SAE USCAR-25-2025 REVISION 4 电连接器组件人体工程学设计标准第4版

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Ergonomics Specification for Electrical Connections

SAE/USCAR-25 REVISION 4

October 2025

ISBN: 978-1-4686-1001-7

__________________________________________________________________________________________________________________________________________

The research data, analysis, conclusion, opinions, and other contents of this document are solely the product of the authors. Neither the SAE International (SAE) nor the United

States Council for Automotive Research (USCAR) certifies the compliance of any products with the requirements of nor makes any representations as to the accuracy of the

contents of this document nor to its applicability for purpose. It is the sole responsibility of the user of this document to determine whether or not it is applicable for their purposes.

QUESTIONS REGARDING THIS DOCUMENT: (248) 273-2470 FAX (248) 273-2494

TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX (724) 776-0790

SAE/USCAR-25 REVISION 4

Issued 2003-05

Revised 2025-10

ERGONOMICS SPECIFICATION FOR ELECTRICAL CONNECTIONS

TABLE OF CONTENTS

1. SCOPE .......................................................................................................................................................... 4

2. REFERENCED DOCUMENTS ..................................................................................................................... 4

3. GENERAL ..................................................................................................................................................... 4

3.1 Assumptions .................................................................................................................................................. 4

3.2 Assembling Connectors Outside of Assumption Conditions ......................................................................... 4

4. DESIGN GUIDELINES - HAND-PLUG CONNECTORS .............................................................................. 5

4.1 Maximum Assembly Force ............................................................................................................................ 5

4.2 Contact Surface Characteristics ................................................................................................................... 5

4.3 Grip Span .................................................................................................................................................... 11

4.4 Wire Harness Use for Connector Assembly ............................................................................................... 11

4.5 Disengage Force ......................................................................................................................................... 12

5. DESIGN GUIDELINES - MECHANICAL ASSIST CONNECTORS ............................................................ 12

5.1 Pre-Lock Positioning for Mechanical Assists .............................................................................................. 13

5.2 Maximum Assembly Force for Mechanical Assists ..................................................................................... 13

5.3 Contact Surface Characteristics for Mechanical Assists ............................................................................ 13

5.4 Lever Mechanical Assist ............................................................................................................................. 15

5.5 Slide Mechanical Assist .............................................................................................................................. 17

5.6 Linear Engagement Mechanical Assist ....................................................................................................... 17

5.7 Grip Span .................................................................................................................................................... 19

5.8 Wire Harness in Connector Assembly ........................................................................................................ 19

5.9 Disengage Force ......................................................................................................................................... 19

6. DESIGN GUIDELINES - TWIST LOCK CONNECTORS ........................................................................... 19

6.1 Torque Requirements ................................................................................................................................. 19

6.2 Contact Surface Characteristics ................................................................................................................. 19

6.3 Grip Span .................................................................................................................................................... 20

6.4 Additional Guidelines .................................................................................................................................. 20

7. DESIGN GUIDELINES - HIGH VOLTAGE CONNECTORS ...................................................................... 21

7.1 Maximum Assembly Force .......................................................................................................................... 21

7.2 Contact Surface Characteristics ................................................................................................................. 21

7.3 Grip Span .................................................................................................................................................... 22

7.4 Wire Harness in Connector Assembly ........................................................................................................ 22

7.5 Disengage Force ......................................................................................................................................... 22

8. DESIGN GUIDELINES - CPA (CONNECTOR POSITION ASSURANCE) ................................................ 23

8.1 Maximum Assembly Force .......................................................................................................................... 23

8.2 Contact Surface Characteristics ................................................................................................................. 23

8.3 Unobstructed CPA Design .......................................................................................................................... 24

8.4 Obstructed CPA Design .............................................................................................................................. 25

8.5 Additional Guidelines .................................................................................................................................. 25

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标签： #工程 #电连接器 #设计标准

摘要：

SAE USCAR-25-2025 REVISION 4 第4版是全球汽车行业关于电连接器组件人体工程学设计的最新权威规范标准。该标准由SAE International与美国汽车研究理事会（USCAR）联合发布，旨在为工程师和制造商提供系统化的设计指南，以优化电连接器在装配、操作及维护过程中的人机交互体验。第4版在先前版本基础上进行了重大修订，新增了针对操作力度、触觉反馈、握持舒适度及重复性动作疲劳风险的量化评估方法，并更严格地定义了测试协议与验收准则。本标准覆盖了从乘用车、商用车到新能源车高

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