03 – Test Plan and Sample Matrix per OCP UQD Specification v2.0.0¶
Source: OCP Design Specification Universal Quick Disconnect (UQD) v2.0.0, §9–§10 and §15.3. Parameters: see 02-Parameters.md. Products: UQD02, UQD04, UQD06, UQD08 (handmate) · UQDB02, UQDB04, UQDB06, UQDB08 (blindmate)
1. Basic rules¶
| Rule | Requirement | Ref |
|---|---|---|
| Samples per test and configuration | n = 5 (minimum) | §9, ISO 18869 |
| Samples per test in cross-verification | n = 3 (minimum) | §10 |
| QD Property Tests (9.1.x) | May run in parallel; separate samples per test | §9 |
| Thermal/Mechanical Tests (9.2.x) | Run in sequence on the same samples | §9 |
| Instruments | Accuracy per ISO 18869:2017 §6.3 | §9 |
| Helium leak test | ASTM E493 | §9 |
| Report | Supplier Verification Report (§15.3.1) + test templates (§15.3.3) | §9, §15.3 |
Terms - Plug = male half, Socket = female half, Pair = plug + socket of the same size and type. - Mated = fully coupled pair. Unmated = individual plug or socket, with closed valve. - Hybrid = UQD plug coupled to a UQDB socket (blindmate). See section 6.
2. Test overview¶
| # | Test | Group | Configurations | n | Destructive |
|---|---|---|---|---|---|
| 9.1.1 | Burst Pressure | Property | UQD: plug, socket, mated · UQDB: plug, socket | 5 per config. | Yes |
| 9.1.2 | Fluid Loss | Property | Pair | 5 | No |
| 9.1.3 | Force to Connect | Property | Pair (UQDB with SA offset) | 5 | No |
| 9.1.4 | Pressure Drop | Property | Pair, both flow directions | 5 | No |
| 9.1.5 | Seal Washout | Property | Pair, both flow directions | 5 | Possibly |
| 9.2.1 | Non-Op temperature cycling | Sequence | Mated + unmated plug/socket | 5 per config. | No |
| 9.2.2 | Op temperature cycling | Sequence | Mated + unmated plug/socket | 5 per config. | No |
| 9.2.4 | Hydrostatic test (after 9.2.2) | Sequence | Same as 9.2.2 | 5 per config. | No |
| 9.2.3 | Mechanical cycling (5000 cycles) | Sequence | Pair | 5 | No |
| 9.2.4 | Hydrostatic test (after 9.2.3) | Sequence | Plug, socket (unmated) and pair | 5 per config. | No |
| 10 | Cross-verification | Separate | Against ≥ 3 other suppliers | 3 per test | – |
3. Pre-check of all samples (before test)¶
Recommended for every sample before it is assigned to a test:
| Check | Criterion | Ref |
|---|---|---|
| Identity/marking | UQDxx v2 / UQDBxx v2 visible when unmated; red/blue colour marking on handmate |
§11 |
| Critical dimensions | Sealing surfaces B/H, C, L, latch geometry (UQD), SA (UQDB) per 02-Parameters §5 | §7 |
| Surface finish of sealing surface | ≤ 32 Ra | §7 |
| Visual inspection | Per Table 10 (zones 1–7) | §15.2 |
| Threads | Thread gauge per Table 5 | §15.2 |
| Termination assembly | Torque per Table 5 | §7.5 |
Each sample gets a unique ID, for example UQD04-P-07 (P = plug, S = socket) and pair UQD04-PR-03.
4. Tests per product¶
The same test matrix applies to all four sizes within each type. Size-dependent values (flows, forces, acceptance limits) are in 02-Parameters.
4.1 UQD02 · UQD04 · UQD06 · UQD08 (handmate)¶
A. QD Property Tests (separate samples per test)¶
| Test ID | Test | Configuration | Samples | Measurements / runs |
|---|---|---|---|---|
| A1 | 9.1.1 Burst | Plug, unmated | 5 plugs | 5 burst pressures |
| A2 | 9.1.1 Burst | Socket, unmated | 5 sockets | 5 burst pressures |
| A3 | 9.1.1 Burst | Mated | 5 pairs | 5 burst pressures |
| A4 | 9.1.2 Fluid Loss | Pair, water | 5 pairs | Fluid loss per cycle per pair |
| A5 | 9.1.3 Force to Connect | Pair, aligned, 0 / 2.76 / 6.89 bar(g) | 5 pairs | 3 pressures × 5 rep. × 5 pairs = 75 |
| A6 | 9.1.4 Pressure Drop | Pair, S→P and P→S, ≥ 6 flows | 5 pairs | 6 × 2 × 5 = 60 points + tare |
| A7 | 9.1.5 Seal Washout | Pair, 2 × rated flow, 60 °C, 6.9 bar(g) | 5 pairs | 20 cycles × 2 directions × 5 pairs = 200 |
B. Thermal / Mechanical sequence (same samples all the way)¶
Population: 5 pairs (tested mated) + 5 plugs and 5 sockets (tested unmated).
| Step | Test | Mated (5 pairs) | Unmated (5 plugs + 5 sockets) |
|---|---|---|---|
| B1 | Helium leak test (optional) | ✓ | ✓ |
| B2 | 9.2.1 Non-Op temp. cycling, air 28–30 psi(g), −40/+70 °C | ✓ | ✓ |
| B3 | Helium leak test (optional) | ✓ | ✓ |
| B4 | 9.2.2 Op temp. cycling, 6.9 bar(g), +5/+65 °C, nominal engagement | ✓ | ✓ |
| B5 | 9.2.4 Hydrostatic test, 6.9 bar(g), ≥ 3 min | ✓ | ✓ |
| B6 | 9.2.3 Mechanical cycling, 5000 cycles, 2.75 bar(g), latch engaged every cycle | ✓ (pairs) | – |
| B7 | 9.2.4 Hydrostatic test: unmated plug + socket and mated | ✓ | – |
4.2 UQDB02 · UQDB04 · UQDB06 · UQDB08 (blindmate)¶
Differences from UQD: burst is not tested mated; force and cycling tests are run with radial offset SA; couplings are tested at hard-stop.
A. QD Property Tests¶
| Test ID | Test | Configuration | Samples | Measurements / runs |
|---|---|---|---|---|
| A1 | 9.1.1 Burst | Plug, unmated | 5 plugs | 5 burst pressures |
| A2 | 9.1.1 Burst | Socket, unmated | 5 sockets | 5 burst pressures |
| A4 | 9.1.2 Fluid Loss | Pair, water | 5 pairs | Fluid loss per cycle per pair |
| A5 | 9.1.3 Force to Connect | Pair, max SA offset (reset every cycle), 0 / 2.76 / 6.89 bar(g) | 5 pairs | 75 measurements, limit per 02-Parameters §2.1 |
| A6 | 9.1.4 Pressure Drop | Pair, hard-stop, S→P and P→S | 5 pairs | 60 points + tare |
| A7 | 9.1.5 Seal Washout | Pair | 5 pairs | 200 cycles in total |
B. Thermal / Mechanical sequence¶
| Step | Test | Mated (5 pairs) | Unmated (5 plugs + 5 sockets) |
|---|---|---|---|
| B1 | Helium leak test (optional) | ✓ | ✓ |
| B2 | 9.2.1 Non-Op temp. cycling, hard-stop | ✓ | ✓ |
| B3 | Helium leak test (optional) | ✓ | ✓ |
| B4 | 9.2.2 Op temp. cycling, nominal engagement | ✓ | ✓ |
| B5 | 9.2.4 Hydrostatic test | ✓ | ✓ |
| B6 | 9.2.3 Mechanical cycling, 5000 cycles with SA offset | ✓ (pairs) | – |
| B7 | 9.2.4 Hydrostatic test: unmated plug + socket and mated | ✓ | – |
5. Sample needs (number of components)¶
Calculated with separate samples for each 9.1 test, since the specification allows parallel runs on different samples. Non-destructive tests (9.1.2–9.1.4) can reuse the same pairs if time allows. This reduces the need by up to 10 pairs per product, but should be documented in the report.
5.1 Per product¶
| Test group | UQD plug | UQD socket | UQDB plug | UQDB socket |
|---|---|---|---|---|
| 9.1.1 Burst – unmated | 5 | 5 | 5 | 5 |
| 9.1.1 Burst – mated | 5 | 5 | – | – |
| 9.1.2 Fluid Loss | 5 | 5 | 5 | 5 |
| 9.1.3 Force to Connect | 5 | 5 | 5 | 5 |
| 9.1.4 Pressure Drop | 5 | 5 | 5 | 5 |
| 9.1.5 Seal Washout | 5 | 5 | 5 | 5 |
| 9.2 sequence – pairs | 5 | 5 | 5 | 5 |
| 9.2 sequence – unmated | 5 | 5 | 5 | 5 |
| Total per size | 40 | 40 | 35 | 35 |
5.2 Total (own verification)¶
| Product | Plug | Socket | Total |
|---|---|---|---|
| UQD02 | 40 | 40 | 80 |
| UQD04 | 40 | 40 | 80 |
| UQD06 | 40 | 40 | 80 |
| UQD08 | 40 | 40 | 80 |
| UQDB02 | 35 | 35 | 70 |
| UQDB04 | 35 | 35 | 70 |
| UQDB06 | 35 | 35 | 70 |
| UQDB08 | 35 | 35 | 70 |
| Total | 300 | 300 | 600 |
Recommendation: order about 10 % spare per size for fixture run-in and retests.
6. Hybrid configuration (UQD plug + UQDB socket)¶
The specification mentions hybrid in 9.1.4 (hard-stop), 9.2.2 and 9.2.3 and in the mated lengths (Figure 4). If hybrid compatibility is marketed, add the following per size (02–08):
| Test | Samples |
|---|---|
| 9.1.4 Pressure Drop (hard-stop) | 5 pairs |
| 9.2.2 Op temp. cycling → 9.2.4 | 5 pairs |
| 9.2.3 Mechanical cycling (on-axis, compliance in the fixture) → 9.2.4 | same 5 pairs |
This gives 10 UQD plugs + 10 UQDB sockets per size. If 9.2.2 and 9.2.3 are run in series on the same pairs, 5 + 5 is enough.
Decision required: is hybrid to be included in the verification?
7. Cross-verification (§10)¶
Performed against at least 3 other UQD suppliers and in both directions: our plug against their socket, and their plug against our socket.
| Test | n per combination |
|---|---|
| 9.1.2 Fluid Loss | 3 |
| 9.1.3 Force to Connect | 3 |
| 9.1.4 Pressure Drop | 3 |
| 9.1.5 Seal Washout | 3 |
Sample need per product and supplier (separate samples per test): 4 tests × 3 = 12 own plugs and 12 own sockets, plus the corresponding parts from the other supplier. Per product with 3 suppliers: 36 plugs + 36 sockets. That is 576 components in total for the 8 products, fewer if non-destructive tests share samples.
Reported with the Supplier Cross-Verification Report (§15.3.2). The list of suppliers with approved cross-verification is to be published.
8. Test log / run order (checklist per product)¶
Copy the block below per product and tick off.
Product: ______ Batch/date of manufacture (T0): ______
[ ] Pre-check (dimensions, visual, marking) – all samples
[ ] A1 9.1.1 Burst plug (5)
[ ] A2 9.1.1 Burst socket (5)
[ ] A3 9.1.1 Burst mated (5) – UQD only
[ ] A4 9.1.2 Fluid Loss (5 pairs)
[ ] A5 9.1.3 Force to Connect 0 bar (5 pairs × 5 rep.)
[ ] A5 9.1.3 Force to Connect 2.76 bar (5 pairs × 5 rep.)
[ ] A5 9.1.3 Force to Connect 6.89 bar (5 pairs × 5 rep.)
[ ] A6 9.1.4 Tare measurement
[ ] A6 9.1.4 Pressure Drop S→P (5 pairs × ≥6 flows)
[ ] A6 9.1.4 Pressure Drop P→S (5 pairs × ≥6 flows)
[ ] A7 9.1.5 Seal Washout P→S (5 pairs × 20)
[ ] A7 9.1.5 Seal Washout S→P (5 pairs × 20)
[ ] B1 Helium (optional)
[ ] B2 9.2.1 Non-Op temp. cycling (−40 °C 72 h / +70 °C 72 h)
[ ] B3 Helium (optional)
[ ] B4 9.2.2 Op temp. cycling (+5 °C 72 h / +65 °C 72 h)
[ ] B5 9.2.4 Hydrostatic test
[ ] B6 9.2.3 Mechanical cycling 5000 cycles
[ ] B7 9.2.4 Hydrostatic test
[ ] Supplier Verification Report completed
Time estimate for sequence B (per batch)¶
| Step | Minimum time |
|---|---|
| 9.2.1 | 72 h + 72 h + ramps (~1 h) ≈ 6.2 days |
| 9.2.2 | 72 h + 72 h + ramps ≈ 6.2 days |
| 9.2.3 | 5000 cycles; at ~3 s/cycle ≈ 4–5 h per pair and fixture |
| 9.2.4 (×2) | ≥ 3 min + preparation |
The climate chambers determine the lead time. Run several sizes at the same time in the same chamber cycle if the fixtures allow, since all sizes have the same temperature profile.
9. Open decisions before test start¶
- Proof pressure for 9.1.1 – value missing in the specification, which affects the max test pressure.
- Hybrid – should it be included (section 6)?
- Reuse of samples between non-destructive 9.1 tests – yes/no (affects section 5).
- Test medium for 9.1.5, 9.2.2–9.2.4: water or PG25.
- Population for 9.2 – one common population in series, or two separate (mated and unmated). The specification allows both; the plan above uses two.
- Cross-verification partners – which 3 suppliers?