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Connector Application 101

CTIS # 29960

Prepared By John Yurtin

Updated 1-20-2005

Connection Systems Training

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Giving the customer the right connection for the application will result in a stronger relationship leading to more business. Understanding the things that drive the decisions of which connection to use is key to proper application.

This training should help you pick the right connection based on an understanding of the “drivers” or things you need to consider when making connector decisions.

Excellence

Focus: Your customer

Performance Goal: Do it right the first time, every time

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Agenda

Connector Application Drivers

Application Checklist

Component Design Request Advice

Tools To Use

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System

StandardsCustomerPreference

Assembly

PhysicalIssues

Electrical

Location /Environment

RegionalPreferences

Connector Application Drivers

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System Drivers

Body Systems

Chassis Systems

Powertrain Systems

Convenience Systems

Entertainment Systems

Safety & Security Systems

Comfort Systems

Driver Information Systems

High Power Systems

“Often, systems use common types of connections, and can direct you to other connections typically used in similar applications.”

System

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Current requirements– High Current, Low Current, Signal Level

– Drives terminal type / contact size / plating (0.64mm – 8.0mm pins / blades)

– Steady State, Cyclic, Intermittent

Cable size / insulation requirements– Addresses voltage drop and / or abrasion resistance concerns

– Drives connector centerline spacing (2.54mm C/L current smallest application)

“The electrical requirement is extremely important and often not well understood even by the customer.”

Electrical

Electrical Drivers

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Temperature– Under-hood - Sealed, >105oC ambient, vibration, fluid

compatibility

– Passenger Compartment - Unsealed, <85oC ambient, package size critical

Sealing– Potential for High Pressure Splash

– Potential for Immersion

– Humidity

– Types of fluids

– For device connections, is the device sealed

“The environment can vary greatly with small changes in location and should be well understood, e.g. not just “engine compartment”.”

Location /Environment

Location /Environmental Drivers

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Standards Drivers

Standards– Customer Standards

– Organizational Standards

– National Standards

– International Standards

Connector performance validation requirements– Buried within the system level specification

– Usually USCAR for GM, Ford, DCX

» On-engine applications have higher vibration requirements

– Other OEM’s usually have their own requirements (similar to USCAR)

– Trend: Device supplier responsible for mating connector performance

» Device = ½ of the connection system interface for panel mount systems

» Device supplier requested to communicate mating connector pricing

“Most of these are very similar, however it is important to understand any specific requirements the customer has. In most cases our testing can be shown to meet the customers requirements.”

Standards

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Customer Drivers

Terminal Types

Design Features

Preferred Product Strategies– Purchasing-driven to reduce connection system costs

– Determined through design competitions

– Application-specific: Ford – Door connector design competition

– Ford: Preferred terminal design / supplier (contact interface focus)

– GM: Preferred terminal design (connector cavity focused)

– DCX: Preferred terminal / plastic supplier strategy

“Customer preferences can often narrow down the potential products we can offer.”

Customer Preferences

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Regional Drivers

North America– USCAR footprints / performance / design criteria

» Tangless terminals, TPA’s, CPA provisions– Wiring harness supplier has significant influence in many instance

Europe– Terminal contact design influenced / co-developed by major OEM’s.

– Two piece terminals preferred, although cost pressures and N.A. transplant business forcing OEM’s to consider N.A. technology.

– Tanged terminals are accepted. “Cloning” is common.– Long-standing OEM / Supplier relationships.

Asia– Traditionally influenced by Toyota. Long-standing relationships with Yazaki and

Sumitomo.

– Proven performance and trusted relationships are key drivers.– Significant focus on assemble-ability (ergonomics), which influences warranty.– N.A. influences in China changing the landscape. Low cost solutions are the premium.

“Surely we should all understand our regional positions and focus on the connections applicable to our regions of operation.”

Regional Preferences

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System Drivers

Size

Number of Circuits

Location for mating

In-Line or Device Connection

Mechanical assist features – Levers, bolts

Hand Mate-able – Multiple connectors for higher I/O applications

Footprint requirements (USCAR)

“The size, location, position and assembly method often hasve an influence on what kind of connection can be used.”

Physical Issues

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Assembly Drivers

Wire-to-connector insertion force

Audible, tactile, visual operator feedback

Ergonomics

High speed manual operation

Provisions to assure quality / reliability – Accommodate on-line testing / ring-out procedures

– TPA’s, CPA’s

– Reparability

– Reduce the number of loose piece parts (staged preferred)

“Does the location of the connector allow one hand mating? Are there obstructions? Is it a blind mate? What about repair? These are all questions that should be asked.”

Assembly

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Application Checklist

“This information is not only important but is required when filling out the Request For Design”

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Customer Checklist Electrical Requirements

– What is the current? (continuous current or cycled current / duty cycle)

Environmental Conditions– Is the connector location considered a sealed or unsealed environment?

– Will the connector be subjected to high pressure spray or unusual fluids?

– What is the ambient temperature in the connector location?

Packaging– Are there space limitations in the vehicle where the connector will be placed? (package

“envelope”)

– Are there known space limitations during the vehicle assembly process?

Timing – Are non-functional samples needed to evaluate packaging? When?

– When are functional prototypes required? What quantity? (Note: We need a Purchase Order generally)

– When are parts off of production tools needed? When is PPAP due?

– When is component – level validation testing due? Is it required?

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Customer Checklist Volume

– What quantity of SLA’s / non-functional samples are required? (Note: There are lead times)

– What quantity of functional prototype samples are required? (Note: There are lead times)

– What is the projected annual production volume and program life (number of years)?

Testing– Is there a specific validation test requirement?

– Is the testing for validation or evaluation purposes?

– For on-engine applications especially, is there a specific engine vibration profile?

– Will the customer accept the validation testing we have already completed for that family of connectors? (USCAR, C-4006, T-1000G, etc.)

Commercial– Will the customer pay for prototype tooling if required?

– Will the customer pay for production tooling?

– Is there a target production piece price?

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Component Design Request

/ Advice

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Component Design Request / Advice

The Component Design Request Form (CDR) drives all new component activity. This needs to be submitted for new designs.

– Some CDR’s get rejected for business case, product line reasons. Don’t take this personally. Keep the new opportunities coming!

The component project engineer is responsible for project management activities unless a program manager is assigned.

Any pre-production sample parts are coordinated through the component project engineer.

The CDR Form should be utilized to communicate additional volume requirements for existing components.

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Component Design Request / Advice

Modify the CDR Form when program requirements warrant. (Timing changes, volume changes, technical requirement changes).

The Application Engineer is responsible to assure that the connection system selection is appropriate for the vehicle application.

Frequent internal design reviews are encouraged. You need to be satisfied with the progress of the design.

Take ownership!! You own the customer interface. You are representing Delphi Connection Systems to the customer and you are representing the customer to Delphi Connection Systems.

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Tools Available To Help You Choose

The Right Connection

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Connector Families

Pack-Con I

Pack Con II

Com Pack I, II, & III

Edge board Connectors (Fork, ECM & Bow Types)

188 Series (4.7mm)

Twin Lock Connectors

ACT Series

ES-Kontakt

0.64mm Buchsenkontakt

Connector Types

Pin Grip Connectors

Application Specific

Battery Terminals

Ignition Connectors

OBD-II Connectors

0.64 Saturn Sensor Connectors.

Lamp Sockets

Remote Battery Posts

Connector Types

IDC (1.5mm and Larger)

Fuse and Relay Holders

Edgeboard Connectors (Pack-Con Types)

Connector Families

Weather-Pack

Metri-Pack

Micro-Pack

Ducon

56 Series

58 Series

59 Series

Ring / Spade Terminals

Micro-Timer

DS Series

VF Series

Modu IV

SF Series

Pack Con III

AF Kontakt

Doors-Off Connectors

Connections To Glass

Flex Circuit Connectors

Shock & Strut Connectors

Maxi-Fuse Connectors

Airbag (Squib) Conns.

Individual Cable Seals

Multiple Cable Seals

Connector Seals

Cavity Plugs

Capillary Action Preventer

Remote Battery Conns.

USCAR Connectors

Connector Types

Fiber Optic Connectors

Splice Savers

High Current Pin & Sleeve

HC QuickMate Clip

Lever-Lock Connectors

Connector Families

Micro 64

GT Connectors

Slim Line Connectors

Gold Dot Connectors

800 Maxi Connectors

DHD Heavy Duty Conns.

ATS Terminal

MTS 064 Terminal

187 Series

DSQ Terminal

2.8 BTS Terminal

090 II Series

070 Series

040 III Series

250 Series

W Series Connectors

Power-Pack Connectors

Mixed Family Connectors

Application Specific

Dock-n-Lock Connectors

Connector Families

ZRT Zero Resistance Term

Micro 050 Series

1.5 & 2.8mm CTS Term.

2.8 & 6.3 PCB Terminals

1.5 & 2.8 ETS Terminals

0.64 MTSB Terminal

GT 100

High Value Connection

Application Specific

Multi Drop Connectors

Smart Connectors

Connector Types

IDC (1mm and smaller)

42V Connectors

High Current Pin & Sleeve

High Current Flat Blade

RF Connectors

Develop Introduce and Grow Maintain Exit

Delphi Connection Systems PortfolioThe Connection Systems Portfolio places Delphi’s connection systems into categories. Each category has a specific strategy and objective which should be understood. Detailed strategies, objectives and technical information is available in the Connection Systems Toolbox on the Delphi intranet.

“The Connection Systems Portfolio in the Toolbox is a good start. It classifies connections by product strategies and contains all our connection offering.”

Connection Systems Portfolio

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Connection Systems On-Line Catalog

http://delphi.com/products/connect/

Search Capability allows a search by:– Number of cavities

– Color

– Terminal size

– Sealed /unsealed

– Blade size

– Current carrying capacity

– Etc.

You can search for competitor replacements or clones

You can search by specific applications e.g. Doors-Off Connections

Each Connection has a description with some regional recommendations

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Other Resources

Product Line Engineers– Should know what new products are available

Product Managers– Understand the priorities and strategies of the products within their control

Customer Management– Should know the Customer’s preferences and special requirements.

“ Of course, most important is to keep up-to-date on our latest products. Our websites are full of information and sometimes we just have to go searching. We also know what our mainstream products are and should be prepared to propose latest products wherever possible.”