Connection Systems

USCAR and Delphi’s USCAR and Delphi’s USCAR USCAR Compliant Compliant

Connection Connection Systems Systems

Presented by :Presented by : John Yurtin John Yurtin

May, 2002May, 2002

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Connection Systems

• The USCAR / EWCAP Organizations

• USCAR/EWCAP Objectives

• USCAR Compliance Requirements

• Delphi’s USCAR Compliant Connections

• Delphi’s Continuing Commitment to USCAR

Agenda

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Connection Systems

What Is USCAR ?

The United States Council for Automotive Research

(USCAR) is an organization formed by DaimlerChrysler, Ford, and

General Motors to strengthen the technology base

of the domestic auto industry through cooperative

pre-competitive research. Located in Southfield, Michigan.

http://www.uscar.org/

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Connection Systems

WHAT IS EWCAP?

ELECTRICAL WIRING COMPONENT APPLICATION PARTNERSHIP

Mission:• Facilitate and encourage cooperative research and development

including sharing of technologies and resources to develop common electrical connection systems and standard electrical components (e.g., motors, relays, and switches)

Staff:• Four full-time engineers, representing Ford, GM and

DaimlerChrysler, located in Southfield, MI

• http://www.uscarteams.org/

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Connection Systems

USCAR/EWCAP OBJECTIVES

1. Develop common electrical connector specifications

2. Establish a standard “footprint” for electrical connections

3. Reduce the number of different connectors on a vehicle by using common device connection footprints

4. Establish and Catalog common families of “Best-in-Class” connection systems

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Connection Systems

USCAR/EWCAP OBJECTIVES

1. Develop common electrical connector specifications

SAE/USCAR-2: Performance Standard for Automotive Electrical Connector Systems SAE/USCAR-3: Standard for Testing Automotive Miniature Bulbs SAE/USCAR-4: Standard for Cigar Lighters and Power Outlets SAE/USCAR-12: Wiring Component Design Guidelines

SAE/USCAR-13: Standard for In-Tank Electric Fuel Pumps

SAE/USCAR-17: Specification for Automotive RF Connector Systems

SAE/USCAR-18: FAKRA SMB RF Connector Supplement

SAE/USCAR-20: Field Correlated Life Test

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Connection Systems

• Centerline Spacing

• Mating Shroud Dimensions

• Lock Feature Detail

• Index Feature Detail

2. Establish a standard “footprint” for electrical connections

USCAR/EWCAP OBJECTIVES

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Connection Systems

USCAR/EWCAP OBJECTIVES

• Cigar Lighter• Fuel Injector Conn.• Oil Press Switch• Light Bulb Housing• Power Seat Motors• ABS Controller Connection• Mirror Connection• Batteries

• Windshield Wiper Motors

• Power Outlet Connection

• Trailer Connectors

• A/C Pressure Switch

• Air Bag Initiator Conn.

• Horn Connector

• O2 Sensor Conn.

• Fan Motors

3. Reduce the number of different connectors on a vehicle by using common device connection footprints

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Connection Systems

USCAR/EWCAP OBJECTIVES

4. Establish and Catalog common families of “Best-in-Class” connection systems

0.64 mm Sealed Systems

0.64 mm Unsealed Systems

1.5 mm Sealed Systems

1.5 mm Unsealed Systems

2.8 mm Sealed Systems

2.8 mm Unsealed Systems

6.3 mm Sealed Systems

Hybrid Systems

Example of listing of 0.64mm unsealed systems from the USCAR website

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Connection Systems

What Is USCAR Compliance?

A Device connection that meets the dimensional requirements (footprint) specified by USCAR, and…

A Harness connection that mates to a device which meets USCAR dimensional requirements and…..

When mated, a Connection System that meets the performance requirements of the SAE/USCAR 2 specification and…

A connection system that conforms to SAE/USCAR-12 Wiring Component Design Guidelines…

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USCAR Compliant Connections

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USCAR Compliant Connections

Off Shelf Device Connections USCAR Specific Device

Connectors

0.64mm USCAR Header Connections 3.5 mm Slim-Line

Connections

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Connection Systems

These connections meet all USCAR design and performance requirements.

USCAR Compliant “Off Shelf”Device Connections

2 Way 1.5 mm SealedIndex A

Knock Sensor

2 Way 1.5 mm SealedIndex B

Crank Sensor

3 Way 1.5 mm SealedIndex C (Gray)

3 Way 1.5 mm SealedIndex B ( Dk Gray)

5 Way Sealed 1.5 mm Index A (Gray)

5 Way Sealed 1.5 mm Index B (Black)

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Connection Systems

USCAR Compliant Specific Device Connections

30 Way SealedABS Connector

7 Way Sealed Trailer Tow Connector

2 Way Sealed Fuel Injector, Horn & Underhood Lamp Connector

3 Way Unsealed Cigar Lighter/Power Outlet Connectors

These connections meet all USCAR design and performance requirements.

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Connection Systems

• Mates to USCAR standard 3.5mm footprint

• Smaller package size

• Mates to existing devices tooled for “pull-to-seat” connections

• Uses same terminal design as the 4.5mm USCAR connectors

• Meets SAE/USCAR-2 performance requirements with exception of Immersion after High Temp Exposure ( meets immersion after High temp exposure of ESA 710 Metri-Pack spec and ISO-8092).

•Available “off-shelf” in 2 thru 6 way configurations

3.5 mm Slim-Line Connections

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Connection Systems

Delphi’s Continuing Commitment

• Delphi will continue support of USCAR/EWCAP activities, and harmonization with ISO standards

• New connectors will be designed and tested to USCAR requirements.

• Connectors with footprints not yet specified by USCAR will also meet USCAR performance and guidelines.

• With a customer commitment, we will quickly tool any design or index as requested.

• Delphi is also committed to meeting the USCAR-20 Field Correlated Life Test (Key Life) requirements.

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Connection Systems

Delphi USCAR Connections Systems

FunctionalityDelphi USCAR connections are…

…connections that meet USCAR dimensions and…

…harness connections that mate to USCAR devices, and

…when mated, meet the performance of SAE/USCAR-2, and

…conform to SAE/USCAR-12 guidelines.

BenefitsDelphi has all current USCAR connections available and has the largest portfolio of USCAR standard connections of any supplier.

LeadershipDelphi has actively participated in the Electrical Wiring Component Applications Partnership (EWCAP) since its formation in 1984.

CommitmentDelphi is committed to providing connections that meet all USCAR requirements.

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