uscar25

__________________________________________________________________________________________________________________________________________Theresearchdata,analysis,conclusion,opinionsandothercontentsofthisdocumentaresolelytheproductoftheauthors.NeithertheSAEInternational(SAE)northeUnitedStatesCouncilforAutomotiveResearch(USCAR)certifiesthecomplianceofanyproductswiththerequirementsofnormakesanyrepresentationsastotheaccuracyofthecontentsofthisdocumentnortoitsapplicabilityforpurpose.Itisthesoleresponsibilityoftheuserofthisdocumenttodeterminewhetherornotitisapplicablefortheirpurposes.Copyright©2008USCARPrintedinU.S.A.Allrightsreserved.QUESTIONSREGARDINGTHISDOCUMENT:[phone]FAX[phone]TOPLACEADOCUMENTORDER:[phone]FAX[phone]SAE/USCAR-25REVISION1IssuedMay2003RevisedProposedDraft2008-08-05ELECTRICALCONNECTORASSEMBLYERGONOMICDESIGNCRITERIATABLEOFCONTENTS1.0SCOPE........................................................................................................................................................................22.0REFERENCEDDOCUMENTS...............................................................................................................................23.0GENERAL..................................................................................................................................................................24.0DESIGNGUIDELINES–HAND-PLUGCONNECTORS...................................................................................25.0DESIGNGUIDELINES–MECHANICALASSISTCONNECTORS................................................................86.0DESIGNGUIDELINES–TWISTLOCKCONNECTORS...............................................................................147.0TESTING–HAND-PLUGANDMECHANICALASSISTCONNECTORS...................................................158.0DESIGNGUIDELINES–CPAs(CONNECTORPOSITIONASSURANCE).................................................169.0HANDCLEARANCEGUIDELINES...................................................................................................................17APPENDIXA:GLOSSARY...........................................................................................................................................31APPENDIXB:SURFACEAREACALCULATIONS.................................................................................................32APPENDIXC:REFERENCES......................................................................................................................................35APPENDIXD:REVISIONS...........................................................................................................................................36SAE/USCAR-25REVISION1Revised2008-08-05ELECTRICALCONNECTORASSEMBLYERGONOMICDESIGNCRITERIA-2-1.0SCOPEThisdocumentdescribesthedesign,assemblyforce,andpackagingguidelinesforconventionalhand-plug,mechanicalassistandtwistlockelectricalconnectors,aswellasConnectorPositionAssurances(CPAs).Allpossibledesignsandapplicationscouldnotbeanticipatedincreatingtheseguidelines.Wheretherearequestionsofadherencetothisdocument,suchasuseofan“off-the-shelf”design,alwaysconsulttheresponsibleErgonomicsDepartment.RefertoSAE/USCAR-12WiringComponentDesignGuidelinesforadditionalguidelines.2.0REFERENCEDDOCUMENTSSAE/USCAR-2PerformanceStandardforAutomotiveElectricalConnectorSystemsSAE/USCAR-12WiringComponentDesignGuidelinesSeeAppendixCforadditionalreferences3.0GENERALInallcases,assemblyforcesshouldbeaslowaspossiblewhilemaintainingsatisfactoryelectrical,mechanicalandenvironmentalperformance.Partpackaging,processandworkstationdesignrequirements/constraintsallhavethepotentialtonegativelyimpacttheforcesspecifiedinthisdocument.Suchsituationsincludebutarenotlimitedto:-Obstructedaccess-Awkwardornon-neutralpostures,suchaswristdeviationorextendedreaches-ForcesappliedlaterallyacrossthebodyThishasnecessitatedthecreationofaHandClearanceGuidelinessection.ConsulttheErgonomicsDepartmentwithanyquestionsorifclarificationsareneeded.4.0DESIGNGUIDELINES-HAND-PLUGCONNECTORSAhand-plugconnectorisanelectricalconnectorwhichrequiresanoperatortomanuallyassemble/matetwoconnectorhalvesoraconnectortoadevicewithouttheuseofamechanicalassist.Hand-plugconnectorsfallintothreeclassesasshowninTable4.1(seepage7).Eachclassisdefinedbymaximumassemblyforceandcorrespondingcontactsurfacearearequirements.SAE/USCAR-25REVISION1Revised2008-08-05ELECTRICALCONNECTORASSEMBLYERGONOMICDESIGNCRITERIA-3-4.1MAXIMUMASSEMBLYFORCEUnderidealconditionsdescribedintheseGuidelines,themaximumassemblyforcesmustnotexceed75N.Whentheseconditionscannotbemet,themaximumassemblyforceisreduced(seeTable4.1).4.2CONTACTSURFACECHARACTERISTICSThecontactsurfaceisanessentiallycontinuousplaneuponwhichtheoperatorcanapplyassemblyforce.Contactsurfacedimensionsarederivedfromalargemaleglovedhandorasmallfemaleglovedhandasappropriate.Wherepossible,everyeffortshouldbemadetodesigntheconnectortomeetthetargetsurfaceareadimensions.Whenthisisnotpossible,theminimumcontactsurfaceareamustbemet.Thesed