conn app 101

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8/12/2019 Conn App 101


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Giving the customer the right connection for the application

will result in a stronger relationship leading to morebusiness. 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 itright 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

StandardsCustomer

Preference

Assembly

Physical

Issues

Electrical

Location /

Environment

Regional

Preferences

Connector Application Drivers

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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 smallestapplication)

“The electrical requirement is extremely important and often notwell understood even by the customer.”

Electrical

Electrical Drivers

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8/12/2019 Conn App 101


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 anyspecif ic requ irements the customer has. In most cases our test ing 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.”

CustomerPreferences

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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 businessforcing 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 focuson 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 aninfluence 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? Arethere obstruc t ions? Is i t a bl ind 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 whenfilling 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 PurchaseOrder 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 leadtimes)

– 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 familyof 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

Modify the CDR Form when program requirements warrant. (Timingchanges, 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 representingDelphi Connection Systems to the customer and you are representing the

customer to Delphi Connection Systems.

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Tools Available To Help You ChooseThe 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 SensorConnectors.

Lamp SocketsRemote 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


Dock-n-Lock Connectors

Connector Families

ZRT Zero Resistance Term

Micro 050 Series

1.5 & 2.8mm CTS Term.

2.8 & 6.3 PCB T erminals

1.5 & 2.8 ETS T erminals

0.64 MTSB Terminal

GT 100

High Value Connection


Multi Drop Connectors

Smart Connectors

Connector Types

IDC (1mm and smaller)

42V Connectors

High Current Pin & SleeveHigh 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 categoryhas a specific strategy and objective which should be understood. Detailed strategies, objectives andtechnical 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 regionalrecommendations

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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 ou r latestprodu cts. Our websi tes are fu l l of informat ion and somet imes

we just have to go searching. We also know what ourmainstream produc ts are and should be prepared to propo selatest products wherever possible.”

conn app 101

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