uscar-4v001

STANDARDFORCIGARLIGHTERS&POWEROUTLETSTheresearchdata,analysis,conclusion,opinionsandothercontentsofthisdocumentaresolelytheproductoftheauthors.NeithertheSocietyofAutomotiveEngineers,Inc.(SAE)northeUnitedStatesCouncilforAutomotiveResearch(USCAR)certifiesthecomplianceofanyproductswiththerequirementsofnormakesanyrepresentationsastotheaccuracyofthecontentsofthisdocumentnortoitsapplicabilityforpurpose.Itisthesoleresponsibilityoftheuserofthisdocumenttodeterminewhetherornotitisapplicablefortheirpurposes.Copyright1997,USCARAllrightsreserved.PrintedinU.S.A.IssuedNovember1997SAE/USCAR-4QUESTIONSREGARDINGTHISDOCUMENT:(724)772-8545FAX(724)776-0243TOPLACEADOCUMENTORDER:(724)776-4970FAX(724)776-0790SUMMARYOFCONTENTS1.SCOPE.............................................................................31.1Authority31.2Scope31.3Coverage31.4PurposeofthePart31.5PartDescriptionandGlossary41.6HazardousMaterialControl52.REFERENCEDOCUMENTS.......................................52.1PartDrawing52.2Customer&IndustryStandards62.3FailureModeandEffectAnalysis(FMEA)63.GENERALREQUIREMENTS......................................63.1InterfaceDesignRequirements63.1.1ElectricalInterface63.1.2MechanicalMounting73.2SupplierResponsibilities73.3RecordRetention83.4TestPhilosophy83.4.1DesignVerificationTesting83.4.2ProductionValidationTesting83.4.3ContinuingConformanceTesting84.PERFORMANCE&TESTINGREQUIREMENTS....94.1DutyCycleDefinition94.1.1ReliabilityTestRequirements94.2FunctionalRequirements104.2.1SAEStandard104.2.2Flammability104.2.3ThermalPerformance104.2.4KnobTemperature104.2.5KnobRetention104.2.6PowerOutletContact114.3MechanicalRequirements114.3.1InstallationForces114.3.2MountingRetention114.3.3Orientation114.3.4ElementShield114.3.5Concentricity114.3.6ActuationForces124.3.7Terminal/ConnectorRequirements124.4ElectricalRequirements134.4.1NormalVoltage134.4.2CurrentDraw134.4.3ParasiticLoad134.4.4ElectromagneticCompatibility(EMC)134.4.5ThermalProtection134.4.6ReverseVoltage134.4.7OverVoltage144.4.8IsolationResistance144.5ComponentEnvironmentalRequirements144.5.1Shock/DropTests144.5.2ThermalShock144.5.3TemperatureRequirements154.5.4HumidityTesting154.5.5CorrosionResistanceRequirements154.5.6LiquidSpillResistanceRequirements164.5.7VibrationResistance164.6ReliabilityRequirements174.6.1ReliabilityTestSchedule174.6.2DurabilityRequirements17SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-2-5.TESTING.......................................................................185.1TestSequence185.2TestSamples185.2.1SampleIdentification185.2.2SampleSelection185.2.3Performance185.2.4SampleDisposition195.3TestEquipment195.3.1Calibration195.3.2MeasurementAccuracy195.3.3TestRepeatability195.4TestPlug195.4.1Requirements205.5VisualInspection205.6ComponentPerformanceChecks206.REPORTREQUIREMENTS.......................................216.1RequiredDataPackage-AIAGStandard21SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-3-1.SCOPE:1.1Authority:ThisstandardispromulgatedbytheUnitedStatesCouncilforAutomotiveResearch(USCAR),ElectricalWiringComponentApplicationPartnership(EWCAP).DevelopmentwasunderataskforceconsistingofrepresentativesfromtheUSCARparticipants.Applicationofthisstandardtothecoveredcomponentsiscoveredbytheindividualpurchasedocumentsofeachcustomer.Theintentofthisdocumentistostandardizetheelectricalinterfacetothevehicle,themechanicalinterfacetoamountingpanelorsurface,andthegeneraloperationalspecificationsofthesedevices.Theintentofthisspecificationistofullydefineindustry-wideacceptancecharacteristicsandtestingrequiredforinstallationandreliableoperation.Thesecriteriawillensurethatcommonalityandenhancedinterchangeabilityareachievableforallendusers.1.2Scope:Thisstandardisintendedtocovercigarorcigarettelightersaswellaspoweroutletsbasedontheformanddimensionsofthecigarlighter.Thisstandardisafullperformancespecification,itincludesdimensionalandoperationalparametersaswellasperformancecharacteristicswhichmustbemetwhensubmittingacigarlighterassemblyorpoweroutletassemblyforproductionapproval.Thisstandardconstitutesanacceptancespecificationforasurfacemounted,front-loadedcigarlighterorpoweroutlet.1.3Coverage:Thisstandardcoverstheoperational,reliability,durability,acceptance,andtestingrequirementsforafrontloaded,externalcontact,cigarlighter(lighter)forinstallationinproductionvehicles.Thisstandardalsocoverspoweroutletsthatarebasedontheformanddimensionsofthelighterreceptacle.Testingshallbedoneonpartfamiliesasdirectedbytheappropriatecorporateengineeringplatformgroup(s).Partfamilydefinitionshallbemadebythepurchaseraspartofthepurchaseagreement.1.4PurposeofthePart:Thelighterisprovidedasaconvenience,foruseinlightingcigarsandcigarettes,andforuseasapoweroutlet.Theintentistoprovidealighterwhichisusablewithaslittledistractionaspossibletotheprimaryfunctionofsafevehicleoperation,andisrelativelysafewhileusingadevicewhichmayreachfunctionaltemperaturesinexcessof650°C.Whendesignedasapoweroutlet,orasalighterusedasapoweroutlet,thedeviceisexposedtoavarietyofdevicesbeyondtheautomotiveindustry'scontrol.Amongthemostimportantoftheseistheaccessoryplugwhichinterfacestothelighterorpoweroutletbase.Recommendedaccessoryplugdesigncriteriaisprovidedinparagraph5.4ofthisspecification.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-4-1.5PartDescriptionandGlossary:Throughoutthisstandard,descriptionswillbeemployedtoreferencevariouscomponents.Specialnames/termswillbedefinedatfirstusageinthetext,withtheusagename/termshowninparenthesesimmediatelyfollowing.Thetextusagewillbecontinuedthereafter.Forpurposesofthisdocument,thefollowingwillbeused:DEVICE-(Device)Anyofthecomponentsseparatelyorasagroup.LIGHTERASSEMBLY-(Lighter)Acompletesystemofcomponents;includingtheelementassembly,areceptacle,andsomeformofmountingringwhichtakentogetherconstituteacigar/cigaretteignitingsystem.ELEMENTASSEMBLY-(Element)Anassemblycontainingaheatingelementandknob,ashieldorashguard,andotherinternalcomponents.Commonlyreferredtoasthepopoutorknob/elementassembly.RECEPTACLEASSEMBLY-(Receptacle)Thatportionofthesystemconstitutingtheelementwell,theelectricalconnections,theover-temperaturedevice,andthermalreleasemechanism.Usuallyinstalledinthepassengercompartment,thisdevicereceives,heats,andstorestheelementwhennotinuse.Alternativelycalledthehousingorswitchbase.HALORING/MOUNTRING-Thismountingring,usuallymoldedofanopaqueplastic,servestopositionandmountthereceptacletointendedparentpanelinthevehicle.The"Halo"Ringisintendedforilluminatedoperation.The"Halo"Ringisidenticalwiththemountingring,butisofatranslucentcoloredmaterialandusuallycontainsalightsource.Illuminationisnormallyintendedtobepoweredfromthedimmableinstrumentpanellightcircuit.ColormatchwiththerestoftheilluminatedI/Pcomponentsisachievedthroughthismaterial.Themountingringandthehaloringareintendedtobeinterchangeable,bothinfunctionandapplicationonthelighteroroutletreceptacleandinthemountinghole,andmaybesubstitutedforoneanotherdependingonilluminationrequirements.WhenthehaloringcontainsalightsourceitshallgetitsB+fromtheauxiliarycontactofthereceptacleanditsgroundfromthegroundofthereceptaclethroughaconnectionthatself-matesduringinstallationofthereceptacleintothering.POWEROUTLETorPOWERPOINTRECEPTACLE-(Receptacle)Thisdeviceissimilarinappearancetothelighterreceptacle,butwithoutthermalreleaseorthermalover-temperatureprovisions,itisprovidedforthesolepurposeofconnectingaftermarketdevicestothevehicleelectricalsystem.Inthisspecification,thetermreceptacleshallrefertoboththecigarlighterorpowerpointreceptacle,unlessspecificallyidentified.POWEROUTLETPLUG-AplugspecificallydesignedtoinsertintoareceptaclemakingcontactwiththereceptacleshellforthegroundconnectionandtotheB+contactinthecenterbottomofthereceptacle.Forpurposesoftestingthereceptaclesaspoweroutlets,aplugmeetingtherequirementsparagraph5.4shallbeused.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-5-1.5(Continued):BUZZ,SQUEAK,ANDRATTLE(BSR)-Thistermisappliedtoanynumberofannoyingsoundswithinthevehicle.Asvehiclesbecomequieter,BSRbecomesmoreimportant.1.6HazardousMaterialControl:ProductsfurnishedundertheauthorityofthisdocumentandproductsandprocessesusedbysupplierstomanufacturethoseproductsmustconformtohealthandsafetyrequirementsoftheOccupationalSafetyandHealthAdministration.2.REFERENCEDOCUMENTS:Resolutionofdocumentprecedenceintheeventofaconflictbetweenperformancestandards,partdrawings,andrelatedstandardsorspecificationsshallbeasfollowsunlessotherwisespecifiedbelow,orinaspecificcontractorpurchaseorder:1st-ApplicablePartDrawing(s)2nd-Thisstandard3rd-OtherUSCARPerformancestandardsandspecifications4th-OtherrelatedstandardsandspecificationsNothinginthisspecification,however,supersedesapplicablelawsandregulationsunlessspecificexemptionhasbeenobtained.Suppliersareexpectedtobeawareof,andcomplywith,worldwide(e.g.NorthAmerican,European,Asian,GulfStates)vehiclestandardsunlessspecificexemptionhasbeenobtainedfromthecustomer.Anylogoorsymbolappliedtotheknob(whenrequired)shallbeconfiguredtomeetISOrequirements.2.1PartDrawing:Thecomponentpartdrawingshallcontain,ataminimum,thefollowinginformation:.Areferencetothisspecificationforinterfaceandtestingrequirements,.Allpartdimensionalrequirementsnotcoveredherein,includinganyorientation(keying)requirements,.Performancerequirementsnotcoveredherein,suchasmaterialstandardsandcomponentspecifications,.Conformancerequirementsnotcoveredherein,suchasothercorporateorindustrystandardsorregulations,domesticorforeign,.Typicalmatingconnector,terminal,andilluminationrequirements(includingdimensionswhererequired).SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-6-2.2Customer&IndustryStandards:SuppliersareexpectedtosubscribetotheStandardslistedonthepartdrawing.Additionalstandardsmaybereferencedthroughoutthisdocumentasrequired.Unlessotherwisespecified,suppliersshouldusethemostrecentversionsofanyreferenceddocument(s)orstandard(s).2.2.1SAEPublications:AvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001.SAEJ563Six-andTwelve-VoltCigarLighterReceptacles2.2.2ASTMPublications:AvailablefromASTM,100BarrHarbor,WestConshohocken,PA19428-2959.ASTMB117StandardPracticeforOperatingSaltSpray(Fog)TestingApparatus2.2.3AIAGPublications:AvailablefromAIAG,26200Lahser,Suite200,Southfield,MI48034.AIAGProductionPartApprovalProcessAIAGQualitySystemRequirements-QS90002.2.4FMVSSPublications:AvailablefromtheSuperintendentofDocuments,U.S.GovernmentPrintingOffice,MailStopSSOP,Washington,DC20402-9320.FMVSS-302FederalStandard-FlammabilityofInteriorMaterials2.3FailureModeandEffectAnalysis(FMEA):Within90daysofsourceselection,pertheAutomotiveIndustryActionGroup(AIAG)requirements,thesuppliermustsubmitapreliminaryDesignFMEA(DFMEA)basedonthecurrentdesignconcept,totheprojectengineerforreview.ArevisedFMEAmustbesubmitted10weekspriortoprogramtoolingreleaseandmustbeapprovedbytheprojectengineerpriortotoolingrelease.ThesuppliermustcompleteaProcessFMEA(PFMEA)atleast90dayspriortoproductionvalidationtesting.TheProcessFMEAmustbesubmittedtoboththeprojectengineerandtheappropriateSupplierQualityrepresentativeforapproval.Itisrecognizedthattheseare"living"documents,andthatchangeisexpected,therefore,itismostimportantthatFMEAstatusbemaintainedascurrentaspossible.3.GENERALREQUIREMENTS:3.1InterfaceDesignRequirements:3.1.1ElectricalInterface:TheelectricalinterfacetothevehiclewiringharnessshallbebasedonathreeterminalconnectionconsistingofaPrimaryB+contactprovidingcurrentfortheprimaryfunction(lighteroroutlet),aGroundcontactprovidingareturnpathforallfunctions,and,ifilluminationisincluded,aSecondaryB+contactprovidingcurrentfortheilluminationdevice.PinlocationsaredefinedinFig2E.DetaildimensionalrequirementsareshowninFig2.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-7-3.1.2MechanicalMounting:Themechanicalinterfacebetweenthereceptacleandpanelwillbeaccomplishedwithamountingring.Themountingringshalllockintoacircularholeintheparentpanelof27.8mm(+0.25,-0.00mm)diameter(SeeFig3).Thepanelshallbeflatandauniform2.75mm(+0.25/-0.25mm)thickatthemountingholeandforadistanceof5.0mmaroundthehole.Theflatareashallbeperpendiculartothecentralaxisoftheinstalleddevice.Theparentpanelshouldbedesignedtowithstanda260Nforceappliedalongtheaxisofthereceptacleineitherdirection.IfkeyingisrequireditshallbeasshowninFig3.Installationshallbeaccomplishedbyinsertingmountingringintotheparentpanelandtheninsertingthelighterintothemountingring.Lockingactionisaccomplishedviaaminimumoftwotabswhicharedisplacedoutwardtogripthepanelfromthemountringbythereceptaclepassingthrough.Whenfullyseated,thereceptacleislockedtothemountringbywayofmoldedbossesengagingthereceptacle.Themanufacturershallprovideamethodofindexingoralignmenttoinsureorientationbetweencomponentsduringinstallation.Whereanilluminatedmountingring(halo/glowring)isused,thepanelmountingholesize,retentionfeatures,andforcerequirementsshallremainthesameasanon-illuminatedmountingring.Theilluminationfeature(s)shallbesodesignedasnottointerferewithmountingease,norrequireanyadditionalinstallationstepsoverthenon-illuminatedmountingring.Lampconnection(s)shallbemadeautomaticallywithoutaseparateconnectiontothevehiclesystem,throughtheauxiliaryterminalprovidedinthedeviceconnector.3.2SupplierResponsibilities:Thedevicesupplier(s)shallbewhollyresponsibleforallactivitiesregardingdesign,development,conformancetesting,andmanufactureofthesubjectpartwithinthestatedtimeframeinordertomeetallfunctionalandqualityobjectivesasstatedinthisstandard.Specificsupplierresponsibilitiesarelistedthroughoutthisstandard.ThesuppliermustbepreparedforProductionPartApprovalpriortoseriesproduction.DetailedinstructionsforthisprocessarefoundintheAIAGpublication:"ProductionPartApprovalProcess"(PPAP).Subjecttotheapprovalofpurchasingandmaterialhandling,devicesmustbepackagedforshipmenttoavoidanypotentialfordamage.Excessivehandlingofrawmaterials,subcomponents,andfinishedassembliesshouldbeminimizedtoavoidpotentialdamage.Allshipmentsfromthemanufacturershallbeinthesequenceofmanufacture;firstin,firstout.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-8-3.3RecordRetention:Thesuppliershallmaintainacentralizedfilesystemforthestorageoflaboratoryreports,calibrationrecords,andtestingdocumentation.Aretentionpolicyconcerningtheserecordsshallbeestablished.Thisfileshallbeperiodicallyauditedbythefollowingrepresentatives;productengineering,purchasing,quality,andreliability.Outsideauditsshalloccuronlywithcustomerconcurrence.Unlessotherwisespecified,recordretentionshallbeforaminimum10yearperiod.Thereasonsforcompilationandretentionofrecordsare:.Maintainrecordsshowingproofofcomplianceintheaccomplishmentoftheobjectivesstatedinthisstandard..Retainrecordsprovingthat"duecare"wasexercisedinthedevelopmentandtestingoftheproductrepresentedbythisstandard..Tocomplywithlegalrequirementsforthemaintenanceofspecificrecords.3.4TestPhilosophy:3.4.1DesignVerificationTesting:DesignVerification(Development)testsareusedtoevaluatespecificdesignsorareasofdesigns.Theyaretobeusedasatoolforevaluatingdesignalternatives,proposedimprovements,ordeterminingrootcausesoffieldproblems.Thistypeoftestingwill,ataminimum,includethetestsdescribedherein,butmayalsoincludetestsofamorestringentordestructivenature.3.4.2ProductionValidationTesting:ProductionValidation(SampleApproval)testsarethosenecessarytoqualifythedeviceforproductionanduseinautomobiles.Theyarecoveredbytherequirementsofthisspecification.3.4.3ContinuingConformanceTesting:ContinuingConformancetestingisusedtoinsurethattheagreeduponparametersarebeingadheredtoduringtheproductionlifeofthepart.Generally,thesetestsareconductedwhenanewcomponentisintroduced,whenanychangeismadetosubcomponents,whentoolingormanufacturinglocationchange,andperiodicallyduringeachmodelyearasrequiredbythepurchaseagreement,eveniftheparthasnotbeenchanged.Atleastonceperyear,aminimumof10samples(element/knob&base,etc.)shallbeplacedonanautomatedcycletesterandcycleduntilfailure,orthreetimeslife,whicheveroccursfirst.Thetestshallbeessentiallythesameasadurabilitylifetest.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-9-4.PERFORMANCE&TESTINGREQUIREMENTS:Thesedevicesshallbecapableofoperatinginthetypicalautomotiveinteriorenvironmentwithoutdeforming,loosening,orotherwiseadverselyaffectingtheappearanceoroperationofthevehicle,thedevice,and/oranyadjacentcomponents.Thetestingproceduresdescribedinthisstandardaredesignedtoquantifyparticularcomponentcharacteristicstomeetthisrequirement.Alldeviationsfromthisspecificationmustberecordedandreportedatthetimeofsubmissionoftestresults.Acceptablestandardsofperformanceforeachtestarelistedanddetailedwithinthesectiondescribingthatparticulartest.Someattributesmaybedeterminedbyvisualinspectionorbymeasurement.Tolerances,andprocedures,formakingthesemeasurementswillalsobelistedwhereapplicable.4.1DutyCycleDefinition:Forthisstandard,thefollowingisconsideredonedutycycle:LIGHTER:Alightercycleconsistsofthefollowing:Insertedandready(heatedornot);engagedandheating;released;withdrawnandreinserted;andbacktoready.POWEROUTLET:Anoutletcycleconsistsofinsertionofaplugwithaloadconnectedforaperiodoftimeandthenwithdrawalwiththeloadstillconnected.Theoutletloadshallbeamixtureof25%ofthecyclesata20Aloadforaperiodof15minutes,and75%ofthecyclesata5Aloadforaperiodof5minutes.Thetesttimemaybeacceleratedwiththeconcurrenceoftheprojectengineer.4.1.1ReliabilityTestRequirements:Thefollowingshallbecheckedateachcycleunlessotherwisenoted:a.Insertionforce(onceperday)b.ExcessiveEngagementforce(forlighters)c.Failuretoengageortoremainengaged(forlighters)d.Failuretoreleasewithinthetimelimit(forlighters)e.Withdrawforce(onceperday)f.Temperatureprofile(onceperday)(forlighters)g.Currentcontinuitywithoutinterruption(foroutlets)Ifanylighterfailstoengagewithinthemaximumforce,failstoremainengaged,failstoreleaseasspecified,orfailsthetemperatureprofile,thetestshouldbepaused,andthecausedeterminedbeforecontinuingwiththeunfailedsamples.Ifanydeviceexceedstheinsertionorwithdrawforces,thecauseshouldbedeterminedandtheoffendingcomponentremovedfromtest.Ifanyoutletfailstocarrythespecifiedcurrentforthespecifiedcycletimewithoutinterruption,thecauseshallbedeterminedbeforecontinuingwiththeunfailedsamples.SAE/USCAR-4STANDARDFORCIGARLIGHTERS&POWEROUTLETSNovember1997-10-4.1.1(Continued):Areplacementdevicemaybeinstalledinplaceofafailedunitinordertocontinuetestingamatingcomponentortobalancetheforceswithinthetestfixture,howeverthereplacementunitisnottobeincludedinthesamplesizeorcalculations.Ifportionsofthistestaredoneasseparatetests,theresultsshallbecombinedstatisticallytoindicatethetotalreliabilityvalueofthelighterassembly.4.2FunctionalRequirements:Specificrequirementsforeachfunctionalcharacteristicarelistedbelowintheappropriateparagraphs.4.2.1SAEStandard:ThelightershallmeettherequirementsofStyle"A"ofSAEJ563.Dimensionalrequirementsinvolvingmaximumandminimumdiametersofthegroundlancefingersandofthebi-metalthermostatsshallbefollowed.4.2.2Flammability:Material(s)usedintheconstructionofpartscoveredbythisstandardshallmeettheflammabilityrequirementsofFMVSS302.4.2.3ThermalPerformance:4.2.3.1InitialRelease:Withthedeviceatastabilizedtemperatureof25°+/-5°C,theelementshallreleasewithin20secondsofbeingengagedforheating.Thereleasetimeshallnotexceed25secondsatanystabilizedambienttemperaturefrom-20°Cto+55°C.Anaverageofthreereadingsshallbeusedtodeterminecompliance.4.2.3.2HeatProfile:Theheatedelementwillprovideauniformheatpatternacrossthesurfaceoftheelement.Minimumtemperaturesatejectionshallbeasfollows:After10sec480°CAfter20sec380°C4.2.3.3Reenergizing:Afterinitialreleaseandremovalforatleast60seconds,theelementassemblyshallbecapableofre-engagementtothethermostat,reheattoaminimumtemperatureof480°C.4.2.4KnobTemperature:Knobtemperatureatinitialreleaseshallremainbelow35°C.Re-energizingthreetimes,with60secondintervalsbetweenreleaseandre-engagement,knobtemperatureshallremainbelowof60°C.4.2.5KnobRetention:Thelighterknobshallberetainedtotheelementportionofthesub-assemblysuchthatitcanwithstandanaxialpullof90Napp