汽车线束端子接插件应用介绍

OUTLINE

IntroductionofCrimpConnectionTechnology

端子压接技术介绍IntroductionofWaterProofTestforaSealedConnector

密封接插件防水测试介绍

IntroductionofConnector/Contact/SealApplicationSpec.

接插件/端子/密封件应用规范介绍Introductionofcabledesign&layout导线设计和线束布置走向要求WhatIsCrimping?什么是压接？page2Crimpingistheprocessofattachingaterminalontoawireundermechanicalpressure.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ThesolderlessconnectionstartedfromAMPin1941.无焊连接技术最早源于AMP1941年提出

RequirementsonaCrimpConnection压接要求Inseparable,longtimereliableelectricalandmechanicalconnection

ofoneorseveralconductorsandthecrimpterminal.

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Easeofmanufacturingoftheconnection

压接应便于生产加工CrimpTypes端子压接类型page4

Advantages优势:OptimumdesignofCrimpBarrelfordesiredwiresizerangeandmaterialthicknessbycalculation.通过计算即可得出适合特定线径范围和料厚的压接结构FitsforseveralwiresizesonlybyadjustingCrimpHeight.仅调整压接高度即可用于不同线径压接Terminalmanufacturingatlowcostbysequentialstampingdies通过连续冲压生产实现低成本Easeoftermination,fullyautomatedpossible压接自动化Stableelectricalconnection,evenunderhazardousEnvironment.苛刻环境下性能稳定QualifiedCrimpedConnectionRequirement合格压接的要求：

Wire导线:1.选用线径符合压接端子适用性要求2.剥线符合要求（长度适合，不损镀层，末端不

开裂分叉）

Terminal端子1.按形式不同，分为开筒式和闭筒式

2.按镀层不同，分为镀锡，镀银，镀金，镀镍等

3.按是否含绝缘压接或密封部分进行区分

CrimpingTool压接工具CrimpComponents压接三要素压接准备：端子选用CrimpComponents压接三要素合格的剥线不合格的剥线压接准备：剥线要求CrimpComponents压接三要素剥线长度参考端子114使用规范CrimpingMachineandHandToolKits压接设备和工具page8Alpha356Multi-FunctionalFully-AutomaticCrimpingMachine多功能全自动端子压接机Alpha477LeadMakerDoubleCrimpConnectionswithtwodifferentwiresAlpha477可同时压接两种不同线径Thiskindofmachineissuitableforsamplemaking

常用于样品制作HandToolKits手工压接工具CrimpApplicator压接模具和刀片

page9CommonCrimpTerminals常用压接端子page10AMPMCPContactFamilyMCONContactFamilyDIA1,5/2,5mmMQSFamilyTimersContactFamilySensorFlatContactCommonCrimpTerminals常用压接端子page11DeutschCommonContactsContactCurrentCarryingCapacity端子载流能力page12MQSAMPMCP1.5AMPMCP6.3AMPMCP2.8StandardPowerTimerMicroTimerJuniorPowerTimerFASTINFASTONMultilockPositivLockRoundcontactsDIA1,5mmupto7,5ASignalcurrentsupto50Aupto15Aupto40ASensorFlatcontactRoundcontactsDIA2,5mmMaxi

PowerTimerAMPMCP9.5upto90AMCON1.2MQSAMPSeal„size16“contactpage12WireDefinition导线page13Core:Material/Plating/Gaugesize/StrandquantityInsulation:Material/ODDesignationofWireSizeforconductors导线尺寸定义

Wiresectionsizecanbedefinedas:

-mm²

CommonforEuropeanmarket

-AWG

AmericanWireGaugetableofwiresizes,orderedinoppositedirectione.g.AWG240,205mm² AWG161,3mm²noeasyconversiontomm²possiblecommonformagnetwireconversion:1mm²=1973,51CMA-CMA

CircularMilAreaTemperatureClassofTERaychemAutomotiveWirepage15CrimpingProducts压接产品page16Single-wireCrimp单线压接Double-wireCrimp双线压接Multi-wireCrimp多线压接Conductor/InsulationCrimping芯线压接与绝缘皮压接page17Thereisadifferentiationtobemadebetweenaconductorcrimpandacrimpforaninsulationsupport.芯线压接与绝缘皮压接有一定的区别：Theconductorcrimpinsuresagoodconnectionbetweenthewireandtheterminal.芯线压接保证了端子与电线的良好连接Theinsulationcrimpsupportsthewiretoreducetheaffectsofvibrationsandmovementontheconductorcrimp.绝缘皮压接是为了减少震动以及移动对芯线压接的影响ProcessofF-Crimp压接过程page18压接刀具打开，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。Theapplicationtoolisopened.Acontactispositionedontheanvil.Theleadisinsertedbyhandormechanically.Thecrimpermovesdownandpressestheleadintothecrimpbarrelandmakescontactwiththecrimpedges.Inthenextprocessingstagethecrimpedgesarerolled-round,theconductoriscompressedatthesametime,andthecrimpisformed.Thefinalpositionatagivencrimpingheightguaranteesthenecessarycompressionofthecon-ductortoformatightlycompressedcrimp.压接过程中，导体受到套管的挤压，在经度和纬度两个方向上均发生形变，形成冷焊：导体与套管表面的原氧化膜变形破裂导体与端子套管的纯净金属表面充分紧密接触挤压变形过程中的微运动显微镜下，可观察到金属表面互相交融粘连BasicPhilosophyofCrimp压接原理WirePositioning放线位置（后送料）page20前切料刀后切料刀下模WirePositioning放线位置（侧送料）page21下模端子支撑page22Thequalitativeassessmentofaconductorcrimp(usingtheexampleofan

F-crimp)isdeterminedby.端子压接质量判断有以下几个方面：Visualinspection外观检测Measurementofthecrimpheight压接高度测量Analysisofcrosssection压接剖面分析Measurementofpulloutforce压接保持力测量

EvaluationofaCrimpTermination端子压接质量判断page23Visualinspection外观检测Measurementofthecrimpheight压接高度测量Analysisofcrosssection压接剖面分析Measurementofpulloutforce压接保持力测量

EvaluationofaCrimpTermination端子压接质量判断端子压接典型位置和术语

Bellmouth：钟形口（喇叭口）Front：前部（钟形口）Rear：后部（钟形口）ContactBody：触点本体CutoffTab：切断突起LockingLance：锁定针WireCrimp：导体压接区InsulationCrimp：绝缘压接区ConductorEnd：导体端部InsulationEnd：绝缘体端部Cable：线缆FeaturesofCrimpedTerminal端子压接区域特征

端子压接质量判断方法：外观检查

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familyseal,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：绝缘层顶端需在wirecrimp和insulationcrimp之间区域（图中b区域）可见。abVisualInspection外观检查导线截面积喇叭口长度端子压接质量判断方法：外观检查

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。VisualInspection

外观检查page27端子压接质量判断方法：外观检查

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.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familyseal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。VisualInspection

外观检查page28Visualinspection外观检测Measurementofthecrimpheight压接高度测量Analysisofcrosssection压接剖面分析Measurementofpulloutforce压接保持力测量

EvaluationofaCrimpTermination端子压接质量判断端子压接质量判断方法：高度测量

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。导线截面积压接高度公差

CrimpHeightMeasurement压接高度测量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。page30压高偏小（1mm)截面无孔隙好的电气性能差的机械性能正常压高截面无孔隙好的电气性能好的机械性能压高偏大(1.2mm）截面有小孔隙差的电气性能较好的机械性能压高偏大(1.3mm)截面有较多孔隙差的电气性能差的机械性能CrimpHeightandPerformance压接高度与性能对比page31CrimpPerformanceCurve压接高度与性能对比Mechanicalandelectricalperformancevarywiththecorecrimpheight.page32Visualinspection外观检测Measurementofthecrimpheight压接高度测量Analysisofcrosssection压接剖面分析Measurementofpulloutforce压接保持力测量

EvaluationofaCrimpTermination端子压接质量判断端子压接质量判断方法：剖面检测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.剖面的切割方向需是垂直方向

b.剖面位置需在wirecrimp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serrationCrossSectionAnalysis

剖面分析MakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事项Processofcrosssectionmaking剖面制作基本流程Purpose:Aclearoutlineandgoodseparationofthecrimpbarrelandthesinglestrandshastobeobtained.目的：看到截面清晰的轮廓，并且能清楚的分辨出端子压接部分和电线导体。Errorsatthepreparationofcrosssectionleadtopoororevenimpossibleabilitytojudgethem.

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。TerminalCutting切割端子Polishingsectionsurface切割表面抛光Etchingsectionsurface表面酸蚀MakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事项page35Crossperpendiculartothelongaxisin

themiddleandofthecrimpbarrel,but

avoidingbeinginsideofaserration.切割端子：剖切面和底面垂直；

在压接区域中部；

避开serration；Duringthecuttingandpolishing,donottoopenthecrimpbarrelwings.切割和抛光时卷曲部分被破坏；Duringpolishingcarehastobetakentoavoidtheouteredgetoberounded.Otherwisenosharpoutlinecanbedisplayed.抛光时，周边形成圆角MakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事项

Allstrandsshouldbedeformed.电线的每根导体有明显的压缩Materialthicknessmustbeatleast¾ofthenominalmaterialthicknessofthecrimpbarreltoavoidoverpressing.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¾。Whenetchingispoor,thereisnoclearseparationofinnercontourandofthesinglestrands酸蚀不佳，端子和电线导体无法清晰可辨Crimpbarrelmustbeclose(¼tbut0.1mmmin).Opencrimpbarrelsarenotacceptable.端子两边完全闭合，并有一定的支撑长度MakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事项Theremustbeavisibledistanceofthecrimpwingendstothebottomaswellastothesideofthecrimpbarrelinnerwall.卷边与侧面或者底面有可见的距离

Maximumallowedsupportangleis30º卷边重合后，支撑角≤30º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。Ifthetouchinglineofthecrimpwingsisnotstraight,alinethroughtheoutermosttouchingpointsisusedtoevaluatethesupportangle.MakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事项flashheight<tflashwidth<¾twhenflashheight<½tforlongerflashthewidthmustnot

exceed½t注意毛边的厚度和宽度Tearsorcracksattheinnerorouterwallofthecrimpbarrelareunacceptable.不允许有压接裂痕otherfailures:-Strandcrimpedatouterwall-Insulationbeingcrimpedincrimpbarrel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端子压接质量判断方法：剖面检测

剖面检测参数是：① CH压接高度；根据产品规范定义② CB压接宽度（名义）；根据产品规范定义③ CBm可测量压接宽度；=1*CB~1.1*CB④ W支撑角度；≤30º⑤ L支撑长度；≥¼*S(0.1mmmin.)⑥ R侧底部距离；≥1*S⑦ GH毛边高度；≤1*S⑧ GB毛边宽度；

GB≤¾*S,ifGH<½*SGB≤½*S,ifGH≥½*S⑨ SB底部厚度；≥¾*SS=端子材料厚度

EvaluationofCrossSection剖面检测thesedimensionshavetobemeasuredviamicroscopephotographexamples…通过显微镜检测相应尺寸

EvaluationofCrossSection剖面检测Documentationacc.CrimpTechnology压接使用规范114-xxxxx:XXXCONTACTSYSTEMAPPLICATIONSPEC(特定端子使用规范）114-18022:GENERALGUIDELINESFORAPPLICATIONOFCONTACTSWITHOPENCRIMPBARRELS

（开口压接端子的应用总则）114-18022-10:MAKINGANDEVALUATIONOFCRSSSECTIONSFORF-CRIMPTEMINATIONS

（F型压接的剖面制作及评估）DINEN60352-2:CRIMPCONNECTIONS,SOLDLESSELECTRICALCONNECTIONS

（压接，非焊接连接）ExamplesforCrossSections–goodsamples剖面样品Nocavitiesarevisible无孔隙Symmetric截面对称Compactionofallstrands所有导线都应被压实Wingstouchonlyconductor翼端只接触导线Terminalstockfreeofcracks/breaks端子无裂纹Corewings“Locked”(NoGap)attopofcrimp.端

子两边完全闭合，并有一定的支撑长度ExampleforCrossSections–badsamples不良的剖面样品unsymmetricalrollinwiresizetoosmalltears/bulgingCrimpheighttoohighCrimpheighttoolow/overpressedpage44Exampleforcrosssections–badsamples其他不良剖面page45Visualinspection外观检测Measurementofthecrimpheight压接高度测量Analysisofcrosssection压接剖面分析Measurementofpulloutforce压接保持力测量

EvaluationofaCrimpTermination端子压接质量判断MeasurementofPullOutForce压接保持力测量destroyingWirepulloutforce

(withinsulationcrimpopened)

Requirement:acc.DINEN60352-2(upto10mm²)acc.VDE0220(for>10mm²)

>60N/mm²wiresection端子压接质量判断方法：绝缘压接检查绝缘层压接要求：端子的绝缘皮处一般有3种压接方式，其压接截面见下图，其压接要求分别是：a.Fcrimp压接处两端接触b.overlapcrimp压接处交叠长度大于等于一个板材厚度c.wrapcrimp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

InsulationCrimping绝缘皮压接DIN41611T3page48ExampleforCrossSections–badsamples不良的剖面OUTLINE

IntroductionofCrimpConnectionTechnology

端子压接技术介绍

IntroductionofWaterProofTestforaSealedConnector

密封接插件防水测试介绍

IntroductionofConnector/Contact/SealApplicationSpec.

接插件/端子/密封件应用规范介绍Constructionofthecode1stnumberindicatestheprotectionofsolidobjectsandmaterial2ndnumberindicatestheprotectionofliquid(water)Additionalnumber:againstaccesstohazardouspartsSupplementaryinformationDegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)DegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)IPX.0 Nonprotected,NospecialprotectionIPX.1 ProtectedagainstfallingwaterEquivalentto3-5mmrainfallperminuteforadurationof10 minutes.Unitisplacedinitsnormaloperatingposition.IPX.2 Protectedagainstfallingwaterwhentiltedupto15degrees.Sameas(1)abovebutunitis testedin4fixedpositions-tilted15degreeineachdirectionfromnormaloperating position.IPX.3 Protectedagainstsprayingwater,Watersprayingupto60degreesfromverticalat10 liters/minatagagepressureof50-150kN/m²for5min.IPX.4(K) Protectedagainstsplashingwater.Sameaslevel3butwaterissprayedatallangles(andincreasedpressure).IPX.5 ProtectedagainstwaterjetsWaterprojectedatallanglesthrougha6.3mmnozzleataflowrateof12.5liters/minatagagepressureof30kN/m²for3minutesfroma distanceof2.5~3meters.IPX.6(K) Protectedagainstheavyseas.Waterprojectedatallanglesthrougha12.5(6.3)mmnozzleata flowrateof75(100)liters/minatagagepressureof100(1000)kN/m²for3minutesfromadistanceof2.5~3meters.IPX.7 Protectedagainstwaterimmersion.Immersionfor30minutesatadepthof1meter.IPX.8 ProtectedagainstwatersubmersionTheequipmentissuitableforcontinuoussubmersioninwaterunderconditionswhichareidentifiedbythemanufacturer.IPX.9K ProtectedagainsthighpressureJet.Waterjetsfromnozzlesshallexhibitfollowing characteristics: -Temperature80±5°C -Flowrate14-16l/min -Pressure8000-10000kPameasuredasnearaspracticabletonozzleDegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)page53DegreesofProtectionagainstWater(GB4208)防水等级(GB4208)page54DegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)IPX.1/IPX.2page55DegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)IPX.3/IPX.4/IPX.4Kpage56IPX.5/IPX.6/IPX.6KDegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)page57IPX.7/IPX.8/IPX.9KDegreesofProtectionagainstWater(IPCodeDIN40050)防水等级(DIN40050)page58SensorConnector1visualinspection2contactresistance3watertightsealing(airblowingupto98kPa)4thermalshock(-50to+120°C,100h)5contactresistance6watertightsealing(airblowingupto29.4kPa)7watertightsplash(IPX.9K)Superseal1.5

Group1Group21visualinspectionvisualinspection2insluationresistanceheataging(125°C)3IPX.6K/IPX.9Kwaterresistance(30min,0.01barpressure)4insluationresistanceinsulationresistanceMCON1.2Connector1visualinspection2rapidchangeoftemperature(-40-130°C)3protectionagaistwater(airblowingupto600mbar)4IPX.4K/IPX.9KHDSCSConnector1visualinspection2pre-aging(120/-40°C,500h/120°C,120h/140°C)3IP67/IP69K4visualinspectionSuperseal1.0mmConnector

Group1Group21visualinspectionvisualinspection2insulationresistanceIPX.9K(leakcurrent)4sealingtest:

airblowupto98kPa,leakcurrent(28V,100uA)

5visualinspection

154P(94+60)Connector1visualinspection2IPX.9K3thermalshock(-40to+130°C)4IPX.9K5waterbathtest(airblowupto60kPa)6waterimmersionaftertemperaturechangeSealingTestforCommonConnector常用连接器防水测试ValidationofSealingBehavior验证密封性能Analyzethesealshape,contactpressurebyCAE.CAE模拟接触压力Measurethesealingpressurebytests.实验室进行气密性测试Stress&ContactPressureDifferentTypesofSealsinConnector连接器中的密封圈21January2023Wire/CavitySeals:SWSFamilySealPeripheralSeals:RadialSealFaceSealLshapedperipheralsealinterferenceSINGLEWIRESEALpositioningTheSWSisplacedonthewireatadefineddimensionthroughanautomated/annualprocess.Tofacilitatethisoperation,oil(about2%)isaddedtothebasematerial.ThewiresizeisdeterminedbytheholedimensionsoftheSWS.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Single

WireSealThecontactbarrelsmustcloseandretaintheSWSwithoutgeneratingcutsonthesurfaces;TheSWSmustbealignedwiththecontactcenterline.确保SWS被端子包筒包牢；避免SWS被刺破SWS中心须与端子中心对齐Thesealcrimpedontothecontactisinsertedintothecavity.Thedifferencebetweenthedia.ofthelipsoftheSWSvidescompressiononthesiliconewhichgeneratestwoadditionaleffects:FrictionwhenthecontactisinsertedintothecavityAdditionalclosurepressureonthewireinterface装入SWS,通过对硅胶的压缩达到密封功能CavityPlugsareusedtosealunusedcavitieswithadistancetothetop.未用孔位使用盲堵密封,确保与HSG端面有一段距离CavityPlugSingle

WireSealHowtoFindSuitableSWSforaConnector?如何找接插件对应的密封圈?SmallTip1:tofindoutonaconnectordrawingweprovided查找接插件图纸Otherusefulinfo.couldalsobefound:SuitablecontactforthisconnectorSuitablewirerangeforthisconnectorCounterpartMatingcomponentsforthisconnector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SmallTip2:tofindoutonacontactdrawing/catalogweprovided查找端子图纸或产品目录手册SuitableSWSindicatedonterminaldrawingSuitableSWSindicatedonproductcatalogHowtoFindSuitableSWSforaConnector?如何找接插件对应的密封圈?SmallTip3:tofindoutonrelated114spec查找端子使用规范HowtoFindSuitableSWSforaConnector?如何找接插件对应的密封圈?FamilysealPolarizationplateLongitudinalsectionThefamilysealmustbeintegratedintotheconnector.Familyseal通常是预先组装在接插件里Thepolarizationplateisnecessarytoguidethecontact.Familyseal保护盖可用于端子导向

FamilySealandUsableContacts

SealPlugFamilySealMQScleanbodyMQSstdversionThecontactsuitableforagrommetmustbefreeofanycut(sharp)edgesinallpro