uscar-17revision2v002

PerformanceSpecificationforAutomotiveRFConnectorSystemsTheresearchdata,analysis,conclusion,opinionsandothercontentsofthisdocumentaresolelytheproductoftheauthors.NeithertheSocietyofAutomotiveEngineers,Inc.(SAE)northeUnitedStatesCouncilforAutomotiveResearch(USCAR)certifiesthecomplianceofanyproductswiththerequirementsofnormakesanyrepresentationsastotheaccuracyofthecontentsofthisdocumentnortoitsapplicabilityforpurpose.Itisthesoleresponsibilityoftheuserofthisdocumenttodeterminewhetherornotitisapplicablefortheirpurposes.Copyright2004,USCARAllrightsreserved.PrintedinU.S.A.IssuedFebruary2002RevisedNovember2004SAE/USCAR-17Revision2QUESTIONSREGARDINGTHISDOCUMENT:(724)772-8518FAX(724)776-3036TOPLACEADOCUMENTORDER:(724)776-4970FAX(724)776-0790SUMMARYOFCONTENTS1SCOPE..................................................................................................................................22REFERENCES......................................................................................................................23GENERALREQUIREMENTS...............................................................................................23.1SAMPLESIZE................................................................................................................23.2EQUIPMENT..................................................................................................................34TESTANDACCEPTANCEREQUIREMENTS.....................................................................44.1GENERAL......................................................................................................................44.2CONNECTORMECHANICALTESTS............................................................................44.3TERMINALELECTRICALTESTS..................................................................................84.4CONNECTORELECTRICALTESTS.............................................................................94.5TESTSEQUENCE.......................................................................................................134.6TESTREPORT.............................................................................................................18APPENDIXA-DEFINITIONS.....................................................................................................19APPENDIXB-REVISIONS........................................................................................................20SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-2-1SCOPE1.Proceduresincludedwithinthisspecificationareintendedtocoverperformancetestingatallphasesofdevelopment,production,andfieldanalysisofelectricalterminals,connectorsandcomponentsforcoaxialcableconnectionsystems(hereafterreferredtoasRFconnectors)intendedforroadvehicleapplications.2.TheintentofthisspecificationistoqualifyRFconnectorsthatoperateatfrequenciesgreaterthan200MHz.Thisdoesnotexcludelowerfrequencyapplications;theacceptancecriteriamaynotapply,however(i.e.,theAM/FMacceptancecriteriaisspecifiedonPage3ofUSCARprint999-U-001-1-A013.Thisspecificationdoesnotapplytosingleconductorwireortwistedpairconnectionsystems.2REFERENCESSAE/USCAR-2PerformanceSpecificationforAutomotiveElectricalConnectorSystemsSAE/USCAR-25ElectricalConnectorAssemblyErgonomicDesignCriteriaSocietyOfAutomotiveEngineering400CommonwealthDrWarrendale,PA15096-0001USAhttp://www.sae.orgIEC61726Cableassemblies,cables,connectorsandpassivemicrowavecomponents-ScreeningattenuationmeasurementbythereverberationchambermethodMIL-PRF-39012PerformanceSpecification,Connectors,Coaxial,Radiofrequency,GeneralSpecificationforIEC61196-1Radio-frequencycables-Part1:Genericspecification-General,definitions,requirementsandtestmethodsIEC60512-23-3Electromechanicalcomponentsforelectronicequipment-Basictestingproceduresandmeasuringmethods-Part23-3:Test23c:ShieldingeffectivenessofconnectorsandaccessoriesDIN-72594-1RoadVehicles–50OHMRadioFrequencyInterface(50ΩRFI)3GENERALREQUIREMENTS3.1SAMPLESIZE1.Terminalsusedforvalidationtestingareappliedtocablesusingthemanufacturersrecommendedtoolsandprocesses.2.Thetotalnumberoftestsamplesrequiredforeachtestislistedintables4.5.2and4.5.3.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-3-3.Numbereachsamplepairofconnectorsandrecordcrimpdimensionsasapplicablefromarepresentativegroupfromeachsetofsamples(Seetables4.5.2and4.5.3).Documentcableinformationsuchastype,supplierandsupplierpartnumber.Alltestdata,includingsweptSWRandIL,mustbemaintainedbythesupplierforpossiblereview.ThesuppliermustalsokeepthetestsamplessuchthateachnewcustomercanvisuallyinspectthesamplesorconfirmSWRandIL.3.2CONNECTORQUALIFICATION1.TheRFconnectionsystemwillbequalifiedforaspecificcoaxialcablepertheseprocedures.TheguidelinesinTable3.2applyforqualifyingtheproductforuseonadditionalcablessizesandconstructions.ConnectorConstruction(dimensions/materials)sameasoriginallyvalidated.Example:connectorforRG174vs.RG316havingsamecableinterfacedimensionsCompleteSection4.2.1(mechanicalPull)and4.3(TerminalElectricalTests)onlyandothertestingasrequiredbyendcustomerConnectorconstructiondiffersfromoriginallyvalidateddesignduetocoaxcablesize/geometry.Example:connectorforRG174vs.RG58andhavingdifferentcableinterfacedimensions.Completere-qualificationisrequiredTable3.2:ConnectorQualificationforAdditionalCableConstruction2.FinaldeterminationastheleveloftestingneededforqualificationonadditionalcablesshallbedeterminedbyagreementbetweenthesupplierandtheOEM.Thequalifiedcoaxialcable(s)andfrequencyrangeofinterestmustbelistedontheconnectordrawing.3.ThisspecificationisasupplementtotheSAE/USCAR-2PerformanceSpecificationforAutomotiveElectricalConnectorSystemsandallrequirementshereinmustbemetinadditiontoallrequirementsofthemostrecentrevisionofSAE/USCAR-2,unlessotherwisespecified.OnlyRFconnectorrelatedadditionsand/orsubtractionstotheSAE/USCAR-2specificationarecontainedinthisdocument.3.3EQUIPMENTInadditiontotheequipmentlistedintheSAE/USCAR-2PerformanceSpecification,theequipmentlistedinTable3.3isrequired.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-4-ItemDescriptionRequirements1HighVoltageSource800VAC2NetworkAnalyzer6GHzMinimumSParameterw/TimeDomainCapabilityTable3.3:RFConn.AdditionalEquipment4TESTANDACCEPTANCEREQUIREMENTS4.1GENERALRefertotheSAE/USCAR-2PerformanceSpecificationforthemajorityofRFconnectortestandacceptancerequirements.Theexceptionstothosetestsarelistedinthefollowingsections:1.TheTerminal–MechanicalTestsofSAE/USCAR-2arenotrequiredforRFconnectorqualification.TheTerminalBendResistancetestistobeconsideredasoptionaldependentontheterminaldesignandasdeterminedbyagreementbetweenthesupplierandtheOEM.2.TheMaximumTestCurrentCapabilitytestisoptional.4.2CONNECTORMECHANICALTESTS4.2.1MechanicalPullTest4.2.1.1PurposeThistestverifiesthattheconnectorlatch,terminalretentionsystem,andcableattachmentwillmaintaincontinuitywhensubjectedtomechanicalstress.ForRFconnectors,thisMechanicalPulltestisinadditiontothemechanicalconnectortestsinSAE/USCAR-2PerformanceSpecification.Thisisastand-alonetestandrequiressamplesforeachcabletypequalified.Note:Thistestisadestructivedesignvalidationtestandshallnotbeusedasaproductionacceptanceorqualitycontroltest.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-5-4.2.1.2ProcedurePrepareConnectorUnderTest(CUT)assembliesforeachcablebeingqualifiedperProcedure4.4.2.2,Steps1through7.Attachacontinuitytestersoastocheckcontinuitythroughboththecentercontactandshieldofthematedconnectorpair.In-linesandBoardMountconnectors:Subjecttheconnectionsystemtoadirectpullforceparallelwiththeaxisoftheconnectors(directionAofFigure4.2.1.2)bygrippingontheSMAconnectors(orbyattachingamatingSMAconnectortotheassemblyandgrippingonthat).FortheoptionalsamplespreparedforSWRmeasurement,(per4.4.2.2,NoteC)itisalsoacceptabletowrapthecablearounda2-inchdiametermandrel,securingthecabletothemandrelwithelectricaltapeorsomeothersuitablemeans.Boardmountconnectorsmayhavethecircuitboardendfirmlyattachedtoasuitablefixture.Increasethepullforceatauniformrateuntilthefulltestforceisachievedandthenholdtheforcefor5secondswhilemonitoringforcontinuity.SubjectSMBconnectionsystemsto110NforceandSquareOuterConductorconnectionsystemsto80Nforce.OEMpulltestrequirementsforSquareOuterConductorconnectorsystemsmaybehigherdependingoncablesize.Priortoconductingthistest,alwaysconsultwiththeresponsibleOEMengineeringdepartmentfortherequiredacceptancecriteria.AdditionalBoardMountonlytesting:AgainbygrippingonthecablesideSMAconnector,subjecttheboardmountconnectionsystemtoatleastthefollowingdirectionalforces,allat75N:1C,3C,5B,7B,8C(perFigure4.2.1.2.)SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-6-Figure4.2.1.2:BoardMountMechanicalPull1.MeasureSWRandI.L.perProcedure4.4.2.2,Steps4,6,&7.2.Disassembleeachsampleandvisuallycheckfordamagethatcouldaffecttheperformanceoftheconnectionsystem.Note:Optionally,toaccountforSMAcrimpdegradationandthecorrespondingincreasedinsertionloss,aminimumof10SMAconnectorassemblies(samecrimpprocessandlengthasCUTassemblyperFigure4.4.2.21a.)maybesubjectedtothistest(statisticalevaluation).4.2.1.3AcceptanceCriteria1.Thereshallbenointerruptionsincontinuityonanysampleduringthetest.2.TheRFconnectorSWRandInsertionLossvaluesmustbeequaltoorlessthanthoselistedinTables4.4.2.3-aand4.4.2.3-b3.Thereshallbenovisualdamagetoanypartoftheconnectionsystemincludingconnectorbody,metalterminalsorcableattachment.FailureoftheSMAterminalsisnottobeinterpretedasafailureoftheCUT.SamplesidentifiedashavingSMAfailuresthroughfailureanalysismaybereplacedandretestedthroughtheentiresequence.186247A35BCSAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-7-4.2.2ConnectorMating/Un-matingForce4.2.2.1PurposeThistestdeterminesthemating/un-matingforcesassociatedwithRFconnectors.4.2.2.2ProcedureFollowtheprocedureforConnectorMating/Un-matingForcefoundinthelatestrevisionofSAE/USCAR-2.4.2.2.3AcceptanceCriteria1.Forsinglecontactconnectors,thematingforcemustbelessthanorequalto40N;theun-matingforcemustbelessthanorequalto35Nwiththeprimaryconnectorlockcompletelydisengaged/disabled.2.Formultiplecontactconnectors,SAE/USCAR-2acceptancecriteriaapply.4.2.3PolarizationFeatureEffectiveness4.2.3.1PurposeThistestpreventsmatingofaconnectorhousingwithanyunintendedmate.4.2.3.2ProcedureFollowtheprocedureofSAE/USCAR-2“PolarizationFeatureEffectiveness”withthefollowingexceptions:1.Testaminimumof3setsforeachselectedmis-orientationormis-index.2.Terminalswithelectricalaccesstothecenterconductorarerequiredtobeloadedineachconnectorofeachtestpairtoallowverificationofcontinuity.4.2.3.3AcceptanceCriteria1.ForsinglecontactSMBconnectionsystems,theminimummis-matingforcetoachievecentercontactelectricalcontinuityis80N.(Itisknownthatcertainkeycodecombinationswillnotmeetthisrequirement.Eachmanufacturermustpublishthelistoftestedkeycodecombinationsthatdonotmeetthisrequirement.)FormultiplecontactSMBconnectionsystems,theminimummis-matingforcetoachievecentercontactelectricalcontinuityis100N.2.ForSquareOuterConductorconnectionsystems,SAE/USCAR-2acceptancecriteriaapply.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-8-4.3TERMINALELECTRICALTESTS4.3.1ContactResistance4.3.1.1PurposeThistestdeterminestheelectricalresistanceofboththeouterconductorcrimpsandcorrespondingcontactinterfaceandtheinnerconductorcrimpsandcorrespondingcontactinterfaceunderlowenergyconditions.ForRFconnectors,thisContactResistancetestreplacestheDryCircuitResistancetestingintheSAE/USCAR-2PerformanceSpecification.4.3.1.2ProcedureFollowtheDryCircuitResistanceprocedureinthelatestSAE/USCAR-2PerformanceSpecification.Sincegainingaccesstotheinnerconductormaydamagetheouterconductor,themillivoltleadlocationsneednotfollowtheSAE/USCAR-2PerformanceSpecification.Subtractthecableresistanceportionfromthemeasuredvalue.4.3.1.3AcceptanceCriteriaThetotalconnectionresistanceoftheinnerconductormustnotexceed40mΩ.Likewise,thetotalconnectionresistanceoftheouterconductormustnotexceed40mΩ.4.3.2DielectricWithstandingVoltage4.3.2.1PurposeThedielectricwithstandingvoltagetestisusedtodemonstratethattheconnectioncanwithstandmomentaryover-potentialsduetoswitching,surges,andothersimilarphenomena.Itservestodeterminewhetherinsulatingmaterialsandspacingsintheconnectorareadequate.ForRFconnectors,thisDielectricWithstandingVoltagetestreplacestheCurrentCycletestingintheSAE/USCAR-2PerformanceSpecification4.3.2.2ProcedureWiththeconnectorengaged,apply800voltsofcommercialfrequencyalternatingvoltagebetweentheinternalandexternalconductorterminalsfor60seconds.Thetestvoltageshallberaisedfrom0tothe800V(rms)asuniformlyaspossible.4.3.2.3AcceptanceCriteriaTheremustbenodielectricbreakdowns.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-9-4.4CONNECTORELECTRICALTESTS4.4.1IsolationResistance4.4.1.1PurposeThistestverifiesthattheelectricalresistancebetweenthecentercontactandtheoutercontactwillpreventdetrimentalelectricalconductivity.ForRFconnectors,thisIsolationResistancetestreplacestheIsolationResistancetestingintheSAE/USCAR-2PerformanceSpecification.4.4.1.2ProcedureFollowtheIsolationResistanceprocedureinthelatestSAE/USCAR-2PerformanceSpecificationasitpertainstothecenterconductorandouterconductoroftheRFconnector.4.4.1.3AcceptanceCriteriaThecentercontacttooutercontactresistanceshallbe>100MΩ.4.4.2StandingWaveRatioandInsertionLoss4.4.2.1PurposeThistestmeasuresboththemismatchlossbetweentheconnectorandthecableandtheinsertionlossthroughthecabletestassemblyatthefrequenciesofinterest.TheSWRisequalto1whenthecableimpedanceisperfectlymatchedtotheconnector.Theinsertionlossforanidealconnectionsystemwithnolossis0dB.OnlytheSWRwillbemeasuredforboardmountconnectors,however,theInsertionLossofthecorrespondingin-linemustalsomeetspecificationtoqualifytheboardmountconnectorinquestion.ForRFconnectors,StandingWaveRatio/InsertionLosstestingreplacetheNominalCurrentResistance(VoltageDrop)testintheSAE/USCAR-2PerformanceSpecification.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-10-4.4.2.2Procedure1.ThefollowingminimumsamplesetsshouldbepreparedforeachsegmentofenvironmentaltestingperSAE/USCAR-2.In-LineConnectors:PreparesampleswithSMAconnectorstothepreferredlength,asshowninFigure4.4.2.2-1a.Theoveralllengthoftheleadsshallbe150mmlessthelengthduetoinsertionoftheCUT.(Samplelengthtoleranceis+0/-5mm)BoardMountConnectors:PreparesampleswithSMAconnectorstothepreferredlengthasshowninFigure4.4.2.2-1c.Note:Alternativemeasurementmethodsareacceptable.Recordequipmentdetails,testparametersandtestmethodinthetestreport.2.Performafull2portTimeDomainCalibration(lowpassstepresponserecommended).3.Forin-linesonly,measure/recordtheS21parameter(transmittedpowerindB)ofeachSMAconnectorassembly(Figure4.4.2.2-1a)overthefrequencyrangelistedinTable4.4.2.3-b.AffixaCUTinthemiddleofeachoftheseassembliesallowingthesamplelengthtoincreaseto150+0/-5overall.(Figure4.4.2.2-1b.showsthepreferredlength).4.Forin-linesonly,measuretheS21parameteroftheCUTassemblyandsubtractthecorrespondingSMAconnectorassembly'sS21value.ThisisthenetInsertionLossofeachCUT.5.Forin-linesonly,prepareoneadditionalsamplewiththeoveralllengthof500+0/-5mmwhentheCUTisengaged.DeterminethestartgateandstopgateofjusttheCUTwithinthisadditionalsampleusingtheS11TDRplot,creatingagatespaninpico-seconds.6.Forin-linesonly,setthegatespandeterminedinstep5andplacethegatecenterinthe"electricalmiddle"ofeachCUTsample(SeeNoteCbelowforoptionalSWRsamplepreparation).MeasuretheSWRforallsamplesoverthefrequencyrangelistedinTable4.4.2.3-a.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-11-7.Forboardmountconnectors,determinethestartgateandstopgateofjusttheCUTwithinasampleusingtheS11TDRplot,creatingagatespaninpico-seconds.MeasurethegatedSWRoftheCUTforallsamplesoverthefrequencyrangelistedinTable4.4.2.3-a.8.Completelyun-mateandmateeachsampleatotalof10timesandleavethemmated.9.Repeatsteps4,6and7.Notes:A.TheSMAconnectorsshouldbeprotectedduringenvironmentalexposurewithamatingconnectororplug.B.Optionally,toaccountforSMAinsertionlossdegradationduetoenvironmentalexposure,aminimumof10SMAconnectorassemblies(samecrimpprocessandlengthasCUTassembly(fig.4.4.2.2-1a))maybepreparedforeachsegmentofenvironmentalexposure(statisticalevaluation).ThestatisticaldatafromtheseassembliesistobeusedasreferencefordeterminingthenetInsertionLossofeachCUT.C.Optionalin-lineSWRsamples:TooptimizeSWRresultsbyimprovinggatingaccuracyandprovidingimprovedisolationoftheSMAtestconnectors,additionalsamplesmaybeusedsolelyforSWRmeasurements.Preparethesesamplesper4.4.2.2,Step5.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-12-1a.1b.1c.150mmlessallowanceforCUTinsertionlength1aplusincreasedlengthduetoCUTinsertion(150+0/-5mm)250-300mmFigure4.4.2.2:SWRTestSample4.4.2.3AcceptanceCriteriaTheRFconnectormaximumSWRandinsertionlossvaluesareshowninTables4.4.2.3-aand4.4.2.3-b.Note:Thesearemaximumacceptablevalues.Specificapplicationsmaydictatelowervalues.ActualtestdatamustbeavailableforOEMevaluationagainstsystemrequirements.RFConnectorTypeMax.SWR[freq.]SquareOuterConductor,EWCAP1.35[0-1GHz]1.60[1-2GHz]SMB3GHz,FAKRA1.40[0-2GHz]1.50[2-3GHz]SMB0.5GHz1.35[0-0.5GHz]Table4.4.2.3-a:MaximumSWRValuesSMASMACUTBOARDSMACUTSAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-13-RFConnectorTypeMax.InsertionLoss[freq.]SquareOuterConductor,EWCAP0.2[0-1GHz]0.4[1-2GHz]SMB3GHzFAKRA0.3[≤3GHz]SMB0.5GHz0.25[≤0.5GHz]Table4.4.2.3-b:MaximumInsertionlossValues(In-lineConnectorsonly)4.4.3RFLeakage4.4.3.1PurposeThistestverifiestheleakageofRFconnectors(sometimesreferredtoasShieldingEffectiveness),measuredindB.Thisisastand-alonetestforin-lineconnectorsonlyandrequiressamplesforeachcabletypebeingqualified.SamplesshouldbemadeasshortaspossibletominimizetheeffectsofRFleakagefromthecoaxcable.4.4.3.2ProcedureThefollowingproceduresareacceptable:1.IEC61726(modestirrer)2.MIL-PRF-39012,paragraph4.7.23(triaxchamber)3.IEC61196-1,paragraph12.6(matchedtri-axial)4.IEC60512-23-3(lineinjection)4.4.3.3AcceptanceCriteriaSMBconnectionsystemsmustnotexceed-45dBthroughoutfrequencyrange.SquareOuterConductorconnectionsystemsmustnotexceed-25dBthroughoutfrequencyrange.4.5TESTSEQUENCEFollowtheTestSequenceparagraphspecifiedintheSAE/USCAR-2PerformanceSpecification,replacingalloccurrencesofthosetestslistedinTable4.5.SAE/USCAR-17Revision2RevisedNovember2004PerformanceSpecificationforAutomotiveRFConnectorSystems-14-RFConnectorSpec.SAE/USCAR-2Section4.3.1,ContactResistanceDryCircuitResistanceSection4.3.2,DielectricWithstandingVoltageCurrentCyclingSection4.4.1,IsolationResistanceIsolationResistanceSection4.4.2,SWRandInsertionLossNom.CurrentResistance(VoltageDrop)Table4.5:TestSequenceReplacements4.5.1TestSequenceGeneralNotes1.ThesequentialtesttablesinthissectionarebasesequencesandmaybealteredasdeterminedbytheAuthorizedPerson.2.Testsequenceistheorderinwhichtestsareperformed.Thesequenceshouldbelogicalandinterrelatedinordertoaccuratelyestablishtheperformancecharacteristicsofthecomponentorassembly.3.NumbersinthebodyofTables4.5.2and4.5.3indicatetheorderinwhichthetestsorconditioningproceduresareperformed.Wherethereareduplicatenumbersinthesamecolumn,theproceduresareperformedconcurrently.4.Destructivetestsshouldbeperformedonlyonsamplesthatarenotintendedforuseinfurthertestsequences.5.Theminimumnumberoftestsamplesneededforsequentialtestsisshownatthetopofeachcolumn.Samplesmaybere-usedformorethanonetestsequence,buttheacceptancerequirementsremainthesameasifseparatesampleswereused.6.Tables4.5.2and4.5.3containtestproceduresfromthisdocumentaswellasfromSAE/USCAR-2,PerformanceSpecificationforAutomotiveElectricalConnectorSystems.ParagraphnumbersfromSAE/USCAR-2aregivenforreferenceonlyandarelistedintheirowncolumn.Usetheappropriatelytitledprocedureintheevent