汽车线束端子接插件应用介绍课件.ppt

1、page 2Crimping is the process of attaching a terminal onto a wire under mechanical pressure. 压接是在导线和端子接触区域施加压力使其成型，实现紧密连接的工艺The solderless connection started from AMP in 1941.无焊连接技术最早源于AMP1941年提出 Inseparable, long time reliable electrical and mechanical connection of one or several conductors and th

2、e crimp terminal. 在压接端子与导线之间提供不可分离的, 长时间可靠的电气和机械连接Ease of manufacturing of the connection 压接应便于生产加工page 4 Advantages 优势:Optimum design of Crimp Barrel for desired wire size range and material thickness by calculation. 通过计算即可得出适合特定线径范围和料厚的压接结构Fits for several wire sizes only by adjusting Crimp Height

3、 .仅调整压接高度即可用于不同线径压接Terminal manufacturing at low cost by sequential stamping dies 通过连续冲压生产实现低成本Ease of termination, fully automated possible 压接自动化Stable electrical connection, even under hazardous Environment. 苛刻环境下性能稳定剥线长度参考端子114使用规范page 8Alpha 356 Multi-Functional Fully-Automatic Crimping Machine

4、多功能全自动端子压接机Alpha 477 Lead Maker Double Crimp Connections with two different wiresAlpha 477可同时压接两种不同线径This kind of machine is suitable for sample making 常用于样品制作Hand Tool Kits手工压接工具page 9page 10AMP MCP Contact FamilyMCON Contact FamilyDIA 1,5/ 2,5mm MQS FamilyTimers Contact FamilySensor Flat Contact常用

5、压接端子page 11Deutsch Common Contacts端子载流能力page 12MQS AMP MCP1.5 AMP MCP6.3AMP MCP2.8Standard Power Timer Micro TimerJunior Power TimerFASTIN FASTONMultilockPositiv LockRound contacts DIA 1,5 mmup to 7,5 A Signal currentsup to 50 Aup to 15 Aup to 40 ASensor Flat contactRound contacts DIA 2,5 mmMaxi Pow

6、er Timer AMP MCP9.5 up to 90 AMCON1.2MQSAMP Seal size16“ contactpage 12page 13Core: Material/ Plating/ Gauge size/ Strand quantityInsulation: Material/ OD 导线尺寸定义 Wire section size can be defined as: - - mm mmCommon for European market - - AWGAWGAmerican Wire Gaugetable of wire sizes, ordered in oppo

7、site directione.g. AWG24 0,205mm AWG16 1,3mmno easy conversion to mm possiblecommon for magnet wireconversion: 1mm = 1973,51 CMA- CMACircular Mil Areapage 15page 16Single-wire Crimp单线压接Double-wire Crimp双线压接Multi-wire Crimp多线压接page 17There is a differentiation to be made between a conductor crimp and

8、 a crimp for an insulation support. 芯线压接与绝缘皮压接有一定的区别：The conductor crimp insures a good connection between the wire and the terminal. 芯线压接保证了端子与电线的良好连接The insulation crimp supports the wire to reduce the affects of vibrations and movement on the conductor crimp.绝缘皮压接是为了减少震动以及移动对芯线 压接的影响page 18压接刀具打开

9、，端子放置在下刀上，导线由手或机械设备送至合适的位置。上刀向下移动，把导线压入包筒。包筒随上刀折弯，压接成型。设定的压接高度保证了压接质量。The application tool is opened. A contact is positioned on the anvil. The lead is inserted by hand or mechanically.The crimper moves downand presses the lead intothe crimp barrel and makescontact with the crimpedges. In the next p

10、rocessing stage the crimp edges are rolled-round, the conductor is compressed at the same time, and thecrimp is formed. The final position at agiven crimping height guarantees the necessarycompression of the con-ductor to form a tightlycompressed crimp. page 20前切料刀后切料刀下模page 21下模端子支撑page 22The quali

11、tative assessment of a conductor crimp (using the example of an F-crimp) is determined by. Visual inspection 外观检测Measurement of the crimp height 压接高度测量Analysis of cross section 压接剖面分析Measurement of pull out force 压接保持力测量 page 23Visual inspection 外观检测Measurement of the crimp height 压接高度测量Analysis of

12、cross section 压接剖面分析Measurement of pull out force 压接保持力测量 Bellmouth：钟形口（喇叭口）Front：前部（钟形口）Rear：后部（钟形口）Contact Body：触点本体Cut off Tab：切断突起Locking Lance：锁定针Wire Crimp：导体压接区Insulation Crimp：绝缘压接区Conductor End：导体端部Insulation End：绝缘体端部Cable：线缆 导体端部要求：导体端部要求： a. 导体端部应与导体压接区域顶端平齐，最多不超过压接区域顶端1mm （图中a 区域） b. 超过

13、导体压接区域端的导体部分不能阻碍端子的对配功能和锁扣功能 c. 若端子对配的连接器采用的是family seal,则导体压接区域顶端的导体部分长度建议不大于0.5mm 绝缘层顶端要求：绝缘层顶端要求： 绝缘层顶端需在wire crimp和insulation crimp之间区域（图中b 区域）可见。ab导线截面积喇叭口长度 压接两端喇叭口要求：压接两端喇叭口要求： a.导体压接区域后端需有喇叭口结构，喇叭口长度尺寸根据线径决定。 b.导体压接区域前端喇叭口可允许的最大值与后端一致。page 27 端部切断突起（料头）要求：端部切断突起（料头）要求： a. 料头必须可见，以保证端子没有损伤。 b

14、. 料头不应影响端子正常插入塑壳和对配。 c. 料头最大长度不应超过0.5mm，对于使用family seal的连接器，料头最大长度不应超过0.3mm， 料头不能损伤密封圈。page 28Visual inspection 外观检测Measurement of the crimp height 压接高度测量Analysis of cross section 压接剖面分析Measurement of pull out force 压接保持力测量 导体部分压接高度测量和公差要求：导体部分压接高度测量和公差要求： a. 导体压接高度的公差由电线线径决定。 b. 导体压接高度在生产过程中需持续管控。导

15、线截面积压接高度公差 压接宽度与压接模具尺寸有关，压接宽度压接宽度与压接模具尺寸有关，压接宽度 不作为生产控制尺寸。不作为生产控制尺寸。page 30压高偏小（压高偏小（1 1mmmm) )-截面无孔隙截面无孔隙-好的电气性能好的电气性能-差的机械性能差的机械性能正常压高正常压高-截面无孔隙截面无孔隙-好的电气性能好的电气性能-好的机械性能好的机械性能压高偏大压高偏大(1.2(1.2mmmm）-截面有小孔隙截面有小孔隙-差的电气性能差的电气性能-较好的机械性能较好的机械性能压高偏大压高偏大(1.3(1.3mmmm) )-截面有较多孔隙截面有较多孔隙-差的电气性能差的电气性能-差的机械性能差的机

16、械性能page 31压接高度与性能对比Mechanical and electrical performance vary with the core crimp height.page 32Visual inspection 外观检测Measurement of the crimp height 压接高度测量Analysis of cross section 压接剖面分析Measurement of pull out force 压接保持力测量 为检查端子压接的质量，经常要做压接剖面检测，检测剖面的要求是：为检查端子压接的质量，经常要做压接剖面检测，检测剖面的要求是： a. 剖面的切割方向需

17、是垂直方向 b. 剖面位置需在wire crimp中间，且需避开serration（齿状突起） c. 做剖面时，需在端子周围和内部灌入人工合成胶，避免端子和导线移动偏移 d. 切割后需要进行表面研磨和酸蚀，便于观察检验合理剖切位置serration 剖面分析Process of cross section making 剖面制作基本流程 Purpose: A clear outline and good separation of the crimp barrel and the single strands has to be obtained. 目的：看到截面清晰的轮廓，并且能清楚的分辨出

18、端子压接部分和电线导体。Errors at the preparation of cross section lead to poor or even impossible ability to judge them. 不良的截面制作可能会影响截面判定结果，甚至无法进行判定。Terminal Cutting切割端子Polishing section surface 切割表面抛光Etching section surface表面酸蚀page 35 Cross perpendicular to the long axis in the middle and of the crimp barrel,

19、 but avoiding being inside of a serration. 切割端子： 剖切面和底面垂直； 在压接区域中部； 避开serration；During the cutting and polishing, do not to open the crimp barrel wings. 切割和抛光时卷曲部分被破坏；During polishing care has to be taken to avoid the outer edge to be rounded. Otherwise no sharp outline can be displayed. 抛光时，周边形成圆角

20、All strands should be deformed. 电线的每根导体有明显的压缩 Material thickness must be at least of the nominal material thickness of the crimp barrel to avoid over pressing. 压缩量较大时，端子底部会被压缩。为防 止过量压缩，要求底部厚度必须端子原 始厚度的。 When etching is poor, there is no clear separation of inner contour and of the single strands 酸蚀不

21、佳，端子和电线导体无法清晰可辨 Crimp barrel must be close( t but 0.1mm min). Open crimp barrels are not acceptable. 端子两边完全闭合，并有一定的支撑长度 There must be a visible distance of the crimp wing ends to the bottom as well as to the side of the crimp barrel inner wall. 卷边与侧面或者底面有可见的距离 Maximum allowed support angle is 30 卷边重

22、合后，支撑角30如果重合线不是直线，取轮廓最外部的两点来确认支撑角度。 If the touching line of the crimp wings is not straight, a line through the outermost touching points is used to evaluate the support angle. flash height t flash width t when flash height t for longer flash the width must not exceed t 注意毛边的厚度和宽度 Tears or cracks at

23、 the inner or outer wall of the crimp barrel are unacceptable. 不允许有压接裂痕 other failures: - Strand crimped at outer wall - Insulation being crimped in crimp barrel 其余不良 - 有电线导体未被压入端子 - 有电线绝缘皮被压入导体部分 剖面检测参数是：CH - CH - 压接高度；根据产品规范定义压接高度；根据产品规范定义CB - CB - 压接宽度（名义）；压接宽度（名义）； 根据产品规范定义根据产品规范定义CBmCBm - - 可测量

24、压接宽度；可测量压接宽度；= 1 = 1 * * CB 1.1 CB 1.1 * * CB CBW - W - 支撑角度；支撑角度； 3030L - L - 支撑长度；支撑长度； * * S (0.1mm min.) S (0.1mm min.)R - R - 侧底部距离；侧底部距离； 1 1 * * S SGH - GH - 毛边高度；毛边高度；1 1 * * S S GB - GB - 毛边宽度；毛边宽度； GB GB * * S, if GH S, if GH 10mm)60 N/mm wire section绝缘层压接要求： 端子的绝缘皮处一般有3种压接方式，其压接截面见下图，其压接要

25、求分别是：a. F crimp 压接处两端接触b. overlap crimp 压接处交叠长度大于等于一个板材厚度c. wrap crimp 压接处相交长度大于等于一个板材厚度d. 经过一个循环的折弯实验，绝缘皮压接处不能松脱导线绝缘层端子折弯角30折弯长度50mm DIN 41611 T3page 48 bad samples 不良的剖面Construction of the code1st number indicates the protection of solid objects and material2nd number indicates the protection of l

26、iquid (water) Additional number: against access to hazardous partsSupplementary informationIP X.0 Non protected, No special protectionIP X.1 Protected against falling water Equivalent to 3-5mm rainfall per minute for a duration of 10 minutes. Unit is placed in its normal operating position.IP X.2 Pr

27、otected against falling water when tilted up to 15 degrees. Same as (1) above but unit istested in 4 fixed positions - tilted 15 degree in each direction from normal operating position.IP X.3 Protected against spraying water, Water spraying up to 60 degrees from vertical at 10liters/min at a gage pr

28、essure of 50-150kN/m for 5 min.IP X.4(K) Protected against splashing water. Same as level 3 but water is sprayed at all angles( and increased pressure).IP X.5 Protected against water jets Water projected at all angles through a 6.3mm nozzle at a flow rate of 12.5 liters/min at a gage pressure of 30k

29、N/m for 3 minutes from a distance of 2.53 meters.IP X.6(K) Protected against heavy seas. Water projected at all angles through a 12.5(6.3)mm nozzle at a flow rate of 75(100) liters/min at a gage pressure of 100(1000)kN/m for 3 minutes from a distance of 2.53 meters.IP X.7 Protected against water imm

30、ersion. Immersion for 30 minutes at a depth of 1 meter.IP X.8 Protected against water submersion The equipment is suitable for continuous submersion in water under conditions which are identified by the manufacturer.IP X.9K Protected against high pressure Jet. Water jets from nozzles shall exhibit f

31、ollowing characteristics:- Temperature 805C- Flow rate 14-16 l/min- Pressure 8000 - 10000 kPa measured as near as practicable to nozzlepage 53page 54IPX.1/ IPX.2page 55IP X.3/ IP X.4/ IP X.4Kpage 56IP X.5/ IP X.6/ IP X.6Kpage 57IP X.7/ IP X.8/ IP X.9Kpage 58Sensor ConnectorSensor Connector1visual in

32、spection2contact resistance3watertight sealing(air blowing up to 98kPa)4thermal shock(-50 to +120C, 100h)5contact resistance6watertight sealing(air blowing up to 29.4kPa)7watertight splash(IPX.9K)Superseal 1.5Superseal 1.5Group 1Group 21visual inspectionvisual inspection2insluation resistanceheat ag

33、ing( 125C)3IP X.6K /IPX.9Kwater resistance(30min,0.01bar pressure)4insluation resistanceinsulation resistanceMCON 1.2 ConnectorMCON 1.2 Connector1visual inspection2rapid change of temperature( -40 - 130C)3protection agaist water(air blowing up to 600mbar)4IPX.4K/IP X.9KHDSCS ConnectorHDSCS Connector

34、1visual inspection2pre-aging(120/-40C, 500h/120C,120h/140C )3IP 67/IP 69K4visual inspectionSuperseal 1.0mm ConnectorSuperseal 1.0mm ConnectorGroup 1Group 21 visual inspectionvisual inspection2 insulation resistanceIP X.9K( leak current)4sealing test:air blow up to 98kPa, leak current(28V,100uA)5 vis

35、ual inspection154P(94+60) Connector154P(94+60) Connector1 visual inspection2 IP X.9K3 thermal shock(-40 to +130C)4 IP X.9K5 water bath test( air blow up to 60kPa)6water immersion after temperature change Analyze the seal shape, contact pressure by CAE. CAE模拟接触压力 Measure the sealing pressure by tests

36、. 实验室进行气密性测试Stress & Contact PressureJune 10, 2022 Wire / Cavity Seals:- SWS- Family Seal Peripheral Seals:- Radial Seal- Face Seal- L shaped peripheral sealinterferencepositioningThe SWS is placed on the wire at a defined dimension through an automated/annual process.To facilitate this operation, o

37、il (about 2%) is added to the base material.The wire size is determined by the hole dimensions of the SWS. 将电线穿入SWS通常SWS带有硅油以便装配适用的线径由SWS内孔尺寸决定The contact barrels must close and retain the SWS without generating cuts on the surfaces;The SWS must be aligned with the contact centerline.确保SWS被端子包筒包牢；避免

38、SWS被刺破SWS 中心须与端子中心对齐The seal crimped onto the contact is inserted into the cavity. The difference between the dia. of the lips of the SWS and the cavity dia. provides compression on the silicone which generates two additional effects: Friction when the contact is inserted into the cavity Additional

39、closure pressure on the wire interface装入SWS, 通过对硅胶的压缩达到密封功能Cavity Plugs are used to seal unused cavities with a distance to the top.未用孔位使用盲堵密封,确保与HSG端面有一段距离Cavity PlugSmall Tip 1: to find out on a connector drawing we provided 查找接插件图纸Other useful info. could also be found:-Suitable contact for this

40、connector-Suitable wire range for this connector-Counter part-Mating components for this connector其他有用信息如： 接插件端子，适用线径范围，对配件，其他各种组件通常亦可在图纸上找到Small Tip 2: to find out on a contact drawing/ catalog we provided 查找端子图纸或产品目录手册Suitable SWS indicated on terminal drawingSuitable SWS indicated on product cata

41、logSmall Tip 3: to find out on related 114 spec 查找端子使用规范Family sealPolarization plateLongitudinal sectionThe family seal must be integrated into the connector. Family seal 通常是预先组装在接插件里The polarization plate is necessary to guide the contact. Family seal保护盖可用于端子导向 Family Seal and Usable ContactsSeal

42、PlugMQS clean bodyMQS std versionThe contact suitable for a grommet must be free of any cut (sharp) edges in all profiles design and stamping process are more complex.用于Family seal的端子表面不能有任何的尖刃，以免割破密封圈。这种端子称为Clean body和所适用端子Design Considerations: Contact front area / min wire diameter Cavity seal pr

43、ofile (number of lips) Housing interface Poka Yoke assembly featuresFamily Seal and Usable ContactsSealing of contact cavitiesWire sealing和所适用端子A peripheral seal is an element that is used to ensure water-tightness between female and male connectors or female connectors and ECU interfacesPeripheral

44、Seal 用于接插件公端与母端之间的密封，以及母端与ECU接口之间的密封Small tip: pay attention to the orientation of a Contact before inserting into connector.插端子前请注意端子的方向，避免误插page 72Small tip: Insert terminal until an audible “click” is heard or felt小心插入端子，直至听到或感受到“咔嗒”声page 73Connector Product Specification Functional Requirements

45、Test requirements Test Procedure Application Specification Assembly InstructionTerminalTerminalProduct SpecificationProduct SpecificationRatingsElectricalMechanicalApplication EnvironmentPlatingApplication SpecificationApplication SpecificationCrimp SpecSeal Selection 选用导线时需注意：保险丝的熔断电流必须低于导线达到燃烧时的最大

46、电流。 依考虑导线的适应性（如柔性)，电磁特性选择 绞合、屏蔽导线。 导线选择需要考虑有些用电器的电压降，电路电阻要求。 覆盖材料选择要考虑温度等级、耐热、降噪、耐磨等技术要求： 与关键零件保持一定距离；尽量避免高温等恶劣环境；弱信号传感器线与电源线保持一定距离，避免平行； 易装配，易操作，装配时间短；固定支架的数量和位置 ； 线束走向整齐美观；接插件，防护具，固定件色调一致； 由于发动机的工作工况下振动剧烈，布线的安装点务必确保固定牢靠。 固定点位置选择要求为：-固定线束靠近车体上以防止噪音。-线束直的部分固定卡子设计距离200250mm；弯曲部分距离150200mm。-利用长槽孔卡子固定并保持线束方向。-距离运动部件至少20mm。 线束走向美观性很大程度上取决于和发动机缸体的同步设计。 建议： 设计发动机缸体时，同时考虑布线要求； 将线束的走向路径预埋到缸体上，减少外露线束； 布线走向整齐，避免交叉和悬空；