ISO 8092-2:2023

Overview

ISO 8092-2:2023 - Road vehicles - Connections for on-board electrical wiring harnesses - Part 2 provides terminology, test methods and general performance requirements for voltage class A connectors used in on-board electrical wiring harnesses of road vehicles. The standard applies to connectors that, once mounted in the vehicle, are intended to be disconnected only for repair and maintenance. It explicitly excludes internal connections inside electronic devices and does not cover signal communication quality or data integrity.

Keywords: ISO 8092-2:2023, road vehicles connectors, on-board electrical wiring harnesses, voltage class A connectors, test methods, performance requirements.

Key topics and technical requirements

The document defines essential vocabulary and a comprehensive test regime to verify connector performance. Major technical topics include:

• Terms and definitions for consistent use of connector-related vocabulary.
• Test conditions and preconditioning (environmental and mechanical durability) and guidance on test sequences and sample quantities.
• Visual examination procedures and pass/fail criteria.
• Mechanical tests, including:
  • Connection and disconnection behaviour
  • Measurement/classification of mating, unmating and unlocking forces
  • Locking device strength and prevention of unintentional release
  • CPA (connector position assurance) and TPA (terminal position assurance) locking/disengage forces
  • Effectiveness of coding and polarization
  • Connector engagement sound and terminal insertion/extraction forces
  • Tensile strength of terminal-to-wire connections
• Electrical tests, including:
  • Connection resistance (voltage drop) measurements
  • Temperature rise under load
  • Current cycling at ambient temperature
  • Insulation resistance tests

The standard specifies methods to carry out these tests and sets general performance expectations; it does not prescribe specific signal/data integrity assessments.

Practical applications

ISO 8092-2:2023 is used to ensure connector reliability, safety and maintainability in automotive wiring harnesses. Practical benefits include:

• Reducing field failures and warranty costs through validated connector performance
• Ensuring repeatable manufacturing and inspection criteria
• Facilitating supplier qualification and incoming inspection
• Supporting design decisions for connector selection and harness layout

Keywords: automotive connector testing, wiring harness reliability, connector performance requirements.

Who should use this standard

• Automotive OEMs and vehicle electrical system designers
• Connector and wiring-harness manufacturers and suppliers
• Test laboratories and quality assurance teams
• Regulatory and compliance personnel assessing component conformity

Related standards

ISO 8092-2:2023 is part of the broader set of standards addressing on-board connector design and testing. Users should consider other parts of the ISO 8092 series and applicable vehicle electrical system standards when specifying or qualifying connectors.