Harnesses and Cables Automotive Application

1、Harnesses and CablesAutomotive Application Last Updated: Mar 2011MolexIncorporatedSales andMarketingMicroProductsIntegratedProducts MolexFiberOpticsMolexPremiseNetworksCableProductsGroupFlex PrintedCircuitProductsRFPCBA andThermalProductsLittle Rock USASulecinPolandDongguanChinaGuadalajaraMexicoBang

2、kokThailandBangaloreIndiaAutomatedElectrical ProductsCommercialProducts &TransportationProductsMolex Global Division StructureMOLEX CONFIDENTIALBeijingTianjinDalianQingdaoShanghaiSuzhouHong KongDongguan (2)TaipeiChengduGuangzhouShenzhenXiamenKaoshiungMolex China FacilitiesProduct & Process Developme

3、nt CenterFactoriesNew FactorySales OfficesNanjingDongGuan (1)MOLEX CONFIDENTIALMolex Dongguan DG 1 Greater China Integrated ProductsDongguan City, 2 PlantsGuangdong Province, P.R.C.Began operation from 1988 in ChinaISO 9001, TS16949, Ford Q1 Certificate3,000 employees20,000 Square metersRun 24 hours

4、 per day Cable Products (IPD1) - Automotive Harnesses - Wire Harness - I/O Cable Assemblies - Custom Overmold Cable Assy. - Storage Cable Assy - High Performance (High Speed) Cable Assy for High End Telecom markets - Overmold cable assy for Medical industriesMOLEX CONFIDENTIALMolex Dongguan DG 2 Com

5、mencing 2002ISO9001 2,000 employeesRun 24 hours per dayManufacturing, Product & Process Design Center for: (IPD2)Fiber Optic Rigid & Flex PCBAMembrane SwitchesTotal area of 25,000 sq.m. MOLEX CONFIDENTIALMolex DoungGuan - History 1984 Molex-HK/Nanco started operation in HK1988 Started operation as a

6、 joint venture company in Shilong, producing simple harnesses1992 Started overmold cable assembly production1993 All Hong Kong production moved to Dongguan1994 Certified as ISO 9000 company1997 Moved to Shijie town and became a 100% Molex owned company1999 Started PCBA production2000 Start heat sink

7、 production2002 Started Membrane switches production2002 Started automotive harnesses production2002 Certified as QS 9000 company2003 Certified as TS 16949 company2004 Certified as ISO 14000 company2005 Started High Performance cable productionMOLEX CONFIDENTIALTS 16949Ford Q1Molex Automotive Sub-Ha

8、rnessDiversificationMolex Automotive OverviewDirect CustomersMolex Automotive OverviewOEM CustomersProduct DiversificationPowertrainSafety / ChassisBody ElectronicsInfotainment/NetworkingProduct FocusDevice CablesHSAutoLink CABLESWith industry standard input/output (I/O) or Customized connectors and

9、 overmoldingSensor CABLESSpecial terminate process and testing for automotive special application Product FocusSmall Harness and Jumpers JUMPERSPoint to Point With industry standard connectors.SMALL HARNESSESMore complex custom wire assemblies utilizing any wire-terminated connectorsMolex Product fo

10、cusMissionMolex Dongguan OverviewMolex Dongguan quality systemMolex Automotive Sub-Harness DiversificationAutomotive Customers and Products PowertrainBody ElectronicsSafety/ChassisInfotainment/NetworkingMolex Automotive Sub-Harness CapabilitiesAutomotive Engineering CapabilityManufacture and Test Eq

11、uipments CapabilitiesMolex Marketing Focus and Development.Working process Product ApplicationEngine Control SystemEngine Cooling SystemFuel SystemTransmission SystemSub-Harness for Power TrainPower train cablesEngine Crank/Knock sensor FeaturesInsert molding designTension enhance molding designNylo

12、n + 30% glass fiberPositive latch prevents accidental disconnectShielded cableSolid stamped terminalCustomizable for AWG, length, circuitsPolarized housingCustomized solution availablePower train cablesEngine Oxygen sensor FeaturesMeets automotive standards for chemical resistance and specific tempe

13、raturesGlass fiber protect tubePTFE wireWire both end sealedStainless steel terminalCrimping and Laser welding processLeakage testingCustomized solution availableWater pump cableDescription24AWG TPFE wiresHousing1.5mm TerminalSR molding Power train cablesFuel rail FeaturesMeets automotive standards

14、for chemical resistance and specific temperaturesProtect conduitDiversify clipsMolex MX150 seal connectorPower train cablesFuel Pump FeaturesPolarized terminalLow cost designCustomizable for AWG, length, circuitsPolarized housingPower train cablesEngine Cooling Fan FeaturesMeets automotive standards

15、 for chemical resistance and specific temperaturesProtect tubeDiversify clipsWire sealedCustomized wire gage, lengthCrimping and Pot welding terminatorUltrasonic welding and H/S protectSafety/Chassis cablesAuto gear lock release Combine with micro switchHot melt molding Product ApplicationMirror Sys

16、temLighting SystemDoors Seating SystemRoof SystemSub-Harness for Car BodyCar Body ElectricLamp harness FeaturesMeets automotive standards for chemical resistance and specific temperaturesMolex Compact size sockets provides space savingSimple design allows light weight and reduce defects in assemblin

17、gMaterial is well endurable to high temperatureSealed application available.Car Body ElectricCar body LED lighting cableCar Body ElectricSeat Adjustment Harness FeaturesFlexible and easy mount in the seatSplice to simplifies wiring100% wiring and Hi-pot testingCar Body ElectricWiper Harness Features

18、Molex Micro-fit PVC molded grommetLead free tinned100% gage verifiedCar Body ElectricMirror adjustment Harness FeaturesLower noise design vibration100% wiring and Hi-Pot testingCar Body ElectricAir Condition Harness FeaturesMeets automotive standards for chemical resistance and specific temperatures

19、Full tape protect Diversify clipsWire sealed100% production Hi-pot testingCar Body ElectricRoof Harness FeaturesLow profile (75% Space Savings)Light Weight (50% Weight Reduction)Easy InstallationImproved Thermal ManagementControlled EMI / RFIAllows Electronics IntegrationShielding and Filtering capa

20、bilitiesLow BSR (Buzz, Squeak, Rattle)Lap Solder Joint for Permanent SplicesProduct ApplicationBreak ControlStability ControlSteeringSub-Harness for Safety/ChassisSafety/Chassis cablesSpeed Sensor FeaturesAssembling GrommetWearable TPU cableCustomizable for AWG, length, circuits and GrommetSamples a

21、vailableSafety/Chassis cablesABS system FeaturesAssembling GrommetWearable TPU cableCustomizable for AWG, length, circuits and GrommetSamples availableSafety/Chassis cablesSteering Cable 125C wire or flat cableCable hold or Molded connectorTop coating wire or cable Safety/Chassis cablesTransmission

22、and Chassis Calibration Insert MoldTerminationSealedDiode and resistor adaptorProduct ApplicationDevice Interconnection GPSCar Networking (Molex HSAutoLink)Sub-Harness for Infotainment/NetworkingInfotainment/NetworkingAudio/Video device jumper FeaturesMolex high performance connectorTerminal lead fr

23、ee platingIDT or crimping terminal optionHigh impact strength, good cut-through and abrasion resistanceHigh dielectric strength and insulation resistanceEasy mount and solder on PCBCustomized pin ways and cable colour100% production wiring testingInfotainment/NetworkingAudio/Video device jumper Feat

24、uresMolex high performance dual row board in connectorTerminal lead free platingIDT manufacture processEasy mount and solder on PCBFlat cable for 24-26AWG2.54mm pitchCustomized connector pin way and wiring100% production wiring testingInfotainment/NetworkingAudio/Video device jumper FeaturesMolex hi

25、gh performance dual row fine pitch connectorIDT and crimping manufacture process0.8mm pitchCustomized connector pin way and wiring100% production wiring testingInfotainment/NetworkingVideo device jumper FeaturesHigh performance STP cableGood EMI/EMC performanceForm tape for low noise in vibration si

26、tuationImpedance 100 ohm100% production wiring testingInfotainment/NetworkingGPS antenna jumper FeaturesHigh performance Molex board in connectorMolex Fakara connectorMolded GrommetLow loss RG174 coaxial cableImpedance 50 ohmInfotainment/NetworkingFakra connector color code Molex Automotive HSAutoli

27、nkMolex Solution for CarProduct ApplicationPolarization Various CableVarious Convenience PortsHSAutolinkProduct ApplicationHeaderSealed cableUnsealed CableHSAutolink IIVertical Sealed Header ( 6ckt)RA Unsealed Header ( 6ckt)Molex USB CablesModule to panel USB cable jumper FeaturesFully Meet USB 2.0

28、and USCAR-2 and USCAR-30STD A 5,000 Times Life Cycles Shrouds and latches standard InterfaceEasy to mount with bezel in panelRubber O-ring for loose proofHigh performance STP cableSuperior signal performance and reduced EMIImpedance 90 ohmCustomized cable lengthMini-B end straight and R/A optionSamp

29、le availableMolex LVDS CablesCar interconnection LVDS cable jumper Application: Module to displayFeaturesFully Meet IEEE LVDS and USCAR-2 and USCAR-30Shrouds and latches standard InterfaceHigh performance STP cableSuperior signal performance and reduced EMIImpedance 100 ohmCustomized cable length2 w

30、ire and 4 wire optionPlug to plug and plug to inline optionPol A and Pol B optionSample availableMolex 1394c CablesCar network IEEE1394 cable jumper Application: Module to Module connectionFeaturesFully Meet IEEE 1394 and USCAR-2 and USCAR-30Shrouds and latches standard InterfaceHigh performance STP

31、 cableSuperior signal performance and reduced EMIImpedance 110 ohmCustomized cable lengthPlug to plug and plug to inline optionPol A and Pol B optionSample availableCutting Total 4Crimping Total 15Automatic Cut & Crimp: Total 3FFC Crimping machine Total 1Over molding 10 x 45 ton Insert Molding m/cHo

32、t Melt molding 1Welding Machine 2 Laser Welding 1 Pot Welding 1 Ultrasonic WeldingAssembly LineEquipment/Tooling CapabilityEquipment/Tooling CapabilityAutomatic Cutting/CrimpingKomax 2CharacterAutomatic wire cutting, striping and terminal crimping 30AWGCrimping quality monitorStripping length verify

33、Capability3500pcs/hour one machineJam1CharacterAutomatic wire cutting, striping and terminal crimpingCrimping quality monitorStripping length verifyLaser welding after crimpingCapability2000pcs/hour one machineEquipment/Tooling CapabilityFFC Automatic CrimpingMolex 1CharacterMulti-way crimping 2.54m

34、m pitchFFC feeding side checkAutomatic crimping quality verifyCapability700 crimping/hour one machineEquipment/Tooling CapabilityWire cutting / StrippingSchleuniger 4CharacterHoop up wire and cable availableCapability2000pcs/hour one machineStripingSchleuniger 1CharacterRotary strip knifeMulti lay s

35、trippingFor round CablesCapability700pcs/hour one machineEquipment/Tooling CapabilityAutomatic SolderMolex2CharacterWork with wire lacing fixtureTemperature and solder time adjustableTin wire auto feedingFlux controlCapability200 soldering/hourAutomatic SolderSchunk1CharacterBare wire splicePower an

36、d welding time adjustableCapability500 welding/hourEquipment/Tooling CapabilityMold Machine5 setsCharacterPVC, PBT, PE molder experienceAuto Material feedingCapability250 molding/hour one machineManual CrimpingMolex 15CharacterFor twist pair cableCapability1200pcs/hour one machineEquipment/Tooling C

37、apabilityPot WeldingMolex 1CharacterStrand wire terminatorWire to copper board weldingCapability500 welding/hour one machineEquipment/Tooling CapabilityHot Melt MoldingMolex 1CharacterLow pressure insertGrommets, Strain Relief, Seal.High Temperature applicationCapability1000 welding/hour one machine

38、TestingCapabilityTesting CapabilityElectric test room Mechanical test roomChemistry test roomProduction line testerElectric Testing CapabilityWithstanding voltage testerApplicationHigh voltage testerCapability1000-5000VAC and DCMicro Ohm meterApplicationTerminator joint resistor measurementCapabilit

39、y0.01 mOhmElectric Testing CapabilityTDRApplicationHigh performance cable impedance testCapabilityCoaxial cableTwist cable( USB, 1394, LVDS.)Twinax cable( Mini SAS, SATA.)Network AnalyzerApplicationInsertion loss and return loss testCapability0-2.5G systemRF cableTwist and Twinax cableElectric Testi

40、ng CapabilityEye open test systemApplicationHigh performance cable testCapabilityTwist cableTwinax cableSmart ScopeMechanical Testing CapabilityApplicationMechanical measurementReadable digital number on screen and can be saved.CapabilityProgrammableMechanical Testing CapabilityCross section analyze

41、rApplicationCrimping Cross section analyzerCapabilityCrimping joint cutting and polishing.Cross photo to computerCrimping joint analysisCrimping die verifyMechanical Testing CapabilityDrop testerApplicationPackage free fall drop testCapabilityCarton box testingBend testerApplicationBend test for cab

42、lesCapabilityProvide 10-60 cycle/MinuteBend counter and electric testChemistry Testing CapabilitySalt spray testerApplicationMetal erosive testingCapabilityCable or terminal testingProtect plating testingElement AnalyzerApplicationSGS element testingCapabilityHg, Pb, Cd, Cr, Ci. Br, In line Testing CapabilityLeak testerApplicationCable assembly leak testingCapabilityCharge and leakage testFixture per differe