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Design principles for selecting automotive connectors

2022-12-17 16:33:36
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Design principles for selecting automotive connectors

The plug-in is the main component of the wiring harness, and its performance has a significant impact on the safety and reliability of the wiring harness. The design principles for plugin selection are as follows:

1. The connector prioritizes the use of a double spring compression structure. Use a protective sleeve with secondary lock to prevent terminal displacement; The sheath must be locked tightly; The sheath must have a locking structure that can be easily installed, and noise can be clearly felt and heard when installed in place.

2. Select the connector based on the wire cross-section and overcurrent size. The current of connectors with different specifications is generally as follows: 1 series, about 10A; 2.2 or 3 series, around 20A; 4.8 series, around 30A; 6.3 series, around 45A; 7.8 or 9.5 series, around 60A.


3. In the wet area, choose a waterproof sheath for docking. Sealing is to prevent water or contamination. The socket is located in a harsh or humid environment. If there may be water or corrosive liquids, a sealing sheath should be chosen. The harsh environment includes the front cabin, wheelhouse, chassis, doors, etc. Users must use sealing sheaths in areas that are easily exposed during use, such as cup holders, instruments, etc. Sealing sheath must be used in places not polluted by liquid. For example, the sheath and terminal of the side airbag may be affected by the seat foam, resulting in the loss of meaning of the gold-plated terminal. Drivers and passengers should choose to place the sealing sheath in the adhesive, as these areas will pay attention to excessive moisture and salt.

4. Adjacent sheaths on the same wire harness should be marked or colored to prevent errors.

5. Priority should be given to hybrid components for docking sheaths. Considering the possibility of increasing circuit requirements in the future, in order to ensure the possibility of increasing circuits in the future, the plug-in must reserve hole positions. If not considered, it is possible to choose a larger sheath or add a pair of sheaths in the future, which will lead to difficulties in installation and fixation. When selecting the connection between the harness end sheath and the electrical sheath, the harness end should choose the female sheath, and the electrical end should choose the public sheath. During the wiring harness assembly process, if a common terminal is used at the wiring harness end, it is easy to cause terminal bending or even damage. In order to ensure the contact performance requirements of the wiring harness after connector docking, the selected sheath should have a structure for installing fixed clips.

6. For connectors with high performance requirements such as airbags, ABS, and ECU, gold plated parts are preferred


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