Lab-field correlation program for automotive electrical connections

摘要

This paper describes the results to date of an ongoing lab-fieldcorrelation program for automotive electrical connections. The goal isto produce an accelerated laboratory life test that is correlated tovehicle performance. The intention is to establish correlation up to150,000 miles. The program has three major phases: junkyard, laboratory,and field. Thousands of samples from ten-year-old vehicles with mileagein excess of 100,000 miles have been measured and classified. Testing isbeing conducted in design of experiments (DOE) fashion for majorinterface and crimp factors and significant related vehicleenvironmental factors are being measured. Custom designed systemscollect test sample, vehicle, and environmental measurements daily.Vehicles have completed 24 months and have accumulated 67,000 mileseach. Resistance distributions representing thousands of samples andextensive databases of field data representing millions of sample andvehicle measurements have been documented. An accelerated laboratorylife test sequence has been developed that produces resistancedistributions greater than corresponding field distributions. Resistanceresponses associated with major factors are similar in lab testing andvehicle settings. Families of the sequence are being run, representingthousands of crimps and interfaces that will permit adaptation tovarious applications