Therelativehumidityduringthisprocessis95%.溫度40℃，相對濕度95%，時(shí)間10天。EN60068-2-30T24Low-temperatureaging低溫老化Period:48H;Temperature-40℃-40℃48小時(shí)EN60068-2-1T25Agingindryheat高溫老化Period:48H;Temperature80℃80℃48小時(shí)EN60068-2-2T26Chemicalresistance耐化學(xué)Undilutedcommerciallyavailablecold-cleaningagentPenetratingoil,e.g.,"Caramba"UndilutedcommerciallyavailablewasherfluidantifreezeUndilutedmethylatedspiritLubricatinggreaseBrakefluid,e.g.,TevesATEDOT4Premium-gradegasolineacc.toDIN51604-2DieselfuelaccordingtoDINEN590Multi-grademotoroilSAE10W?50Hypoidgearboxoil,classSAE80/90Radiatorantifreeze:50%H2O/50%ethyleneglycolBatteryfluid2):undilutedsulfuricacid,density:1,28g/cm3Thespecimensareimmersedinthecorrespondingmediumfor5min.Allowtodrip-dryafterwardsandage48hat50℃intemperaturetestchamberVW75174/PG22BVW60306-1T27High-pressurespraytest（IP6K9K）高壓噴射試驗(yàn)（IP6K9K）TheIPX6K/IPX9Kprotectioncategorymustbefulfilled滿足IP6K9KDIN40050-9MECHANICALTESTT28Droptest跌落測試"Connectorsforelectronicequipment-Testsandmeasurements-Part7-1:Impacttests(freecomponents)-Test7a:Freefall(repeated)"VW75174/PG20C;DINIEC60512-7-1T29Contactsextractionforceforremovalfromhousing端子從塑膠最大的拔出力Acc.toLV215specification(>500N)符合LV215規(guī)范(>500N)EN60512-15-6T30Contactretentionforceforremovalfromthehousing端子在塑膠的保持力500Nfor15s,discontinuousness<200nswith10V100mAmax.monitoring.500N保持15秒，期間用10V最大100mA來監(jiān)視瞬斷小于200ns。EN60512-15-6T31Dynamicload,sinusoidal動態(tài)負(fù)載Duration:22hours*3axialThenormalcurrentisloaded.FordetailsseeVW80302Section9.3.2.1.Frequency(Hz)Accelerationamplitude(m/s2)100302006044060Duringthetest,atemperaturecyclemustbeloaded.MinuteTemperature(℃)02060-40150-402102030012041012048020GBT28046.3乘用車變速器T32RandomVibration隨機(jī)振動Duration:22hours*3axialThenormalcurrentisloaded.FordetailsseeVW80302Section9.3.2.1.Frequency(Hz)Powerdensityspectrum(m/s2)2/Hz1010100103000.51500520005Duringthetest,atemperaturecyclemustbeloaded.MinuteTemperature(℃)02060-40150-402102030012041012048020GBT28046.3乘用車變速器T33Shock機(jī)械沖擊A=30g,no.ofshock12000cyclesofhalfwaves(2000perdirection,in6directions)IEC60512-6-3T34Deratingwithhousing成品的降額曲線Dependonvariouscables.根據(jù)不同的線纜。EN60512-5-2T35Fingerproof(IP2XB)手指防觸摸Acc.toEN60529依據(jù)EN60529.EN60529ADDITIONALTESTT36Airclearanceandcreepagedistance空氣間隙和爬電距離PollutionII,Ratedvoltage:1000VDC;Altitude:2000MAirclearance>2mmCreepagedistance>5.05mm污染等級2級，額定電壓1000VDC,海拔高度2000米，空氣間隙大于2mm,爬電距離大于5.05mmIEC60664-1T37HVInter-Lockfunction高壓互鎖功能Acc.toLV215LV215T38汽車非金屬材料阻燃性試驗(yàn)Acc.ToT39非金屬零部件耐光老化性試驗(yàn)Acc.ToT40Acc.ToJLYY-JT36-08ITEMSequenceMechanicaltestforcontactsElectricaltestforcontactsMaterialandsurfacetestContactinsertionandextractionforceDurabilityThermaltimeconstant(Temperaturerise)Voltagedrop/ContactreisistanceDeratingwithouthousingSpecimenQ’ty51010Pairs3Pairs10Pairs3PairsT1Conditioningandinspectionofasreceivedcondition111111T2Visualinspecton254552,5T4Materialandsurfacetest3T5Contactinsertionandextractionforce2,4T6Durability3T7Crimpretentionforce6T8Thermaltimeconstant(Temperaturerise)3T9Contactresistance2,52,42,43,4T10Voltagedrop3T21Dryheat3ITEMSequenceMechanicaltestforconnectorhousingsMaterialandsurfacetestNon-reversibilitytest(Polarization)DeterminingthemaximumextractionforceDurabilityofhousinglatchConnectorengageandseparationforceEffectivenessofsecondarylatchmechanismSpecimenQ’ty1Pair1Pair3Pairs5Pair5Pair5PairT1Conditioningandinspectionofas-receivedcondition111111T2Visualinspecton3333T3Basicfunctionaltest22T11Materialandsurfaceanalysishousing3T12Polarization3T13Determiningthemaximumextractionforce2T14Durabilityofhousinglatch2T15Connectorengageandseparationforce2T16Effectivenessofsecondarylatchmechanism2ITEMENVIROMENTALTESTFORCONNECTORHOUSINGSequenceENVIROMENTALTESTFORCONNECTORHOUSINGCoastalclimateloadEnvironmentalsimulationClimateloadChemicalresistanceWatertightnessSpecimenQ’ty3Pairs20Pairs10Pairs3Pair10PairT1Conditioningandinspectionofas-receivedcondition11111T2Visualinspecton55,8,115,8,10,12,145T3Basicfunctionaltest2,42,222T9Contactresistance4,7,10T17Insulationresistance4,7,1344,T19Coastalclimateload3T20Changeoftemperature3T21Dryheat63T22Humidheat,cyclic9T23Humidheat,constant6T24Low-temperatureaging9T25Agingindryheat11T26Chemicalresistance3T27High-pressurespraytest3