Principles of automotive connector selection

(1) Electrical Factors Current requirements: high current, low current, signal grade; determines type of terminal/size of contact section/plating (0.64mm to 8.0mm pin and male terminals); steady state, cyclic, transient, wire gauge/insulation requirements: voltage drop and/or corrosion resistance; determines connector center distance. (2) Location/Environment Temperature: Engine compartment - sealed, ambient temperature >105oC, vibration, fluid compatibility; Passenger compartment - unsealed, ambient temperature < 85oC, mainly size factors are more important.　　Sealing: potential high pressure spray/splash; potential submersion; humidity; fluid type; for equipment connectors, whether the equipment is sealed or not. (3) Standards Standards: customer standards; institutional standards; domestic standards; international standards.　　Connector performance testing requirements: included in the system-level specifications; for GM, Ford and Chrysler is usually the USCAR specification "engine-related applications have higher vibration requirements; other OEMs generally have their own standards (similar to the USCAR); Trend: equipment-side suppliers for the mating end of the connector performance responsibility "Equipment makes up half of the connector interface for board fitting" Equipment suppliers are required to have good communication of information about the mating end. (4) Customer Preferences Terminal Type Design Characteristics Preferred Product Strategy: Purchasing-driven - need to reduce cost of connector system; determined by design competition; Specific Applications: Ford-Gate Connector Design Competition; Ford: Preferred Terminal Design/Supplier (focus on contact interface); GM: Preferred Terminal Design (focus on connector holes); Chrysler: preferred terminal/plastic supplier strategy. (5) Regional Preferences North America: USCAR drawings/performance/design standards "Tangless terminals, TPA's, CPA regulations; in many instances, the harness supplier has a significant influence.　　Europe: Design of terminal contacts is very influential/developed with major OEMs; preference for two-piece terminals, even though cost pressures and North American transplant operations are forcing OEMs to consider North American technology; acceptance of Tangled terminals." Cloning" very common; long term relationships between OEMs and suppliers.　　Asia: traditionally influenced by Toyota. Long term relationships with YAZAKI and SUMITOMO; key to good quality and trusted relationships; strong focus on fitment capabilities (ergonomics) that affect warranty; North American influence on China to change the status quo. Low cost solutions are the focus. (6) Physical Factors Size; number of circuits; location of mating; harness docking or equipment connection; mechanical mainstay features: levers, bolts; hand docking capabilities; multiple types of connectors for high input/output applications; drawing requirements. (7) Assembly Harness: Connector insertion force visible, audible, and tactile operator feedback ergonomics high speed manual handling quality and performance reliably assured; in-line testing/after-hours processes practiced; TPA's, CPA's; repairability; reduction in the number of loose parts (staged preferences).

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