Automotive Connector Selection

Automotive Connector Selection
1) Electrical Factor
Current requirements: high current, low current, signal level; 
Steady state, cyclic, transient.
They determine the type of terminal/size of contact segment/plating (0.64mm to 8.0mm pin and male terminal).
Wire diameter/insulation requirements: voltage drop and/or corrosion resistance, which determine the center distance of the connector.
2) Location/Environment
Temperature: Engine compartment – sealed, ambient temperature >105℃; vibration, fluid compatibility, passenger compartment – unsealed, ambient temperature <85℃.
Sealing: Potential for high pressure jet/splash, potential for immersion, humidity; fluid type, sealed or not for device connectors.
3) Standard
Standards: Customer Standards
Institutional Standards
Domestic Standards
International Standards
Connector performance test requirements are included in system-level specifications. For GM, Ford and Chrysler are usually USCAR specifications, that is, engine-related applications have relatively high vibration requirements. Other OEMs generally have their own standards (similar to USCAR). What’s more, equipment-side suppliers are responsible for the performance of mating-side connectors.
4) Customer Preference
Preferred product strategy: Reduce cost of connector systems with different methods:
Ford: Design competition for door connectors.
Ford: Prefer terminal design/supplier (focus on contact interface).
General: Prefer the terminal design (focus on the hole position of the connector).
Chrysler: Strategies for favoring terminal/plastic Part suppliers.
5) Regional preference
North America: USCAR Drawing/Performance/Design Criteria —Tangless Terminals, TPA, CPA regulations. In many instances the harness supplier has a significant influence.
Europe: Design influence of contact contacts/development with major OEMs; preference for two-piece contacts, even if cost pressures and North American porting operations force OEMs to consider U.S technology, that is, accepting Tangled contacts. Long-term relationships between OEMs and suppliers.
Asia: Traditionally influenced by Toyota. Focus on assembly ability (ergonomics) that affects quality assurance; North America influences China to change the status, like low-cost solutions.
6) Physical factors
Size, number of circuits, mating position, wire harness docking or equipment connection, mechanical main features: levers, bolts; manual docking capability; multiple types of connectors for high input/output applications.
7) Assembly
Wire Harness: Insertion force of connector
Visual, audible and tactile operational feedback for users.