The harness connector is the core component of the harness. The performance of the connector directly determines the overall performance of the harness, and plays a decisive role in the electrical stability and safety of the whole vehicle. This paper mainly discusses the following connector selection and design principles and connector material analysis.

1 Selection and design principle of connector

The selection of connectors shall ensure good contact with electrical parts, minimize the contact resistance and improve the reliability. The connectors with double spring compression structure are preferred.

The connector shall be reasonably selected according to the cross-sectional area of the conductor and the passing current.

For the butt joint sheath in the engine compartment, the waterproof sheath must be selected because the temperature and humidity in the compartment are too high and there are many corrosive gases and liquids.

If the same sheath is used in the same harness, its color must be different.

Based on the overall coordination of automobile appearance, black or dark sheath shall be preferred in engine compartment.

In order to reduce the type and quantity of sheaths for harness butt joint, hybrid parts are preferred to make assembly and fixation convenient.

For terminal connectors for airbags, ABS, ECU, etc. with high performance requirements, gold-plated parts shall be preferred to ensure safety and reliability.

The inside of the battery connector (battery clamp) is a cone with a taper of 1:9; The material of battery clamp is tinned copper, galvanized copper or lead antimony alloy.

The current that can be carried by connectors of different specifications is generally as follows: 1 series, about 10A; 2.2 or 3 series, about 20A; 4.8 series, about 30A; 6.3 series, about 45A; 7.8 or 9.5 series, about 60A.

2 performance analysis of raw materials (materials) of connector

Sheath material (plastic parts)

Commonly used materials mainly include PA6, PA66, ABS, PBT, PP, etc. see Table 2 for their specific performance differences. When designing the plug-in, different materials can be selected according to different needs, and flame retardant or reinforcing materials can be added to the plastic according to the actual situation, so as to achieve the purpose of reinforcement or flame retardant, such as adding glass fiber reinforcement, etc.

Selection, design principle and material analysis of connector

Table performance difference of connector sheath material

Terminal material (copper)

The copper used for connectors is mainly brass and bronze (the hardness of brass is slightly lower than that of bronze), of which brass accounts for a large proportion. In addition, different coatings can be selected according to different needs.

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