By John Zuppo
Two trends are being seen in connection systems for the automotive industry — one is the need for smaller electronic connections and the other is the need for high-power connections. A connection system has been engineered to meet the power demands for 12/42 V power systems for commercial vehicles, the increasing use of electric and gas/electric hybrid vehicles, and the additional requirements of the telecommunications and data communications and industrial markets. The system's design flexibility offers a method of providing reliable connections that meet the high-power electrical and environmental demands of diverse commercial vehicles. Its high-power performance also makes it a candidate for electric and hybrid vehicle propulsion systems.
Terminal Design
The heart of the connection system is its terminals or contacts. The key to carrying high current is to keep the total crimp-to-crimp resistance as low as possible. To do this requires a low bulk resistance of the terminal, a stable contact interface resistance and a good crimp. The terminal is made of a preplated (silver over nickel), high-conductivity copper alloy. This high-conductivity material is important for reducing the bulk resistance.
 Figure 1. The two-piece design of the terminal. |
null
The terminal has a two-piece design that assures a constant contact normal force in the interface area while minimizing the mating force of the connection (see Figure 1). A silver-plated beryllium copper insert provides the contact normal force. The insert has uniquely designed "vanes" that also allow for low insertion force and exceptional vibration resistance (see Figure 2). These vanes provide contact force by the torsion action of their design. Unlike typical cantilever beam action, each vane twists slightly as the terminals are mated, which provides the contact normal force.
The system connection is based on a hermaphrodite base terminal design. The terminal mates to a like part that does not have an insert or to a blade-style terminal. This versatility allows the system to be easily applied to wire-to-wire connections as well as wire-to-device connections.
The terminals come in two basic sizes, a 14.50 ¥ 1.63 mm blade-style terminal with a current-carrying capability up to 150 A and a 17.70 ¥ 1.63 mm blade-style terminal with a current-carrying capability up to 200 A. These terminals are designed with crimp wings to accept 13 to 35 mm2 cable and 13 to 62 mm2 cable. In addition, the crimps are designed for crimp-only application without the need for soldering.
One-and Two-way Connections
Because of the terminal design, the connections (one- and two-way) can be engaged and disengaged by hand without special tools or mechanical assists, which meets the requirements of automotive assembly. Mechanical assists are recommended for connections greater than two-way.
The two-way connection, designed for hybrid trucks and all-electric vehicles, is a right-angle design that uses individual cable seals to seal the wire entry and two individual connector seals to seal the connector to the connector interface. The connector sealing assures each terminal cavity is sealed individually. This helps protect the terminal contact areas from debris, helps prevent shorting between terminals and helps provide protection from arcing.
 Figure 2. The insert has "vanes" that provide contact force. |
null
The connector has a positive-lock feature and a connector position assurance (CPA) feature to assure proper connection integrity. The connector also has a terminal position assurance (TPA) feature to assure proper terminal seating and retention.
The one-way connection is designed for in-line (wire-to-wire) as well as device applications. It has multiple mating options including straight or right-angle. One of the unique features of the terminal is that it can easily be modified for straight or right-angle mating by changing the insert. This connection also has the sealing, positive-lock and CPA and TPA features.
Testing
The connection system's ability to meet automotive requirements is strengthened by its passing of extensive testing, including Society of Automotive Engineers (SAE), United States Council for Automotive Research (USCAR) and International Standards Organization standards. The first high-volume application is in vehicles so the connection system must meet the tough electrical, environmental and mechanical performance requirements of SAE/USCAR-2, Class 4. These requirements are the latest thinking in automotive performance goals.
Several manufacturing programs will use the connection system, including a 2004 hybrid truck using a hybrid power train and an all-electric vehicle. In these applications, the connections will be used for 14 to 120 V at a continuous operating current of up to 150 A. The system can also be used in both engine and passenger compartment locations.
Conclusion
This connection system meets the ever-increasing power demands for commercial vehicles, hybrid vehicles, and telecom/datacom and industrial applications. The terminal design assures a constant contact normal force in the interface area while minimizing the mating force of the connection. Each terminal cavity is sealed individually for protection from debris and arcing and to prevent shorting. The connection system is designed to meet SAE/USCAR-2, Class 4 requirements. The connections are ergonomically friendly and can be engaged and disengaged by hand.
JOHN ZUPPO is Product Manager, Delphi Connection Systems, 408 Dana St., P.O. Box 431, Warren, OH 44486; (330) 505-3205; Fax: (330) 505-3280; E-mail: john.zuppo@delphiauto.com; Web site: www.delphi.com/connect.
SPEC SHEET
End Applications:
Commercial, electric and hybrid vehicles, telecom/datacom, industrial
Related Products:
Automotive, high-power, sealed connectors
Main Point:
This connection system meets the ever-increasing power demands for commercial and hybrid vehicles. The terminal design assures a constant contact normal force in the interface area while minimizing the mating force of the connection. Each terminal cavity is sealed individually for protection from debris and arcing and to prevent shorting.
