线束设计初步

,BasicHarnessDesign,BasicHarnessDesign线束设计初步,DelphiPackardElectricSystemEJVPEAugust,2003Presenter:ChenShuiHua,DelphiConfidential,1,Whatmakesagooddesign?,Agoodharnessdesignshallbe:ReflectcustomersrequirementsexactlyandcompletelyQuality:NoerrorNodifferentmeaningdontrelyonlyondifferentcolorconnectors11.MinimizethenumberofconnectorswherepossibleConsidercombiningtwoormoresmallconnectorswithonelowengageconnector12.DesigninoptioncontentOptioncontentshouldbedesignedforsub-assemblybuildandtoformanyP/NvariationswithoutchangetothebaseP/Ncircuits,coverings,ordimensions13.CommonizewiregaugesonleadsoutofsplicesiftheyhavesimilarterminalsandlengthIfsmallergaugeleadispluggedintoacavityrequiringlargegaugeleadthenelectricalproblemsmayresult.Mis-plugscannotbedetectedbyring-outinthissituation.Commonizingtolargestgaugewillpreventeffectsofmis-plugs.14.Questiontheuseof4ormorewiresintwistedcableVerydifficultbuildandaddedtoolingexpensetobuild,4.Layoutdesign(Contd),DelphiConfidential,14,5.CableSelection,Cable,SAE,JIS,DIN,TWP,TXL,SGX:Battery:M1643,STX:M3252,FusibleLink:M3382,R5:M3267,M3075,M3099,M3322,M3089,M3096,GXL:M3101Flexible,STT:FromGeneratortoStarter:M3391,DrainWire:M3098,CableSelectionisbasedonthefollowingconsideration:SchematicsEnvironmenttemperaturegritDuty:HeavyorlightFlexibilitySpecialrequirementCost,DelphiConfidential,15,5.CableSelection(contd),SAEcableGeneralGuideline,TWP,TXL,M3096,M3089,0.35SQ,0.8SQ,1.0SQ,0.5SQ,2.0SQ,3.0SQ,5.0SQ,M3099,M3075,0.35SQ,0.8SQ,1.0SQ,0.5SQ,2.0SQ,3.0SQ,5.0SQ,CostSaving7strandsreplaced19strandsQualityImprovementAnnealedcablereplacesHarddrawn,DelphiConfidential,16,6.Connector,Terminal,SealandPlugSelection,ConnectorSelectionImportantfeaturestobeconsideredduringconnectorselectionareavailabilityofterminalpositionassurance(TPA)orPositiveLockreinforcement(PLR),connectorpositionassurance(CPA),engageforce,positiveconnectorsealretention,andprimarylockfeature.PullToSeatConnectorSystem:Itisrecommendedthatthisconnectionseriesnotbeusedfornewapplicationsorproliferated.,ReftoCircuitprotection,ESA-740andproducthandbook,ConnectionSeries-Metri-Pack-GTseries-Micro100-Weather-Pack-Ducon-Micro64-VF-DS,DelphiConfidential,17,6.Connector,Terminal,SealandPlugSelection(Contd),GTreplacementforPTSconnectorsAllPTSconnectorhasGTReplacement.,ReftoCircuitprotection,ESA-740andproducthandbook,Or,DelphiConfidential,18,ItisNOTenoughtomakeselectionfromHandbookYouMustbeanexperttoknowtheinsightofconnectionMakesurethatterminalinconnectoraredualfail-safeQuestionconnectorswithoutTPA(orhinge)RemoveanyCPAifpossible.,ReftoCircuitprotection,ESA-740andproducthandbook,6.Connector,Terminal,SealandPlugSelection(Contd),+,=,-,DelphiConfidential,19,Toomany“traps”existinproducthandbook,6.Connector,Terminal,SealandPlugSelection(Contd),ThingsInHandbook,ReinforcementInHarnessDrawing!,DelphiConfidential,20,In-lineConnector,6.Connector,Terminal,SealandPlugSelection(Contd),+,QuestionEveryIn-lineConnectorsthathasnomountingclip!,DelphiConfidential,21,Terminalselectionisbasedonthecircuittype,thecrimpapplication,stockmaterial,plating,stockthickness,currentrequirement,sealingrequirements,bladewidth,etc.Platedterminalsshallbeusedinharshenvironments.Avarietyofplatingmaterialsisavailableifnecessarytomeetperformancecriteria.Caution:dissimilarmaterialscanhaveunwantedchemicalreactionsInordertominimizethenumberofterminalsavailable,platedterminalsarerecommendedforallapplications.Duringterminalselection,theengineershouldreviewtheterminalattheoppositeendofthewire,takingintoconsiderationthatmanufacturingcouldpossiblyplugtheoppositeterminalintotheconnectorandjeopardizethemechanical,electrical,and/orenvironmentalperformance.(Example:thinvs.regularstockplatedvs.selectiveplating)TerminalStabilizer:Mylarthiscomponentisusedinlargeconnectorswithmalebladestopositionterminalsandreducebentblades.,6.Connector,Terminal,SealandPlugSelection(Contd),DelphiConfidential,22,QuestionthenecessityofGold/Silverplatedterminal,6.Connector,Terminal,SealandPlugSelection(Contd),ItwouldbebettertheyhavesameplatinginbothconnectorterminalandDevicepins!,Contactofdifferentplatingmaycausechemicalreaction!,DelphiConfidential,23,SealSelectionisbasedonwireOD,connectorcavitysize,andterminaltype.Costsaving:UseloosePiecesealratherthatmylarseal,6.Connector,Terminal,SealandPlugSelection(Contd),Acavityplugisrequiredinsealedconnectors(inWETarea)thatdonothaveawireineachcavity,DelphiConfidential,24,PreferedLoosePieceSealMP150:15324974,15324976,15324973MP280:15324983,5324984,15324980,15324981MP480:15324987,15324988,15324989,15324990,15324991MP630:15324993,15324994,15324995,15324996,15324997GT150:15366021,15366060GT280:15366065,15366066,15366067,6.Connector,Terminal,SealandPlugSelection(Contd),DelphiConfidential,25,PlugAvoidusingpluginconnectorMaximumallowableplugsinoneconnectoris2pcsIfplugisunavoidablechangetheconnector“Flashover”theunusedCavities,6.Connector,Terminal,SealandPlugSelection(Contd),“Flash-Over”unusedcavitieswilleliminateseals!,:Flash-OverLegend,DelphiConfidential,26,ExerciseConnectorPN:12052644Cable:M3101201(0.8SQ)TerminalPN:?SealPN:?,6.Connector,Terminal,SealandPlugSelection(Contd),DelphiConfidential,27,CadarUseCadartoverifyyourselectionComputerAidedDesignAnalysisReportAlsocalled“HarnessAnalysisReport”Agroupof26modulesthatautomaticallycheckforerrorsinharnesswire&itemschartsApplicationEngineeristhepersontosignoffCADARreportOnlyafterCADARreportissignedoffcantheharnessbereleased!,6.Connector,Terminal,SealandPlugSelection(Contd),DelphiConfidential,28,6.Connector,Terminal,SealandPlugSelection(Contd),Aquickviewon“CADARSUMMARY”report,DelphiConfidential,29,ESA-605SEARCHontheEngineeringPage-TodetermineifanapplicationforaterminalP/Nandcablecode(s)isalreadyvalidated,ORLeaveblanktoviewALLcablesvalidatedfortheselectedterminal.,6.Connector,Terminal,SealandPlugSelection(Contd),DelphiConfidential,30,7.Toleranceanddimension,EverydimensiononaW/Adrawinghasaspecifictoleranceassociatedwithit.Thetolerancecanbespecifiedwiththedimension.Example:150.0+/-15.0mm,150.0MAX.150.0MIN,or150.0REF.Whenthetoleranceisnotspecifiedonthedrawing,usethetolerancechartspecified.5.2Fixedpointsaredatums,clips,clamps,andgrommets(excepttaped-ongrommets).150.0+/-15.0mm,150.0MAX.150.0MIN,or150.0REF.,150.0+/-15,150.0MAX,150.0MIN,150.0REF,DelphiConfidential,31,7.Toleranceanddimension(Contd),TrendsofToleranceChart,ThistolerancechartonlyforOldorCarryOverDesigns!,DelphiConfidential,32,7.Toleranceanddimension(Contd),TrendsofToleranceChart.,ThistolerancechartarerecommendedinESA-740fornewGMnewprograms,DelphiConfidential,33,7.Toleranceanddimension(Contd),TrendsofToleranceChart.,SomeNewProgramsinGMareusingthetoleranceChartsabove,DelphiConfidential,34,7.Toleranceanddimension(contd),A.Eliminateprintdimensionsgreaterthan1500mmDifficultforonepersontocontrolandmeasureVerydifficultifchannelsorbendsinvolvedB.EliminatedimensionstoclipsonfloatingpiecesofconduitDimensioncliprelativetoconduitendandnotafixedpointontheprintC.SpecifyatapingdimensionatbackoflargemultiplecavityconnectorCurrentspecrequiresa25mmmaximumgapbetweentapeandbackofconnector.Withlargeconnectors,wiresmaybefanned-outsuchthat25mmisnotpracticalwithoutpotentialterminaldamage.Specifyanappropriatedimensionlargerthan25mm.,DimensioningGuidelines,DelphiConfidential,35,7.Toleranceanddimension(cont),D.ProvideadditionaltoleranceonbranchlengthsforrighangledressedconnectorsAllowswirestohavesomeslacktopromotestrainreliefoftheterminalsE.Eliminatedoubledimensions(excludingreferencedimensions)Occasionallycannotbuildtomeetbothdimensionsduetostack-upoftolerancesF.Useclip-to-clipdimensioning,avoidtheuseof“DATUM”ProvidesbetterharnessdimensioningforVAPandmoredimensionalcontrolduringmanufacturingG.Avoidtheuseoftape-on-grommetsasfixedpointsTheflexibilityofthesegrommetscancausedifficultyinmeasurementtofixedandnon-fixedpoints,DimensioningGuidelines(contd),DelphiConfidential,36,7.Toleranceanddimension(cont),Exercise:improvethedimensioningmethodforthefollowingdrawing,DelphiConfidential,37,8.HarnessCoveringSelection(contd),TapingMethodPreferredTape,M2147021:19mm,M2147021:19mm,M2147001:32mm,GenericPVCTape,DelphiConfidential,38,OperatingTemperatureMaximumTemperaturePreferredConduit8593M1883125155M1888120180M1889120-160180-200M4640,GenericConduit,8.HarnessCoveringSelection(contd),DelphiConfidential,39,ForMoreHarnesscoveringinformation,visit,8.HarnessCoveringSelection(contd),DelphiConfidential,40,9.SpliceDesign,1.Minimizewiresshorterthan150mm.Shortwirescreatequalityproblemsduetohandlingdifficulty.Potentialsafetyhazardtooperatorhandsduetocloseproximitytosplicepresstooling.2.Minimizethenumberofunbalancedsealedsplicesthatdifferbymorethanonelead(e.g.3X1,4X2)Processingproblemsareincurredwhiletryingtosealanunbalancedsplicecausingqualityproblems.3.AvoidtheuseofdissimilarwirelengthsforsealedsplicesProcessingproblemsareincurredwhiletryingtosealasplicewithunequalmassonbothsidesofthesplices.Thisalsocauseswirehandlingdifficulties.4.Questionlargesplices(8ormoreleads)Highscraprate(wrongleadsoftenused).Difficulthandlingonsplicepress.Pressmayrequirefixturestokeepleadsseparate.Longleadsneedmodifiedsplicebuggies.Unbalancedsplicewithmixedgaugesisworstcase.,SpliceDesignGenericGuideline,DelphiConfidential,41,9.SpliceDesign(contd),5.OptimizesplicelocationsMinimizecable,optimizecutting,andstandardizesplicelocationstoprovideforbestleadprepandfinalassemblybuildprocesses.Considerwirelengthsandcrosssectionalarea.Minimumdistancesplicetospli