1、Volex-HG-NPD,NPD Presentation (Power Cord)新产品开发介绍(电源线),NPD-New Product Development,-1. Existing Product Presentation(现有产品介绍）-2. Using Standard & Approval Symbols（产品引用标准及认证标识）-3. Volex Catalog No. Definiens ( Volex 产品目录名称的定义)-4. Power Cord Composing (电源线产品构成)-5. NPD Procedure(新产品开发程序)-6. Product Desi
2、gn (产品设计)-7. Process Flow ( 工艺流程 )-8. Test Request ( 测试要求 )-9. Safety Approval ( 安规认证 )-10. Release Drawing ( 发布图纸 ),Existing Products Presentation（现有产品介绍）,2. Using Standard & Approval Symbols(产品引用标准及认证标识）,3. Volex Catalog No. Definiens (Volex 产品目录名称的定义),4. Power Cord Composing (电源线产品构成）,Plug (Class
3、 1),Cable,Connector (Class 1),Grommet (Normal using For Free End)正常情况下用于自由端,Detachable Power Cord (可移开的电源线) Power Cord with appliance connector and can be removed from the appliances by the consumers ( 带有尾插的, 可以从器具上移开的电源线确),Class 1-With earth pin ( 带地线的三片插头,或尾插),( Strain relief ),MP5004,IT10VS2(Clas
4、s 2),JP15VS2,Non-detachable Power Cord ( 不可以移开的电源线 ) Power Cord with customized end treatment and is meant to be joint to the appliance electric circuit board permanently. The consumers are not able to remove the power cord from the appliances ( 用户化的尾端并永久参于电流巡环的电源线.用户不可能将电源线从器具上移开的 ),Class 2With liv
5、e and neutral pins only, without earth pin (不带地线的两片插头,或尾插),Free End,HP PDU,VAC20S,V1625,Connector + Cable,-Class 1 plug must be supplied with Class 1 connector (等级1的插头配等级1的尾插)-Class 1 plug can also be supplied with Class 2 connector (not applicable to all countries) (等级1的插头可以配等级2的尾插, 但并不适用于所有的国家)-Cl
6、ass 2 plug must be supplied with only Class 2 connector(等级2的插头配等级2的尾插)-Class 2 plug cant be supplied with Class 1 connector(等级2的插头不可以配等级1的尾插)-The rules are meant to protect the consumers who may abuse the use of the cord set unintentionally (这个规则是为了保护消费者错用电线引起的后果)-Plugs with earth shall enable earth
7、 connection to be established before current-carrying connection when insertion into socket-outlet.(带地线端子的插头在插入插座之前必须有可靠的地线联接),Grading confecting ( 等级配制 ),5. NPD Procedure (新产品开发程序）,6. Product Design (产品设计),-6.1 Material Choose （材料的选择）-6.2 Formal Configuration Design（外形和结构设计）-6.3 Cable Choose （电线的选择
8、）-6.4 Strain Relief Design （网尾设计）-6.5 Marking Design ( 印字的设计要求 ),6.1 Material Choose ( 材料的选择),Product BOMTerminal（端子）Housing（套子）Body（主体）,Indicate Product Configuration (产品结构显示),-Shall be of a corrosion-resisting metal (耐腐蚀的金属）-Sufficient hardness for mechanical strength（足够的机械强度）-Electrical conductiv
9、ity（良好的导电性）-Suitable size and form to meet a flexible cord ensure temp raise and pull force test（适当的尺寸配电线）,6.1.1 Terminal ( 端子）,Principle（原则）:,Normal material (常用材料）：,-Copper (铜)-Copper alloy containing at least 58% copper (含铜量的合金）-Stainless steel containing at teast 13% chromium and more than 0.09%
10、 carbon（含至少铬或者大于碳的不锈钢）,Normal method (常用方法):,Plating Ni or SnZn(电镀镍或锡锌) 2+/-0.5um,6.1.2 Housing (套子),Principle（原则）:,-Sufficient hardness for mechanical strength（足够的机械强度）-Glow-wire test 750/850C deg 30S ( 灼热丝测试750C/850C 30S)-Good moisture resistance （良好的防潮性能）-Good insulation resistance（良好的绝缘性能）-Good
11、ball pressure capability（良好的球压性能）-Good aging capability（良好的防老化性能）-Green material (环保材料),Normal material（常用材料）：,-PBT（性能稳定，价格适中，易折） -PC(强度高，价格贵）-PA（性能稳定，价格适中，易吸湿）-PP（价格便宜，缩水大）,-After 48h immersion in water and after all visible drops of water have been removedfrom surface by means of a clean dry cloth
12、 it not have increased in mass by more than 2%(泡入水中48 h, 取出用干布檫干表面水珠后不能有超过总面积渗出）Having a temperature class 6080C deg（的温度等级）-UL listed to UL94 having min HB grade(UL 产品要符合UL94的最低硬度等级)-Does not contain Cadmium, Lead and Brominated flame-retardant(无铅,无镉,无溴)-Must pass Glow-wire test to 750 degree C(必须通过
13、750C 灼热丝30S测试)-Ball pressure test(IEC60884-1 or relevant)(通过球压测试)-Flexing and cord-anchorage test(IEC60884-1 or relevant)(摇摆和锚锭测试)-Electric strength test(IEC60884-1 or relevant)(电气强度测试)-Insulation resistance test(IEC60884-1 or relevant)(绝缘电阻测试)-Resistance to heat and ageing (IEC60884-1 or relevant)(
14、抗热和老化测试),Principle（原则）:,PVC-聚氯乙烯IP40G - 90+/-2A; IP50G -85+/-2A; IP60G - 75+/-2A,Normal material（常用材料）：,6.1.3 Body (主体),6.1.4 BOM (物料表),6.2 Formal Configuration Design（外形和结构设计）,Indicate formal & configuration,6.2.1 Plug Design(插头设计),Dimension and Configuration ( 尺寸和结构):-Shall comply with the appropr
15、iate std sheets, for example: PS204 & VAC5AR(Page25) ( 尺寸顺从相应的标准,如P25的PS204,VAC5AR)-National std usually define dimensions and configurations, must meet check “go” and “no-go” guage (各国标准都有定义尺寸和结构必须通过“过”和“不过”规的测试)-Not possible to engage with a socket-outlet having a higher volltage rating or a lower
16、 current rating ( 插头的电压不能高于插座,电流不能低于插座)-Current: Plug Cable Connector Equipment-Volltage: Plug Cable Connector =3.0mm,D,E,F,Experience Dimension-E,F=1.52.0mm,Doubled Insulation,Equipment (设备)？-Please refer to equipment std which present the cable spec,style of plug and accessories model ( rewirable?
17、 Non-rewirable? With grommet? ) Power rating or current rating?请参照设备标准(IEC335, IEC950, UL95etc）标准可提供电线规格, 插头的类型及附件的型号(可拆卸 的？或非拆卸的？或带有线套？）电源的功率（瓦特）或电流（安培）？-Cable style dimensions which present to you? (可供你选择什么规格尺寸的导线)-Confirm object market? (确定你的目标市场),6.3 Cable Choose (电线的选择),6.3.1 Worldwide Comparis
18、on Of Cable (各标准电线名称与形状),6.3.2 Cable Current Rating and Polarity ( 电线额定电流及极性 ),6.3.3 Three major types of cable in the world ( 三种类型的电线 ),3 major types of cable in the world: ( 三种类型的电线 )-IEC (BS, AS, GB etc)-UL/CSA-JIS (Japan),Europe typ. Cable Ins.,欧洲电线规格说明:-H： 或国家标准-03：轻型 额定电压300/300V 仅有0.5和0.75平方毫
19、米的截面积-05：中型 额定电压300/500V截面积范围为0.75到2.5平方毫米-07：重型 额定电压450/750V1.0平方毫米以上，仅用在橡胶线上(澳大利亚除外)-VV：芯线和外皮材料类型 PVC/PVC通常温度定额为75C，V2V2为90C-RR：芯线和外皮材料类型 都为橡胶定额温度为60C-RN：橡胶芯线和氯丁橡胶外皮-定额温度为60C-RT：橡胶芯线和棉纱线外皮-H2：扁平线-F：软线-3X0.75：3芯线，铜丝的横截面积为0.75平方毫米,UL typ cable Ins.,JIS typ cable Ins.,6.3.4 Object Market ( 目标市场 ),Con
20、firm object market? (确定你的目标市场)-This will confirm plug style (这将 确定你的插头规格):-导线规格表：-3A0.5mmsq-6A0.75mmsq-7A0.75mmsq (Japan & Korea)-10A1.0mmsq, 18AWG (UL)-12A1.25mmsq (Japan & Korea)-13A1.25mmsq (UK), 16AWG (UL)-15A2.0mmsq (Japan & Korea), 14AWG (UL)-16A1.5mmsq,UK market ( 英国市场 ),According to BS1363 t
21、able 2, the fuse allowed to be fitted with regards to plug rating is as followsCable (mmsq)0.50.751.01.251.5Plug Rating (A)36101313Max Fuse (A)513131313Another type of UK plug is known as BS546 rated at 15ABS546 plug is not commonly used.Cables allowed must meet any of the requirement Certified by B
22、ASEC to BS6500 and/or Certified with by any Euro-agencies Certified by any HD or IECEE certification bodies to HD21 or HD22If cables do not meet any, it can be used but will be subjected to type test to BS6500Any new cable types and supplies must first meet above follow by test together with plugs b
23、efore approval,Singapore market,Singapore (250V)Uses the SS145 which is 90% similar to BS1363Major difference is the fuse allowed (table 2)Cable (mmsq)0.50.75 1.01.251.5Plug Rating (A) 3 6 10 13 13Max Fuse (A)3 5 10 13 13It is permissible to downgrade the fuseCables used is SS385 ( similar to BS6500
24、 & IEC60227 ) for PVC cable and IEC60245 for rubber cable,UL/CSA etc market,-Cables, blades and PVC must be UL/CSA approved-NEMA 1-15 (2 pin ) and 5-15 (3 pin ) are rated at max.15A-However actual rating of cord depends on the size of cable 10A with 18Awg 13A with 16Awg ( 15A possible with rubber co
25、rd ) 15A with 14Awg,UL CSA, Argentina (250V):,-Cable used must be certified by SAA to AS3191 or X=10A with Max size appropriate to design of plug and next smallest size,Australia (250V),China, Japan market,-No control on types of cable used but must be certified by CCEE to GB5023 (PVC) or GB5013 (Ru
26、bber). They are equivalent to the IEC60227 and IEC60245 respectively-However cable suppliers must be declared and any change must be informed,China (250V),Japan (125V),Maximum current rating is 15A but actual rating depends on cable size7A- 0.75mmsq (Can be rated to 10A with rubber cord)12A - 1.25mm
27、sq (Can be rated to 15A with rubber cord)15A - 2.0mmsq,6.3.5 Cable supplier control ( 电线供应商的控制 ),-Must be approved to the relevant standards ( 必需符合相关的标准 )-Dimensions must meet the min of the relevant standards (尺寸必需符合相关的标准中的最小值)-Does not use Lead, Cadmium and Brominated flame-retardant as an additiv
28、e on the PVC or Rubber ( PVC 和橡胶料不可含铅,镉,溴等物质)-Suppliers must be able to meet our Volex control on overall diameter (尺寸必需符合VOLEX DWG)-Moulded with our products to conduct the following tests ( 注射成型后能通过下面的测试)-Flexing and cord-anchorage test ( IEC60884-1 or relevant ) ( 摇摆, 锚锭)-Jacket relention test (
29、for UL and cords with sheath ) (外皮保持力)-Strain relief test ( for UL products ) (网尾)-Abrupt pull test ( for UL products ) (突拉)-Suppliers site shall be audited to comply with ISO9002 and process to ensure that cables are always produced consistantly (能通过ISO9002 审核, 生产的产品是环保的),Supplier Control ( 供应商控制 )
30、:,6.4 Strain Relief Design (网尾设计),6.5 Marking Design,产品目录号,商标名称,制造地点,电流,电压值,应用标准,获得的认证号,标明极性,模穴号,标明额定电流,额定电压, 应用的国家,标准,插头电流大于或等于应用尾插,插头电压小于或等于应用尾插, 电线电流小于或等于应用尾插,Process Flow ( 制程 ),Cable cutting Jacket stripping Insulation strippingCrimping Moulding Electrical testing,Process Control - Pull Force,要
31、点 ：拉脱力抽样数量： QA-OP-13 首件检查（FA) - Beginning of shift and model change 定期抽样检查 - 2 hourly and SPC charting标准：产品图纸控制表: QC流程检查表设备：端子拉力测试机行动：停止生产，发PDR,Process Control - Withdrawal Test,要点 ：插拔力抽样数量： 100 标准：小磅起，大磅不起控制表: 目检工位不良记录表设备：标准插磅 IEC-320 小磅（1KG), 大磅（5.0KG)行动：停止生产，发PDR,Process Control - Electrical Test
32、,要点 ：开路，短路，极性，高压不良，绝缘电阻抽样数量：首件检查（FA) - Every beginning of shift and model change; 定期抽样检查- 2 hourly dummy test 生产部100全检 标准：无开路，短路，极性错， 2.5 KV内高压，4.2 KV外高压设备：试电机行动：停止生产，发PDR,要点： 英国Clare公司出品 所检测项目完全符合英国ASTA认证标准检测项目： 导通，绝缘电阻，内高压，外高压，地线大电流（三芯线）自动打: “T “ mark,8. Test Request (测试要求),Mains Plug ( 插头):-Dimen
33、sions & marking (including rating) (尺寸和印字)-Protection against Electric Shock ( 电性能测试)-Tumbling test/pin pull force test ( 滚桶/端子拉力测试)-Construction ( 结构性检查)-Ageing/Ball pressure test (老化/球压测试)-Moisture resistance (潮湿测试)-Insulation resistance & Electric strength (Di-electric) ( 绝缘电阻/高压测试)-Temperature r
34、ise (温升测试)-Flexible/cord anchorge test ( 摇摆/锚锭测试)-Mechanical strength/pressure test (机械强度/压力测试)-Glow wire test (灼热丝测试)-Resistance to heat to fire and to tracking (抗热测试) -Additional tests on pins provided with insulating sleeves ( 带绝缘材料端子的附加测试),Appliance Connectors (尾插):-Dimensions & marking (includi
35、ng rating) (尺寸和印字)-Protection against Electric Shock( 电性能测试)-Terminals (端子检查)-Construction( 结构性检查)-Ageing (老化测试)-Moisture resistance(潮湿测试)-Insulation resistance & Electric strength (Di-electric) ( 绝缘电阻/高压测试)-Operation of contacts ( 接触性检查)-Forces necessary to insert & to withdraw the connector (吊磅测试)
36、-Breaking capacity (破坏性测试)-Temperature rise (温升测试)-Cords and their connection -Mechanical strength(机械强度测试)-Resistance to heat & ageing (抗热/抗老化测试)-Resistance of insulating material to heat, fire and tracking ( 绝缘材料防火,防追踪测试),Electrical Tests Requirement ( 电性能测试要求 ):Part of manufacturing process must b
37、e conducted 100% ( 制造过程中100%测试 )May only be exempted if manufacturing process and design of products can ensure compliance. ( 在设计或制造过程中可以确认能够达到目的不要测试 )This must be verified by agencies audit. ( 必须通过代理行的确认 )Parameters(参数)-Polarity (极性)-Open circuit (断路)-Di-electric strength between current-carrying c
38、onnections(內高压) - 1250V for at least 1 second for UL & Japan - 2000V for at least 1 second for the rest -Insulation resistance( only ASTA no less than 5 M Ohm)(绝缘电阻) -High voltage between current-carrying connection and earth and also between current-carrying connections and exterior surface(外高压) -2000V for at least 1 second for IEC & Europe -4200V for at least 1 second for ASTA(UK)Volex uses the most stringent parameters on all our cords,
