Connection Systems Training

Connector Application 101

CTIS # 29960 Prepared By John Yurtin Updated 1-20-2005
1

Excellence
Focus: Your customer

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

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.
2

Agenda
Connector Application Drivers

Application Checklist
Component Design Request Advice Tools To Use

Connector Application Drivers

Physical Issues Location / Environment

System

Customer Preference

Standards

Assembly Electrical
4

Regional Preferences

System Drivers
Body Systems

Chassis Systems
Powertrain Systems Convenience Systems Entertainment Systems Safety & Security Systems Comfort Systems Driver Information Systems High Power Systems

System

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

Electrical Drivers
Current requirements
High Current, Low Current, Signal Level Drives terminal type / contact size / plating (0.64mm 8.0mm pins / blades) Steady State, Cyclic, Intermittent

Electrical

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.

Location /Environmental Drivers

Temperature
Under-hood - Sealed, >105oC ambient, vibration, fluid compatibility Passenger Compartment - Unsealed, <85oC ambient, package size critical

Location / Environment

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.
7

Standards Drivers
Standards
Customer Standards Organizational Standards National Standards International Standards

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 OEMs usually have their own requirements (similar to USCAR) Trend: Device supplier responsible for mating connector performance Device = 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.
8

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)

Customer Preferences

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.

Regional Drivers
North America
USCAR footprints / performance / design criteria Tangless terminals, TPAs, CPA provisions Wiring harness supplier has significant influence in many instance

Regional Preferences

Europe
Terminal contact design influenced / co-developed by major OEMs. Two piece terminals preferred, although cost pressures and N.A. transplant business forcing OEMs 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.
10

System Drivers
Size
Number of Circuits Location for mating In-Line or Device Connection

Physical Issues

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.
11

Assembly Drivers
Wire-to-connector insertion force Audible, tactile, visual operator feedback

Assembly

Ergonomics
High speed manual operation Provisions to assure quality / reliability
Accommodate on-line testing / ring-out procedures TPAs, CPAs 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.
12

Application Checklist

This information is not only important but is required when filling out the Request For Design
13

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?
14

Customer Checklist
Volume
What quantity of SLAs / 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?

15

Component Design Request

/ Advice

16

Component Design Request / Advice

The Component Design Request Form (CDR) drives all new component activity. This needs to be submitted for new designs.
Some CDRs get rejected for business case, product line reasons. Dont 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.

17

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.

18

Tools Available To Help You Choose The Right Connection

19

Connection Systems Portfolio

Delphi Connection Systems Portfolio
The Connection Systems Portfolio places Delphis 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.

Develop
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 Micro 64

Introduce and Grow

Connector Families 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 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 Doors-Off Connectors Connections To Glass Flex Circuit Connectors Shock & Strut Connectors Maxi-Fuse Connectors Airbag (Squib) Conns. Individual Cable Seals 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

Maintain
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) Pack-Con I Pack Con II

Exit
Connector Families

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

Connector Types IDC (1mm and smaller) 42V Connectors High Current Pin & Sleeve High Current Flat Blade RF Connectors

The Connection Systems Portfolio in the Toolbox is a good start. It classifies connections by product strategies and contains all our connection offering.
20

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

21

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 Customers 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.

22