What is a connector?

Connectors are electronic components that connect the flow of electricity and electrical signals.

 

Connectors support various fields in modern society. Next, we will introduce the functional characteristics of connectors and the technology and production process that support them.

 

Fields of use of connectors

 

Connectors are not only used in cars, smartphones, computers and other items that are closely related to our lives, but also in all electronic-related terminal devices. Because connectors need to cope with various design styles and uses, there are many types of connectors. What kind of connection effect will be produced by using connectors? Let's take a computer as an example.

 

First, there is the memory slot. It is a slot installed on the PCB board inside the computer case and used to connect to the memory card.

 

Secondly, there is a connector for the PCB board inside the computer. Electronic circuits are composed of multiple substrates according to different functions. Connectors are needed to connect these substrates. In addition, connectors are also needed to connect the LCD screen and keyboard to the PCB board.

 

Finally, there is the interface connector. This is a connector used to connect the computer host and printers, mobile devices, TVs and other external devices.

 

In addition, there are card holder connectors for connecting various cards.

Advantages and necessity of connectors

 

So, why do we need to use connectors?

 

For example, when connecting the internal PCB board of the device, although the circuit can be directly connected, it will take a long time to operate. And the removal and other work during repairs are more time-consuming. However, by connecting with connectors, it is easy and quick to "connect" and "disconnect". Therefore, mass production, division of labor production, repair and maintenance work can be easily realized. The interface between peripheral machinery and the network is naturally the same. With the evolution of various devices, the convenience of "connecting" and "disconnecting" of connectors is indispensable.

Connector structure accessories

 

So, what is the structure of the connector?

 

The connector is composed of a pair of plugs and sockets to perform its functions. The plug and socket are composed of terminals that carry electricity, insulators made of plastic to maintain the insulation function between the terminals, and shell parts that protect it.

 

The most critical terminal in the connector component is made of copper alloy material with high conductivity. One side is a plug terminal without elasticity, and the other side is a socket terminal processed with an elastic structure, which can make the plug and the socket tightly combined. The jack is contacted with the plug, and the elastic structure of the connector makes it tightly combined, completing the connection or transmitting power and signals.

Technical factors supporting connectors

 

Connectors have the mission of keeping the power and electrical signals of all electronically connected machines connected smoothly in any environment. In order to improve its reliability, we introduce several technical factors that can support connectors.

 

1. Contact reliability technology

 

In order to make power and electrical signals "uninterrupted", "unchanged" and "undecayed", contact reliability technology is particularly important. In order for the terminal to contact the electrical with stable performance, the terminal spring must be a metal structure with elasticity. Even if the connector is plugged in and out many times, the socket terminal will return to its original position due to its elastic function. If the contact force is unstable, it will not be able to engage normally. Using operability and spring characteristics to improve the contact reliability of the terminal is the most basic and important technical factor.

2. Simulation evaluation technology

 

Next, let's take a look at simulation evaluation technology. Connectors are required to have high-speed and non-interrupted waveforms, and to avoid electromagnetic noise that may cause machine malfunctions. For this reason, when designing connectors, simulation evaluation technology such as structural design is also a very important technical factor.

3. Environmentally resistant design technology

 

In addition, connectors used in outdoor facilities such as automobiles are often affected by vibration and impact, temperature, humidity, wind and rain. Moreover, environmentally resistant design technology that can withstand exhaust gas and dust and always maintain stable contact is also an important technical factor. Our company evaluates contact reliability by implementing various evaluation tests.

Manufacturing technology that supports the production of connectors

 

In addition to launching more competitive new energy models, automakers are also intensively laying out charging networks. In the past two years, 800V high-voltage platforms and 4C charging technologies have been launched one after another, and the era of comprehensive fast charging is approaching. Tesla, Xiaopeng, Ideal, Zeekr, Huawei and other companies are accelerating the construction of supercharging stations and supercharging piles across the country, providing higher charging power and energy replenishment efficiency to bring an evolved charging experience to end users and eliminate mileage anxiety.

 

 

 

On the policy side, the country's strong support for new energy vehicle charging facilities is driving it to become an emerging hot market. As early as 2020, new energy charging piles have been included in one of the seven key areas of "new infrastructure". After years of development, it has been quite effective. According to statistics from the China Charging Alliance, in 2023, the increase in charging infrastructure will be 3.386 million units, and the increase ratio of piles to vehicles will be 1:2.8, which means that the construction speed of charging piles can basically meet the rapid development of new energy vehicles.

 

When the focus is on the charging pile industry chain, downstream companies have an increasingly strong demand for high-power supercharging, DC fast charging, liquid cooling, etc. This demand is transmitted to upstream charging equipment component suppliers, including charging guns, charging cables, power modules, controllers and other components must be upgraded accordingly, and meet safety requirements such as high temperature resistance and high voltage resistance to support the implementation of higher-specification charging piles.

 

In the design of charging piles, the choice of materials is crucial. Especially for indicators such as thermal conductivity, sealing, insulation, and flame retardancy, breakthroughs in materials are needed, including silicone materials. Silicone can be used as thermal conductive adhesive, sealant, adhesive, etc., and is widely used in core components such as thermal management, charging protection, and power modules of charging piles, playing a key role in charging pile components.

 

What challenges does the popularization of supercharging technology bring to charging facilities?

 

If new energy vehicles want to get a charging experience close to that of fuel vehicles, they must improve their charging efficiency in an all-round way. This is why car companies are striving to bring 4C or even 5C supercharging technology to consumers while promoting the 800V high-voltage platform.

 

In August 2023, CATL launched the world's first lithium iron phosphate 4C supercharging battery-Shenxing Supercharging Battery, claiming to achieve 10 minutes of charging and a range of 400 kilometers. After that, 4C fast charging has entered the field of vision of consumers more and more frequently.

 

How is 4C supercharging defined? Simply put, XC refers to the charging rate, that is, the ratio of the maximum charging current that the battery can accept during charging to the rated capacity of the battery, represented by C, which is usually used to describe the speed of charging. Specifically, if the vehicle is equipped with a 100kWh battery pack, the charging power can reach about 200kW at a rate of about 2C; at a rate of about 4C, the charging power can reach about 400kW; at a rate of 6C, the charging power can reach about 600kW. In short, the higher the charging rate, the faster the charging speed.

 

If you want to truly popularize supercharging, in addition to power batteries and high-voltage platforms, you must also adapt to high-power DC charging piles. The power output capacity of the charging pile and the stability of the power supply will affect the charging rate. High-power charging piles and stable power supplies can provide higher charging rates.

 

 

The charging pile is mainly composed of charging gun, charging cable, shell, control module, thermal management module, charging protection module and other components. From AC slow charging to DC fast charging, and then to super fast charging, which may gradually become popular in the future, all components need to be upgraded iteratively to adapt to the change of charging power.

 

In fact, before the super charging technology, in the process of the development of charging piles from AC slow charging to DC fast charging, problems such as high cost, grid burden, compatibility, battery life, and difficult installation have been roughly solved.

 

On the basis of DC fast charging technology, super fast charging provides a higher charging rate, so the charging pile needs to bear higher power, larger current, and higher heat generation. At the same time, it is also necessary to solve the problem of excessive size and weight of the charging pile and stricter cable flexibility requirements.

 

For the charging gun, in order to achieve fast charging, the super charging gun needs to be able to transmit large current. This requires the charging gun to have good conductivity and heat dissipation design to ensure safe and efficient current transmission.

 

 

 

Supercharging technology also needs to be equipped with a complete safety protection mechanism, including overcurrent protection, overvoltage protection, short circuit protection, etc. Charging piles and charging guns should have monitoring and protection functions to prevent malfunctions and dangers during charging.

 

Not only that, since high-power charging will generate a lot of heat, charging piles and charging guns need to be equipped with an effective cooling system to prevent overheating, including fans, heat sinks, water cooling and other heat dissipation methods.

 

What are the requirements for materials for the upgrade of charging facilities?

 

With the increase in charging power, charging piles not only need to design more advanced structures to meet the thermal conductivity under high power, but also, on the material side, it is imperative to use materials with strong insulation, high temperature resistance and high thermal conductivity.

 

Taking the thermal management system of charging piles as an example, unlike traditional air cooling, supercharging requires more use of liquid cooling to solve efficiency and heat dissipation problems. At present, the most commonly used liquid cooling methods on the market are water-based cooling and oil-based cooling. Water cooling has better heat dissipation performance, lower cost, and is more environmentally friendly; oil cooling has good electrical insulation, lower evaporation rate and chemical stability.

 

In the past few years, oil-cooled cables have been used in super charging guns, gaining a first-mover advantage. At present, some manufacturers have developed oil-cooled super charging piles and charging guns, but as the operating time goes by, the cost disadvantage of oil cooling becomes more and more prominent. Now more manufacturers are beginning to study and test water-cooled cables and water-cooled super charging guns.

 

The working principle of water-cooled cables and water-cooled super charging guns is that the water-cooling tube is designed outside the multi-strand charging wire, and water flows in the middle of the tube. Relying on the thermal conductivity of the tube itself, the heat generated by the multi-strand charging cable is transferred to the coolant in the middle of the tube. These coolants exchange heat with the outside world through electronic pumps to achieve temperature control of cables and super charging guns.

 

Based on this principle, many manufacturers used ordinary nylon tubes as the water-cooling tubes in the middle of water-cooled cables. Due to the use of PA material, the thermal conductivity is only 0.2W/m·K. When the current exceeds 400A, the temperature rise accelerates sharply. At this time, due to the insufficient thermal conductivity of the water-cooling tube, the heat cannot be transferred out in time. After calculation, it was found that based on the common structure of the current cables, if the goal of high current fast charging is to be achieved, the thermal conductivity of the cold water pipe must be greatly improved, at least 1.5W/m·K or more. Therefore, the upstream and downstream of the industry chain pay more and more attention to the innovative application of high thermal conductivity materials, and thermal conductive silicone tubes have become one of the key components of thermal management of super charging piles.

 

 

 

 

In addition to the temperature control of the charging cable, how to reduce the temperature rise of the charging gun head during the charging process is also a pain point in the current charging pile design. At present, it is difficult to solve the heat dissipation problem by air cooling. By using innovative thermal conductive potting glue, the heat of the gun head connector can be efficiently transferred out to ensure that the charging efficiency will not decrease due to the temperature increase, and at the same time, the user experience during operation can be further improved.

 

On the other hand, when the voltage platform of new energy vehicles in the future generally reaches 800V, the charging current reaches 600A, and the charging power reaches more than 400kW, any problems in the charging process may cause extremely serious consequences. Therefore, the sealing and anti-leakage properties of structural materials will be unprecedentedly valued.

 

Under the new trend, how to innovate on the material side?

 

When it comes to upstream material suppliers in the charging pile industry chain, Dow is the first to bring many innovative designs and cutting-edge ideas to the industry. Dow can not only provide a rich selection of materials, but also customize exclusive solutions for higher-power DC fast charging infrastructure (including charging stations, charging guns (connectors), cables and charging cabinets) to meet more stringent market needs.

 

In the field of charging facilities, Dow focuses on three major directions. First, in terms of thermal management materials, Dow provides a wide range of adhesive products including caulking agents, adhesives, non-curing thermal interface materials, immersion coolants, gels and potting glues to solve the heat dissipation pain points in charging facilities; in terms of protection and assembly materials, Dow provides adhesives, sealants and conformal coatings to provide all-round protection for charging components; in addition, Dow can also provide elastomers, solid thermal conductive silicone rubber and liquid silicone rubber to support insulation, thermal conductivity and other needs.

 

For example, capturing the thermal conductivity requirements of the charging cable mentioned above, Dow has developed a new thermal conductive silicone rubber - SILASTIC™ HTE5015-90U silicone rubber, which solves the key technical difficulties in the water-cooled super charging gun solution - the cooling water pipe must have both high thermal conductivity and high strength and high toughness materials. The most significant advantage of this product is that it has a higher thermal conductivity, with a thermal conductivity of up to 1.5W/m·K, which can cool the cable of the super charging gun with a current of 600A and provide thermal protection. At the same time, good physical properties and resistance to harsh environments allow it to be used to extrude thermally conductive silicone tubes. High hardness and high strength enable direct twisting with cables. In addition, better flexibility, durability, high and low temperature resistance, coolant resistance, insulation and other indicators provide long-term protection for super charging guns.

 

In response to the heat dissipation and sealing needs of charging gun heads, Dow has developed a series of products. Dow's DOWSIL™ TC-6040 thermal conductive potting glue has a thermal conductivity of 4.0W/m·K, which can quickly cool down overheated charging guns, which will not be hot, and ensure the normal operation of the modules inside the system, especially the most important inverter module. Long-term reliability; for the sealing requirements of liquid-cooled charging piles, the sealing rings and wiring harness sealing rings made of Dow's silicone elastomer materials have achieved good waterproof effects.

 

Conclusion

 

After years of vigorous development in the new energy vehicle industry, the pain points of end users have gradually transitioned from cruising range to efficient energy replenishment experience, and the promotion of high-power and high-efficiency charging facilities is imminent. In this process, upstream and downstream companies in the industrial chain need to work together to cope with the various challenges faced by the fast charging trend, from batteries to charging facilities, from materials to applications. We hope that the leading companies in the upstream and downstream of the industrial chain can bring more efficient and easy-to-use solutions to the fast charging development of new energy vehicles.

       According to the U.S. "Wall Street Journal" website reported on 10 January, 2023, China's auto exports soared to a record level, is expected to exceed Japan as the world's largest auto exporter. This marks a major change in the global auto industry landscape.

       While China has been recognised as a global leader in electric vehicles, traditional fuel vehicles remain the main driver of growth in the car market, with demand surging in Russia in particular, the report said.

　　A report released by the China Passenger Vehicle Market Information Federation (CMPMIF) on 9 September estimated that China's car exports reached 5.26 million units in 2023, adding that this could be nearly one million more than Japan's car exports. According to the latest official data from Japan, the country exported slightly less than 4 million vehicles in the first 11 months of 2023.

 

       Chinese carmaker BYD reportedly exported 242,000 units in 2023. The company replaced Tesla as the world's largest producer of all-electric cars in the fourth quarter of 2023. The company is expanding its showrooms across Europe with a view to selling more cars in Europe this year.

　　Multinational carmakers with plants in China are also looking to export cars made there, the report said. Volkswagen will export cars made in China overseas for the first time and will export up to 60,000 electric coupes made in China to Europe this year, a spokeswoman said.

　　A photo taken on 19 July 2023 shows the Dale Automobile Logistics Base in Liuzhou city, Guangxi province. Some exported new-energy cars are loaded and shipped to major sea ports from here. (AFP)

　　Ford said the company's exports from China expanded to 100,000 vehicles in 2023.

　　The total wholesale volume of passenger cars in China reached a record high of more than 25.5 million in 2023, according to the China Federation of Passenger Vehicles.

       Cui Dongshu, secretary-general of the Passenger Car Association, said Russia contributed nearly 800,000 units of the estimated 2 million incremental vehicle exports from China in 2023.

　　Automaker Chery became the largest Chinese carmaker in passenger car exports in 2023, fuelled by a boom in exports to Russia, reaching a total of more than 900,000 units, Cui said. (Reference News Network)

background:

 

With the gradual launch and popularization of vehicles equipped with 800V system platforms, a series of new challenges in 800V voltage systems compared with traditional 400V voltages are gradually attracting attention. This article will do some analysis and comparison from different systems of the entire vehicle. When we mention 800V now, many people will think of "800V fast charging", "silicon carbide electric drive", etc. What we need to understand is that 800V fast charging or overcharging is just a system in the 800V high-voltage platform. We can divide the charging facility end to the vehicle end into: charging system, battery system, drive electronic control system, auxiliary unit system, etc. The 800V platform requires these dispersed systems to work under the same voltage platform.

 

800V charging "Basic principles of charging"

 

This article mainly talks about some preliminary requirements for 800V charging piles. Let’s first look at the charging principle: when the charging gun head is connected to the vehicle, the charging pile will provide ① low-voltage auxiliary DC power to the vehicle to activate the built-in BMS of the electric vehicle ( Battery management system), after activation, ② Connect the vehicle terminal to the pile terminal, exchange basic charging parameters such as the maximum charging demand power of the vehicle terminal and the maximum output power of the pile terminal. After the two parties match correctly, the BMS (battery management system) of the vehicle terminal will The charging pile sends power demand information, and the charging pile will adjust its output voltage and current based on this information, and officially start charging the vehicle. This is the basic principle of charging connection, and we need to be familiar with it first.

 

800V charging: “Increase voltage or current”

 

Theoretically, if we want to provide charging power and shorten charging time, there are usually two ways: either you increase the battery or increase the voltage; according to W=Pt, if the charging power is doubled, the charging time will naturally be halved; according to P =UI, if the voltage or current is doubled, the charging power can be doubled. This has been mentioned repeatedly and is considered common sense.If the current is larger, there will be two problems. The larger the current, the larger and heavier the cable required to carry the current will be. This will increase the wire diameter and weight, increase the cost, and make it inconvenient for personnel to work; in addition, according to Q=I²Rt, if The higher the current, the greater the power loss. The loss is reflected in the form of heat, which also increases the pressure on thermal management. Therefore, there is no doubt that it is not advisable to increase the charging power by continuously increasing the current, whether it is charging or driving. Internal drive systems are not advisable.

Compared with high-current fast charging, high-voltage fast charging generates less heat and lower losses. At present, almost mainstream car companies have adopted the route of increasing the voltage. In the case of high-voltage fast charging, theoretically the charging time can be shortened by 50%. The increase in voltage can also easily increase the charging power from 120KW to 480KW.

 

800V charging: "Thermal effects corresponding to voltage and current"

 

But whether you are increasing the voltage or the current, first of all, as your charging power increases, your heat will appear, but the heat manifestations of increasing the voltage and increasing the current are different, and the faster one will have a greater impact on the battery. A larger one, a relatively slower one but with more obvious thermal concealment and a more obvious upper limit. But the former is preferable.

Since current encounters lower resistance as it passes through the conductor, increasing the voltage reduces the required cable size and dissipates less heat. While increasing the current, the current-carrying cross-sectional area increases resulting in larger outer diameter cables. It is heavier, and the heat will gradually increase as the charging time increases, making it more concealed. This method has greater risks for the battery.

Analysis and improvement of water intrusion failure of automobile wiring harness connectors

 

Analysis and Improvement of Water Intake Fault of Wiring Harness Plug-in

 

 

 

The article takes the water intrusion failure of a certain model of automobile wiring harness connector as an example, and uses the fault tree analysis method to analyze and improve the water intrusion failure of the automobile wiring harness connector. The purpose is to eliminate the water intrusion failure of the automobile wiring harness connector and improve the safety of the car. It satisfies users' needs for safe driving and provides a reference for the development of later models and the analysis and improvement of similar faults.

 

 

 

 

 

01 Analysis and improvement of water intrusion failure of automobile wiring harness connectors

 

 

 

In the market failure report of a certain model of automobile wiring harness, the fault rate of water intrusion in the wiring harness connector was as high as 47%, and the fault location was mainly concentrated in the nitrogen and oxygen sensor. Water intrusion into the wiring harness connector is the TOP1 fault among the wiring harness failure modes of this model. The following uses "Analysis and Improvement Process of Water Intrusion Failure in the Nitrogen Oxygen Sensor Wiring Harness Connector of This Model" as a case to elaborate on.

 

 

 

After receiving the project task, the company immediately formed a project team, and the company leaders launched the project research. The members of the project team are composed of personnel from suppliers of complete vehicles and wiring harness components who are engaged in cross-disciplinary work such as technology research and development, technology, quality, and production and manufacturing. During the project research process, members of the project team visited markets such as Jiangsu and Zhejiang, conducted on-site investigations on the working conditions of car owners, observed faults on-site, and found that the water ingress was concentrated at the nitrogen and oxygen sensor. The members of the project team and the maintenance technicians from the local maintenance service station worked together to discover, analyze and solve problems at the site of the faulty vehicle, on-site and on-site, and finally formed and implemented a product optimization and improvement plan. The improved product has undergone a large number of experimental verifications and vehicle road tests. The water intrusion failure of the wiring harness connector was finally eliminated, the physical product was switched as scheduled, and the project was successfully completed. During the project development process, the project team members were problem-oriented and aimed at eliminating the water intrusion failure of the nitrogen and oxygen sensor wiring harness connector. They focused on the nitrogen and oxygen sensor wiring harness, compared the product drawings and technical requirements, and used the fault tree analysis method to analyze the problems from people, Systematic discussions and analyzes were carried out on machines, materials, methods, environment, measurement and other aspects, and the reasons for the "water intrusion failure of the nitrogen and oxygen sensor harness connector" were thoroughly searched from the outside to the inside. Through thorough discussion and analysis, three possible reasons were identified:

(1) Process selection issues for wire harness connectors, waterproof plugs, blind plugs, and terminals;

(2) The waterproof bolt is damaged or missing;

(3) Connector design issues.

Further analysis identified two possible reasons for the "process selection problem of wire harness connectors, waterproof plugs, blind plugs, and terminals": one is the problem of wire harness connectors, waterproof plugs, blind plugs, and terminal matching; the second is waterproofing Plug insertion status problem. It was identified that there are two possible reasons for "broken or missing waterproof bolts": one is a problem with employees' standard operations; the other is that the waterproof bolts were damaged during the circulation process. It was identified that there are two possible reasons for the "connector design problem": one is the connector selection problem; the other is the connector assembly position problem.

In summary, through FTA analysis, a total of six potential factors were identified that may cause "water intrusion into the nitrogen and oxygen sensor wiring harness connector", namely: wiring harness connector, waterproof plug, blind plug, terminal matching problem, waterproof plug insertion Status issues, employee standard work issues, waterproof bolts damaged during circulation, connector selection issues, connector assembly location issues. The specific fault tree is shown in the figure below (Figure 1):

 

►Wire harness connectors, waterproof plugs, blind plugs, and terminal matching issues

 

The project team inspected the models and wire diameters of the wiring harness connectors, waterproof plugs, blind plugs, and wiring harness terminals at the nitrogen and oxygen sensor locations. At the production site, 50 physical products were randomly selected for testing. Among them, connectors, waterproof plugs, blind plugs, and wiring harness terminals are all parts specified by the vehicle manufacturer. Their sizes and models comply with the requirements of the technical drawings. Wiring harness connectors, waterproof plugs, Blind plugging and terminal plug-in matching are good. Carry out airtightness test and watertightness waterproofing test on nitrogen and oxygen sensor sheaths, waterproof plugs, blind plugs, etc. in accordance with the definitions in Part 1 of QC/T 417.1-2001, test methods and general performance requirements (automotive part) 4.9 waterproof performance requirements, and observe There was no airflow during the test, and there were no visible traces of water inside the connector. The test results proved that the actual product complied with the technical requirements of 4.9 waterproof performance in QC/T 417.1-2001 Part 1, Test Methods and General Performance Requirements (Automotive Part).

Therefore, "wire harness connectors, waterproof plugs, blind plugs, and terminal matching issues" are not the key factors affecting the water ingress of the nitrogen and oxygen sensor wire harness connectors.

►Problems with the insertion status of waterproof bolts

 

The project team organized design, process, quality and other relevant personnel to jointly conduct process discipline inspections at the production and manufacturing site. The operating standards for the crimping station, waterproof plug assembly station and interpolation station at the manufacturing site are complete and effective. The operator operates the fully automatic offline crimping equipment to crimp the terminals, and the semi-automatic waterproof plug equipment inserts the waterproof plug. The production equipment is operating in good and stable condition, and on-site equipment maintenance records are complete. The insertion status of 100 waterproof bolts was tested on site. The insertion position of the waterproof bolts was stable. The quality of the waterproof bolts after insertion met the technical standards.

Therefore, "the insertion status of the waterproof plug is not the key factor affecting the water ingress of the nitrogen and oxygen sensor harness connector.

►Employee standard operating issues

 

At the manufacturing site, wire harness terminals are crimped using special molds. The mold is regularly maintained and maintained in good and stable condition. The wire harness terminal crimping height, pullout force and other dimensions and performance meet the requirements of technical standards, and the terminal crimping condition is in good condition. A random inspection of the process inspection records of the workshop inspector found that on a certain day the inspector randomly inspected 120 nitrogen and oxygen sensor wire harnesses, and 8 blind bolts were missing. The solution was to rework. Carefully look at the inspector's process inspection record sheet, which shows that a different number of nitrogen and oxygen sensor blind bolts are missing every month. In order to further find out the reason for the missing installation of blind bolts, the project team went to the formwork insertion station of the workshop to conduct an investigation. There is a work standard instruction book on the template inserting and planting station, and the work standard instruction book clearly stipulates that blind bolts must be assembled. During the inspection, it was found that there were multiple operators at the template insertion and planting station at the same time, but the personnel who assembled the blind bolts were not fixed, and the operators installed them by themselves, which easily caused the blind bolts to be missed.

Therefore, "employee standard work issues" are the key factors affecting the water ingress of the nitrogen and oxygen sensor wiring harness connector.

Improvement measures: In order to prevent employees from missing the blind bolt installation, the project team optimized the process and adjusted the blind bolt assembly from the template insertion station to the previous process: the batching station. That is, after the batching personnel assemble the blind bolts, the product flows into the next process: the template insertion station. The planting personnel will check and confirm that the blind bolts in the previous process are in place. In this way, the upper and lower processes perform self-inspections and mutual inspections to prevent missing installation of blind bolts. The project team promptly solidified the optimized process into FMEA, operating standard instructions and other relevant technical documents, and organized training and evaluation of relevant employees on knowledge and skills. Employees who pass the evaluation will be put on the job. After process optimization, project team members tracked the quality of the nitrogen and oxygen sensor wiring harness at the manufacturing site and found no missing blind bolts. They tracked and inspected the inspection records of the workshop process inspector for a month and found no missing blind bolts. Process improvement The results are obvious.

►The waterproof bolt was damaged during circulation

 

At the manufacturing site, the wire harness terminals after crimping are equipped with plastic protective cups for protection, and the terminal protection effect is good. The wiring harness was hung on a special work station equipment trolley and circulated within the workshop. During the circulation process, no damage or missing waterproof plug of the nitrogen and oxygen sensor was found.

Therefore, "the waterproof plug is damaged during the circulation process" is not the key factor affecting the water ingress of the nitrogen and oxygen sensor wiring harness connector.

 

►Connector selection issues

 

There are two types of nitrogen and oxygen sensor wiring harness connectors for this model, namely Part A and Part B. After sorting out the market failure reports, it was found that the faulty connector models were all Part A. However, for vehicles equipped with Part B, there was no water intrusion into the connectors on the market. In order to further identify the cause, the project team dissected the faulty parts and found that the oxidation direction of the wires was from the connector to the wiring harness branch. Then they picked out the terminals and found that the oxidation was from the terminal head to the wires. These phenomena indicate that water enters between the two plug-ins. Comparative analysis of the two connectors, Part A and Part B (Figure 2), shows that the terminals of Part A are exposed to the outside without protection; while Part B has restrictors that completely cover the terminals, resulting in better sealing and higher waterproofing effect.

 

Therefore, the "connector selection problem" is a key factor affecting the water ingress of the nitrogen and oxygen sensor wiring harness connector.

Improvement measures: The connector B was subjected to a watertight and waterproof test, and the test results were qualified and in line with the technical requirements of 4.9 waterproof performance in QC/T417.1-2001 Part 1 Definition, Test Methods and General Performance Requirements (Automotive Part). The project team optimized the product design and switched the nitrogen and oxygen sensor wire harness end connector from Part A to Part B. At the same time, it modified relevant technical documents such as FMEA, product drawings and technical standards, and organized training for relevant employees to form organizational memory and prevent Similar design selection problems occurred again.

►Connector assembly position problem

 

Members of the project team conducted air-tight and waterproof tests on 10 nitrogen and oxygen sensor wire harness connectors returned from the market. The test verification results were all qualified and in line with the definitions, test methods and general performance requirements (automotive part) of QC/T 417.1-2001 Part 1 4.9 Technical requirements for waterproof performance. Place the connector in the vehicle system for analysis. The nitrogen and oxygen sensor is installed above the fuel tank and exhaust pipe. The assembly position here is lower. The temperature is higher when the vehicle is driving. The impact of water pressure here on rainy days. The waterproof level of the wiring harness connector cannot meet the requirements of the vehicle layout environment. A small amount of water vapor will enter the sensor along the sensor wiring harness, causing damage to the nitrogen and oxygen sensor.

Therefore, "connector assembly position problem" is a key factor affecting the water ingress of the nitrogen and oxygen sensor wiring harness connector.

Improvement measures: Adjust the assembly position of the nitrogen and oxygen sensor on the vehicle from the original position of the fuel tank and exhaust pipe to the position inside the chassis frame of the car. At the same time, add dripping points to avoid water accumulation in the nitrogen and oxygen sensor wiring harness connector caused by high temperature and high pressure. According to the improvement plan, five vehicles were installed and tested on the road. There was no water intrusion into the nitrogen and oxygen sensor wiring harness connector, and the improvement measures were effective. The project team modified product drawings, technical standards, technical requirements and related process documents and operating standard instructions, and organized timely training to form organizational memory and prevent similar design problems from happening again.

02 Conclusion

In summary, through fault tree analysis, the three key factors causing water intrusion into the nitrogen and oxygen sensor harness connector were identified: employee standard work issues, connector selection issues, and connector assembly location issues. Based on these three key factors, a product improvement plan was proposed and implemented. The improved vehicle did not have water intrusion into the nitrogen and oxygen sensor wiring harness connector. The project team solidifies and standardizes the product improvement results in a timely manner to form organizational memory. Through the project research, the water intrusion fault of the nitrogen and oxygen sensor wiring harness connector has been eliminated, the safety of the car has been improved, and the users' needs for safe driving have been met for a better life. At the same time, it has provided a reference for the development of later models and provided information for the analysis and improvement of similar faults. Learn from.

In today's digital era, connectors, as an indispensable part of electronic equipment, play a key role. Whether it’s smartphones, computers, cars, or industrial automation, connectors are key components that enable seamless connections between these devices. The continuous innovation and development of connectors creates a more convenient, efficient and exciting digital experience for people.

 

With the continuous advancement of technologies such as 5G communications, Internet of Things, and artificial intelligence, the connector industry is facing new opportunities and challenges. In order to meet the needs of high-speed data transmission and low latency, connector manufacturers are launching various high-speed connectors, such as USB 4.0, Thunderbolt 4, HDMI 2.1, etc. These connectors not only support high-definition video transmission, ultra-fast data transmission and fast charging, but also provide users with a smoother and more realistic multimedia experience.

 

In addition to high-speed connectors, the connector industry is constantly exploring solutions to the challenges of smaller size and higher power. As the Internet of Things becomes more popular, more and more devices need to be connected within a limited space. Therefore, the demand for micro connectors is growing day by day. These small and exquisite connectors not only meet the compact design requirements of the equipment, but also provide stable and reliable connection performance.

 

At the same time, the rise of electric vehicles has also brought new opportunities to the connector industry. Electric vehicles require a large number of connectors to connect battery systems, charging systems, drive systems, etc. To meet the high-power and high-reliability connectivity requirements of electric vehicles, connector manufacturers are developing stronger and more durable connector solutions. These connectors not only ensure the safety and performance of electric vehicles but also accelerate their adoption.

 

In the connector industry, sustainability has also become an important topic. Connector manufacturers are working hard to reduce the use of materials and improve production processes to reduce their impact on the environment. In addition, they are working to develop recyclable and reusable connectors to reduce the generation of electronic waste. By taking these sustainable initiatives, the connector industry can not only meet market demands but also contribute to protecting the global environment.

 

In general, connectors, as an indispensable key component in the digital era, are constantly innovating and developing. High-speed connectors, micro-connectors, electric vehicle connectors and sustainable connector solutions all bring people a more convenient, efficient and reliable digital experience. The connector industry will continue to actively respond to new technological challenges and promote seamless connectivity in the digital world.

In the ever-evolving landscape of automotive technology, one often-overlooked yet essential component stands out – automotive connectors. These small, intricate devices play a pivotal role in the seamless integration of advanced electronics, making them the unsung heroes behind the innovations driving our vehicles into the future.

Connecting the Dots: What Are Automotive Connectors?

Automotive connectors are the silent enablers of connectivity within vehicles. Serving as the bridge between various electronic components, these connectors facilitate the transfer of signals, power, and data throughout the vehicle's intricate network. From engine control units to infotainment systems, connectors are the unseen conductors ensuring the harmonious operation of our automobiles.

Versatility in Design: Tailoring Connectors to Automotive Needs

The world of automotive connectors is diverse, with a myriad of designs catering to specific applications. From traditional wire-to-wire connectors to more advanced fiber-optic connectors, each type is carefully engineered to meet the demands of modern vehicle architectures. As automotive systems become more complex, connectors play a crucial role in ensuring compatibility and reliability.

Materials and Durability: The Backbone of Connectivity

The choice of materials in automotive connector construction is a critical factor in ensuring durability and performance. Manufacturers often opt for materials such as rugged plastics, corrosion-resistant alloys, and gold-plated contacts to withstand the harsh conditions within an automotive environment. These materials contribute to the connectors' ability to endure temperature variations, vibrations, and exposure to elements.

Safety First: The Role of Connectors in Automotive Safety Systems

Connectors in automotive systems go beyond facilitating communication; they are integral to safety features. In modern vehicles, connectors are vital components in airbag systems, anti-lock braking systems (ABS), and advanced driver-assistance systems (ADAS). The reliability of connectors is paramount in ensuring the seamless operation of these safety-critical systems.

Innovation Driven by Connectivity: The Rise of Smart Connectors

As vehicles become smarter and more connected, automotive connectors are evolving to meet new challenges. Smart connectors equipped with sensor technologies, data transmission capabilities, and self-diagnostic features are becoming increasingly prevalent. These innovations contribute to the efficiency, diagnostics, and overall intelligence of modern vehicles.

Future Outlook: Automotive Connectors in the Era of Electric and Autonomous Vehicles

With the rise of electric and autonomous vehicles, the role of automotive connectors becomes even more crucial. High-voltage connectors for electric powertrains and complex data connectors for autonomous systems are at the forefront of innovation. The reliability and precision of connectors will play a pivotal role in shaping the success of these transformative technologies.

Conclusion: Driving Innovation Through Connectivity

In conclusion, automotive connectors are the silent architects of the automotive revolution. As vehicles continue to embrace advanced technologies, the significance of connectors in ensuring seamless communication and functionality cannot be overstated. The road ahead is paved with innovations, and at the heart of it all, automotive connectors will continue to drive the evolution of our vehicles into the next era of mobility.

Introduction:

In today's rapidly changing world, the demand for clean and sustainable energy solutions has never been greater. With the threat of climate change looming large and the finite nature of fossil fuels becoming increasingly apparent, the transition to renewable energy sources has emerged as a crucial imperative. In this blog post, we'll explore the transformative potential of renewable energy and why it's essential for shaping a brighter and more sustainable future for generations to come.

The Promise of Renewable Energy:

Renewable energy, derived from natural resources such as sunlight, wind, water, and biomass, offers a host of compelling benefits. Unlike fossil fuels, which emit harmful greenhouse gases and contribute to climate change, renewable energy sources produce little to no emissions during operation. This makes them a crucial tool in the fight against global warming and air pollution, helping to safeguard our planet's delicate ecosystems and public health.

Moreover, renewable energy is inherently abundant and inexhaustible, unlike finite fossil fuel reserves that are subject to depletion. With advancements in technology and infrastructure, we have the opportunity to harness the vast potential of renewable energy resources on a scale never before imagined. From solar panels blanketing rooftops to wind turbines dotting the landscape, the possibilities for generating clean, renewable energy are virtually limitless.

The Role of Renewable Energy in Economic Development:

In addition to its environmental benefits, renewable energy also holds tremendous economic promise. The transition to renewable energy creates jobs, stimulates economic growth, and enhances energy security. As the renewable energy industry continues to expand, it presents vast opportunities for innovation, entrepreneurship, and investment.

Countries that invest in renewable energy infrastructure stand to gain a competitive edge in the global marketplace, positioning themselves as leaders in the transition to a low-carbon economy. By embracing renewable energy technologies, businesses can reduce their operating costs, increase their energy independence, and enhance their sustainability credentials, all while contributing to a cleaner and more resilient energy future.

Challenges and Opportunities:

Despite the many benefits of renewable energy, significant challenges remain to be addressed. These include intermittency and grid integration issues, the need for investment in infrastructure and storage technologies, and overcoming political and regulatory barriers. However, these challenges also present opportunities for innovation and collaboration, driving advancements in renewable energy technology and policy.

Conclusion:

In conclusion, the rise of renewable energy represents a paradigm shift in how we generate, distribute, and consume energy. By embracing renewable energy sources such as solar, wind, and hydroelectric power, we can reduce our reliance on fossil fuels, mitigate the impacts of climate change, and build a more sustainable and prosperous future for all. The time to act is now – together, we can harness the power of renewable energy to create a cleaner, greener, and more resilient world for generations to come.

In the realm of automotive engineering, the synergy between wiring harnesses and connectors forms the backbone of vehicle electrical systems. Understanding the intricacies of this relationship is pivotal for grasping the essence of modern vehicle design and functionality. Let's delve into the symbiotic relationship between wiring harnesses and connectors:

Wiring Harnesses: Wiring harnesses, also known as cable harnesses or wire looms, are intricate assemblies of wires, cables, and connectors designed to transmit power and signals throughout a vehicle. These harnesses serve as the nervous system of the vehicle, connecting various electrical components such as sensors, actuators, control units, and power sources.

Connectors: Connectors are the essential components embedded within wiring harnesses that facilitate electrical connections between different components or systems. These components allow for the secure attachment and disconnection of wires, ensuring reliable transmission of power and signals. Connectors come in various shapes, sizes, and types, tailored to specific applications and requirements.

 

The Relationship:

Integration: Wiring harnesses and connectors are inherently intertwined, with connectors embedded strategically along the length of the harnesses. These connectors serve as the interface points where wires are terminated, allowing for seamless integration of electrical components within the vehicle.

Functionality: Connectors play a crucial role in determining the functionality and versatility of wiring harnesses. Different types of connectors, such as plugs, sockets, terminals, and headers, enable diverse electrical connections, ranging from power distribution to data transmission.

Design Considerations: The design of wiring harnesses is intricately linked to the selection and placement of connectors. Engineers meticulously plan the layout of connectors within the harnesses, considering factors such as accessibility, serviceability, and electrical performance.

Reliability: The reliability of wiring harnesses hinges on the quality and compatibility of connectors. Well-matched connectors ensure secure connections, minimizing the risk of electrical faults, signal interference, and power loss.

 

In essence, the relationship between wiring harnesses and connectors is one of mutual dependency and collaboration. As integral components of vehicle electrical systems, they work in tandem to provide seamless power and signal distribution, ultimately contributing to the overall performance, safety, and functionality of modern vehicles.

 

Through continuous innovation and refinement, automotive engineers strive to optimize this relationship, enhancing the reliability, efficiency, and scalability of wiring harnesses and connectors in the ever-evolving landscape of automotive technology.

 

This symbiotic relationship underscores the importance of cohesive collaboration between engineering disciplines, driving advancements in vehicle electrification and connectivity, and shaping the future of mobility.

Introduction: As the world marches towards a more sustainable future, the energy landscape continues to evolve rapidly. The year 2024 promises to be pivotal in the realm of new energy, with emerging trends reshaping the way we produce, distribute, and consume power. In this blog post, we'll delve into some of the key trends expected to define the new energy sector in 2024.

1. Accelerated Growth of Renewable Energy: Renewable energy sources such as solar, wind, and hydroelectric power are expected to experience accelerated growth in 2024. Advances in technology, coupled with declining costs, are making renewables increasingly competitive with fossil fuels. Government incentives and ambitious clean energy targets further drive investment in renewable infrastructure, paving the way for a cleaner and more sustainable energy future.

2. Energy Storage Solutions: Energy storage technologies are poised to play a pivotal role in the integration of renewable energy into the grid. In 2024, we anticipate significant advancements in battery storage systems, including improved efficiency, increased capacity, and longer lifespans. These developments will enhance the reliability and stability of renewable energy sources, enabling smoother integration into existing power grids while supporting the transition to a decentralized energy system.

3. Electrification of Transportation: The electrification of transportation is set to gain momentum in 2024, with electric vehicles (EVs) becoming increasingly mainstream. Technological advancements, coupled with growing environmental awareness and stricter emissions regulations, are driving the adoption of EVs across the globe. Moreover, the expansion of charging infrastructure and the introduction of next-generation batteries are addressing concerns regarding range anxiety, further bolstering the appeal of electric mobility.

4. Decentralization and Microgrids: The decentralization of energy generation and distribution will continue to gather pace in 2024, fueled by advancements in distributed energy resources (DERs) and the proliferation of microgrid solutions. Microgrids, powered by a combination of renewable energy sources and energy storage systems, offer resilience, reliability, and greater energy independence. As communities and businesses seek to enhance their energy security and resilience in the face of climate change and grid disruptions, microgrids are emerging as a viable solution.

5. Hydrogen as a Clean Energy Carrier: Hydrogen is poised to emerge as a key player in the transition to a low-carbon economy. In 2024, we anticipate significant developments in hydrogen production, storage, and utilization technologies. Green hydrogen, produced through electrolysis powered by renewable energy, holds particular promise as a clean energy carrier for sectors such as industry, transportation, and heating. With growing interest and investment in hydrogen infrastructure, 2024 could mark a turning point in the adoption of this versatile energy vector.

Conclusion: The year 2024 is poised to witness significant advancements and transformations in the field of new energy. From the continued expansion of renewable energy to the electrification of transportation and the rise of energy storage solutions, the momentum towards a cleaner, more sustainable energy future is palpable. As stakeholders across industries and governments worldwide embrace these trends, the journey towards a carbon-neutral world accelerates, offering promising opportunities for innovation, investment, and positive environmental impact.