ISO 8092-5:2021 PDF

Road vehicles — Connections for on-board electrical wiring harnesses — Part 5: Test methods and general performance requirements for wiring harness connector operation

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Title (English):

ISO 8092-5:2021

Road vehicles — Connections for on-board electrical wiring harnesses — Part 5: Test methods and general performance requirements for wiring harness connector operation

Document status:: Active
Format:: Electronic (PDF)
Number of pages:: 10
Publication date:: January 21, 2021
Edition:: ISO IS 8092 edition 1 version 1
ICS:: 43.040.10

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Description (English):

This document defines terms and specifies test methods and general performance requirements for single-pole and multi-pole connections used with on-board electrical wiring harnesses of road vehicles. This document is applicable to connectors designed to be disconnected after mounting in the vehicle for repair and maintenance only. It does not cover one-part connections, i.e. where one part of the connection has direct contact to the pattern of the printed circuit board. This document is not applicable to internal connections of electronic devices.

Technical details

Technical committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
SKU: ISO 8092-5:2021

Abstract

Overview

ISO 8092-5:2021 - "Road vehicles - Connections for on-board electrical wiring harnesses - Part 5" specifies test methods and general performance requirements for wiring harness connector operation. It applies to single‑pole and multi‑pole automotive connectors designed to be disconnected after vehicle installation for repair or maintenance. It does not cover one‑part PCB contacts or internal electronic device connections. The standard addresses ergonomic and assembly concerns by defining reproducible measurements for connector mate/unmate behaviour.

Key topics and technical requirements

Scope and conditions
- Preconditioning: samples conditioned at (23 ± 5) °C and 45–75% RH for 24 h.
- Measurement environment: unused samples measured at (23 ± 5) °C and 45–75% RH. Cable types must comply with ISO 19642 series.
Mating force measurement and classification
- Minimum sample size: 10 fully populated connector pairs (or representative device interface).
- Mating at constant speed (50 ± 10 mm/min) with force vs. stroke recorded.
- Classification examples provided: maximum mating force classes (≤45 N, 45–70 N, >70 N); mating stroke classes; and a mating force gap ratio R = (g / F) × 100 to classify completion force behaviour.
Connector mating sound
- Measures audible feedback used by assembly workers.
- Procedure uses an IEC 61672‑1 compliant sound level meter, defined geometry and insertion angles, and cotton gloves to simulate worst‑case assembly.
- Minimum sound requirements: peak >5 kHz ≥ 60 dB (Lp); overall sound level ≥ 70 dB (LoA).
Locking latch release and unmating force
- Unlock (release) force measured on 5 samples; classified (≤30 N, 30–45 N, >45 N).
- Unmating force tests require deactivating locks where applicable; fixtures or cable pulls allowed if drilling is impractical.
Terminology and test reporting
- Defines male/female connectors, terminals, inertial locks and prescribes reporting of test speed, cable used, and measurement diagrams.

Applications and users

Who uses it: automotive OEMs, harness and connector suppliers, test labs, design engineers, and quality/ergonomics teams.
Practical uses:
- Validate connector ergonomics (mate/unmate effort and audible feedback) for assembly and maintenance.
- Ensure repeatable performance specifications for supplier contracts and component acceptance.
- Support ergonomic risk assessments and assembly line quality controls.

Related standards

ISO 8092 series (other parts covering different connector aspects)
ISO 19642 (automotive cables) - cited for cable requirements
IEC 61672‑1 - sound level meter specifications used for mating sound tests

For implementation or certification, obtain the full ISO 8092-5:2021 document for complete test setups, figures, and mandatory reporting requirements.

Related standards

Standards mentioned in the description

Abstract

Overview

Key topics and technical requirements

Scope and conditions
- Preconditioning: samples conditioned at (23 ± 5) °C and 45–75% RH for 24 h.
- Measurement environment: unused samples measured at (23 ± 5) °C and 45–75% RH. Cable types must comply with ISO 19642 series.
Mating force measurement and classification
- Minimum sample size: 10 fully populated connector pairs (or representative device interface).
- Mating at constant speed (50 ± 10 mm/min) with force vs. stroke recorded.
- Classification examples provided: maximum mating force classes (≤45 N, 45–70 N, >70 N); mating stroke classes; and a mating force gap ratio R = (g / F) × 100 to classify completion force behaviour.
Connector mating sound
- Measures audible feedback used by assembly workers.
- Procedure uses an IEC 61672‑1 compliant sound level meter, defined geometry and insertion angles, and cotton gloves to simulate worst‑case assembly.
- Minimum sound requirements: peak >5 kHz ≥ 60 dB (Lp); overall sound level ≥ 70 dB (LoA).
Locking latch release and unmating force
- Unlock (release) force measured on 5 samples; classified (≤30 N, 30–45 N, >45 N).
- Unmating force tests require deactivating locks where applicable; fixtures or cable pulls allowed if drilling is impractical.
Terminology and test reporting
- Defines male/female connectors, terminals, inertial locks and prescribes reporting of test speed, cable used, and measurement diagrams.

Applications and users

Who uses it: automotive OEMs, harness and connector suppliers, test labs, design engineers, and quality/ergonomics teams.
Practical uses:
- Validate connector ergonomics (mate/unmate effort and audible feedback) for assembly and maintenance.
- Ensure repeatable performance specifications for supplier contracts and component acceptance.
- Support ergonomic risk assessments and assembly line quality controls.

Related standards

ISO 8092 series (other parts covering different connector aspects)
ISO 19642 (automotive cables) - cited for cable requirements
IEC 61672‑1 - sound level meter specifications used for mating sound tests

For implementation or certification, obtain the full ISO 8092-5:2021 document for complete test setups, figures, and mandatory reporting requirements.

ISO 8092-5:2021 PDF

Technical details

Abstract

Overview

Key topics and technical requirements

Applications and users

Related standards

Related standards

Abstract

Overview

Key topics and technical requirements

Applications and users

Related standards

Related standards

Road vehicles — Automotive cables — Part 1: Vocabulary and design guidelines

Electroacoustics - Sound level meters - Part 1: Specifications

Road vehicles — Connections for on-board electrical wiring harnesses — Part 2: Definitions, test methods and…