1、Delphi Confidential,1,Basic Harness Design,Basic Harness Design 線束設計初步,Delphi Packard Electric System EJV PE August,2003 Presenter: Chen Shui Hua,Delphi Confidential,2,What makes a good design?,A good harness design shall be: Reflect customers requirements exactly and completely Quality: No error No

2、 different meaning dont rely only on different color connectors 11. Minimize the number of connectors where possible Consider combining two or more small connectors with one low engage connector 12. Design in option content Option content should be designed for sub-assembly build and to form any P/N

3、 variations without change to the base P/N circuits, coverings, or dimensions 13. Commonize wire gauges on leads out of splices if they have similar terminals and length If smaller gauge lead is plugged into a cavity requiring large gauge lead then electrical problems may result. Mis-plugs cannot be

4、 detected by ring-out in this situation. Commonizing to largest gauge will prevent effects of mis-plugs. 14. Question the use of 4 or more wires in twisted cable Very difficult build and added tooling expense to build,4.Layout design(Contd),Delphi Confidential,15,5.Cable Selection,Cable,SAE,JIS,DIN,

5、TWP,TXL,SGX:Battery: M1643,STX: M3252,Fusible Link: M3382,R 5: M3267,M3075,M3099,M3322,M3089,M3096,GXL: M3101 Flexible,STT : From Generator to Starter:M3391,Drain Wire: M3098,Cable Selection is based on the following consideration: Schematics Environment temperature grit Duty: Heavy or light Flexibi

6、lity Special requirement Cost,Delphi Confidential,16,5.Cable Selection(contd),SAE cable General Guideline,TWP,TXL,M3096,M3089,0.35 SQ,0.8 SQ,1.0 SQ,0.5 SQ,2.0 SQ,3.0 SQ,5.0 SQ,M3099,M3075,0.35 SQ,0.8 SQ,1.0 SQ,0.5 SQ,2.0 SQ,3.0 SQ,5.0 SQ,Cost Saving 7 strands replaced 19 strands Quality Improvement

7、Annealed cable replaces Harddrawn,Delphi Confidential,17,6. Connector ,Terminal , Seal and Plug Selection,Connector Selection Important features to be considered during connector selection are availability of terminal position assurance (TPA) or Positive Lock reinforcement (PLR), connector position

8、assurance (CPA), engage force, positive connector seal retention, and primary lock feature. Pull To Seat Connector System: It is recommended that this connection series not be used for new applications or proliferated.,Ref to Circuit protection , ESA-740 and product handbook,Connection Series -Metri

9、-Pack -GT series -Micro 100 -Weather-Pack -Ducon -Micro 64 -VF -DS,Delphi Confidential,18,6. Connector ,Terminal , Seal and Plug Selection(Contd),GT replacement for PTS connectors All PTS connector has GT Replacement.,Ref to Circuit protection , ESA-740 and product handbook,Or,Delphi Confidential,19

10、,It is NOT enough to make selection from Handbook You Must be an expert to know the insight of connection Make sure that terminal in connector are dual fail-safe Question connectors without TPA (or hinge) Remove any CPA if possible.,Ref to Circuit protection , ESA-740 and product handbook,6. Connect

11、or ,Terminal , Seal and Plug Selection(Contd),+,=,-,Delphi Confidential,20,Too many “traps” exist in product handbook,6. Connector ,Terminal , Seal and Plug Selection(Contd),Things In Handbook,Reinforcement In Harness Drawing !,Delphi Confidential,21,In-line Connector,6. Connector ,Terminal , Seal a

12、nd Plug Selection(Contd),+,Question Every In-line Connectors that has no mounting clip!,Delphi Confidential,22,Terminal selection is based on the circuit type, the crimp application, stock material, plating, stock thickness, current requirement, sealing requirements, blade width, etc. Plated termina

13、ls shall be used in harsh environments. A variety of plating materials is available if necessary to meet performance criteria. Caution:dissimilar materials can have unwanted chemical reactions In order to minimize the number of terminals available, plated terminals are recommended for all applicatio

14、ns. During terminal selection, the engineer should review the terminal at the opposite end of the wire, taking into consideration that manufacturing could possibly plug the opposite terminal into the connector and jeopardize the mechanical,electrical, and/or environmental performance. (Example: thin

15、 vs. regular stock plated vs. selective plating) Terminal Stabilizer: Mylar this component is used in large connectors with male blades to position terminals and reduce bent blades.,6. Connector ,Terminal , Seal and Plug Selection(Contd),Delphi Confidential,23,Question the necessity of Gold/Silver p

16、lated terminal,6. Connector ,Terminal , Seal and Plug Selection(Contd),It would be better they have same plating in both connector terminal and Device pins!,Contact of different plating may cause chemical reaction !,Delphi Confidential,24,Seal Selection is based on wire OD, connector cavity size, an

17、d terminal type. Cost saving: Use loose Piece seal rather that mylar seal,6. Connector ,Terminal , Seal and Plug Selection(Contd),A cavity plug is required in sealed connectors (in WET area) that do not have a wire in each cavity,Delphi Confidential,25,Prefered Loose Piece Seal MP150:15324974,153249

18、76,15324973 MP280:15324983,5324984, 15324980, 15324981 MP480: 15324987 ,15324988, 15324989,15324990, 15324991 MP630: 15324993, 15324994, 15324995, 15324996, 15324997 GT150:15366021,15366060 GT280:15366065, 15366066,15366067,6. Connector ,Terminal , Seal and Plug Selection(Contd),Delphi Confidential,

19、26,Plug Avoid using plug in connector Maximum allowable plugs in one connector is 2 pcs If plug is unavoidable change the connector “Flash over” the unused Cavities,6. Connector ,Terminal , Seal and Plug Selection(Contd),“Flash-Over” unused cavities will eliminate seals !,: Flash-Over Legend,Delphi

20、Confidential,27,Exercise Connector PN: 12052644 Cable: M3101201(0.8 SQ) Terminal PN: ? Seal PN: ?,6. Connector ,Terminal , Seal and Plug Selection(Contd),Delphi Confidential,28,Cadar Use Cadar to verify your selection Computer Aided Design Analysis Report Also called “Harness Analysis Report” A grou

21、p of 26 modules that automatically check for errors in harness wire & items charts Application Engineer is the person to sign off CADAR report Only after CADAR report is signed off can the harness be released!,6. Connector ,Terminal , Seal and Plug Selection(Contd),Delphi Confidential,29,6. Connecto

22、r ,Terminal , Seal and Plug Selection(Contd),A quick view on “CADAR SUMMARY” report,Delphi Confidential,30,ESA-605 SEARCH on the Engineering Page - To determine if an application for a terminal P/N and cable code(s) is already validated,OR Leave blank to view ALL cables validated for the selected te

23、rminal.,6. Connector ,Terminal , Seal and Plug Selection(Contd),Delphi Confidential,31,7.Tolerance and dimension,Every dimension on a W/A drawing has a specific tolerance associated with it. The tolerance can be specified with the dimension. Example: 150.0 +/- 15.0 mm, 150.0 MAX.150.0 MIN, or 150.0

24、REF. When the tolerance is not specified on the drawing, use the tolerance chart specified. 5.2 Fixed points are datums, clips, clamps, and grommets (except taped-on grommets). 150.0 +/- 15.0 mm, 150.0 MAX.150.0 MIN, or 150.0 REF.,150.0+/-15,150.0MAX,150.0MIN,150.0REF,Delphi Confidential,32,7.Tolera

25、nce and dimension(Contd),Trends of Tolerance Chart,This tolerance chart only for Old or Carry Over Designs !,Delphi Confidential,33,7.Tolerance and dimension(Contd),Trends of Tolerance Chart.,This tolerance chart are recommended in ESA-740 for new GM new programs,Delphi Confidential,34,7.Tolerance a

26、nd dimension(Contd),Trends of Tolerance Chart.,Some New Programs in GM are using the tolerance Charts above,Delphi Confidential,35,7.Tolerance and dimension(contd),A. Eliminate print dimensions greater than 1500 mm Difficult for one person to control and measure Very difficult if channels or bends i

27、nvolved B. Eliminate dimensions to clips on floating pieces of conduit Dimension clip relative to conduit end and not a fixed point on the print C. Specify a taping dimension at back of large multiple cavity connector Current spec requires a 25 mm maximum gap between tape and back of connector. With

28、 large connectors, wires may be fanned-out such that 25 mm is not practical without potential terminal damage. Specify an appropriate dimension larger than 25 mm.,Dimensioning Guidelines,Delphi Confidential,36,7.Tolerance and dimension(cont),D. Provide additional tolerance on branch lengths for righ

29、 angle dressed connectors Allows wires to have some slack to promote strain relief of the terminals E. Eliminate double dimensions (excluding reference dimensions) Occasionally cannot build to meet both dimensions due to stack-up of tolerances F. Use clip-to-clip dimensioning,avoid the use of “DATUM

30、” Provides better harness dimensioning for VAP and more dimensional control during manufacturing G. Avoid the use of tape-on-grommets as fixed points The flexibility of these grommets can cause difficulty in measurement to fixed and non-fixed points,Dimensioning Guidelines(contd),Delphi Confidential

31、,37,7.Tolerance and dimension(cont),Exercise: improve the dimensioning method for the following drawing,Delphi Confidential,38,8. Harness Covering Selection(contd),Taping Method Preferred Tape,M2147021: 19mm,M2147021: 19mm,M2147001: 32mm,Generic PVC Tape,Delphi Confidential,39,Operating Temperature

32、Maximum Temperature Preferred Conduit 8593M1883 125155M1888 120180M1889 120-160180-200M4640,Generic Conduit,8. Harness Covering Selection(contd),Delphi Confidential,40,For More Harness covering information, visit,8. Harness Covering Selection(contd),Delphi Confidential,41,9.Splice Design,1. Minimize

33、 wires shorter than 150 mm. Short wires create quality problems due to handling difficulty. Potential safety hazard to operator hands due to close proximity to splice press tooling. 2. Minimize the number of unbalanced sealed splices that differ by more than one lead (e.g. 3 X 1, 4 X 2) Processing p

34、roblems are incurred while trying to seal an unbalanced splice causing quality problems. 3. Avoid the use of dissimilar wire lengths for sealed splices Processing problems are incurred while trying to seal a splice with unequal mass on both sides of the splices. This also causes wire handling diffic

35、ulties. 4. Question large splices (8 or more leads) High scrap rate (wrong leads often used). Difficult handling on splice press. Press mayrequire fixtures to keep leads separate. Long leads need modified splice buggies. Unbalanced splice with mixed gauges is worst case.,Splice Design Generic Guidel

36、ine,Delphi Confidential,42,9.Splice Design (contd),5. Optimize splice locations Minimize cable, optimize cutting, and standardize splice locations to provide for best lead prep and final assembly build processes. Consider wire lengths and cross sectional area. Minimum distance splice to splice or splice to outlet is 50 m