1 USCAR / EWCAP & USCAR Compliant Connections Prepared By John Yurtin Revised and Updated 4-5--05...

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USCAR / EWCAP & USCAR Compliant Connections

Prepared By John Yurtin

Revised and Updated 4-5--05

CTIS # 29955

Connection Systems Training

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Working together with customers, suppliers and competitors can result in improved products for the customer. Understanding this relationship within standards activities is essential to this process.

This training will help you understand the USCAR activities and how it can benefit our business

Excellence

Focus: Your Customer

Style: Teamwork

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• The USCAR Organization

• The USCAR / EWCAP Organization

• USCAR/EWCAP Objectives

• USCAR Compliance Requirements

• USCAR Compliant Connections

• Delphi’s Continuing Commitment to USCAR

Agenda

Southfield Town Center 1000 Town Center Drive Suite 300 Southfield, MI 48075

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United States Council for Automotive Research (USCAR) is

the umbrella organization for collaborative research among

DaimlerChrysler Corporation, Ford Motor Company and General Motors Corporation.

http://www.uscar.org/

Sharing technology for a stronger America

What Is USCAR?

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USCAR AS UBRELLA FOR BIG THREE RESEARCH

Collective research-and-development work among the Big Three has been underway since 1988.

USCAR was formed in 1992 to help coordinate administrative and information services for existing and future Big Three research consortia devoted to tackling shared technological and environmental concerns.

Incentive came after famous visit of President Bush and the Big Three Auto company presidents to Japan to try to limit imports.

USCAR, an Umbrella for Big Three Research

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The USCAR Organization

USCAR Council

USCAR Leadership Group

Advanced Powertrain

Manufacturing

Energy Storage

Environmental

E/E

Fuel Cell

Hydrogen

Materials

Safety


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USCAR Objectives

The main objectives of USCAR are: – Monitor current joint research projects and consortia;

– Consider and recommend new joint research and development projects and consortia;

– Interact with other organizations (Society of Automotive Engineers, etc.), supplier companies and governmental agencies;

– Share results of joint projects with member companies;

– Seek and recommend funding from public and private sources for joint research and development, and

– Provide facilities and administration for consortia.

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Consortia / Technical Teams / Working Groups

ACC – Automotive Composites Consortium

ERC – Environmental Research Consortium

EWCAP – Electrical Wiring Applications Partnership

LEP – Low Emissions Partnership

LEPC – Low Emissions Paint Consortium

OSRP – Occupant Safety Research Partnership

SCAAP – Super Computer Automotive Applications Partnership

USABC – United States Advanced Battery Consortium

VRP – Vehicle Recycling Partnership

USAMP - United States Automotive Materials Partnership

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Freedom Car & Fuel Partnership

– Advanced Combustion & Emissions Control

– Electrochemical Energy Storage Team

– Electrical & Electronics

– Fuel Cells

– Materials

– Vehicle Systems Analysis Tech Team

– Hydrogen Storage

– Hydrogen Codes & Standards

U.S. A-Team

– Manufacturing Competitiveness


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Electrical Power Systems (Formerly 42 Volt)

Manufacturing

Transmissions


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Partnering Adds Value

Accelerates technical development

Provides common voice to supply base

Increases value of research investments

Improves quality and reduces cost for noncompetitive technologies

Addresses more than single company can accomplish alone


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Freedom from foreign petroleum dependence

Freedom from pollutant and carbon dioxide emissions

Freedom for Americans to drive where they want, when they want in the vehicle of their choice

Freedom to obtain fuel affordably and conveniently

FreedomCAR & Fuel Partnership


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Technology Solutions for the Automobiles of Today and Tomorrow


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… thus, the need to continue R&D for all technologies

Freedom CAR Technology AlternativesNo single global technology solution has yet

emerged…

Near Term Mid Term Long Term

Sp

ecifi

c B

en

efi

t

Deployment Timeframe

Advanced Gasoline ICE

Hybrid Powertrain

Diesel ICE

TodayFuel Cell

Hydrogen ICE

Deployment

Development


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Strategic Partnerships

Increase competitiveness of United States

manufacturing base

Digital tools

Plant floor controllers

Ergonomics

US A TEAM (U.S. Alliance for Technology and Engineering for Automotive Manufacturing)


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Low Emissions Partnership Engine Benchmarking Why run the same tests three times when once will do? Partners exchanged data sets on 38 of their own engines Each partner saved close to $2M How each company applies that data becomes competitive

Advancing Technology with Collaboration


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Vehicle Recycling Partnership Promotes technical and

economic feasibility for

recycling

Collaborates with Argonne

National Laboratory on

Plastics Recycling


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Lightweight Materials

Redesigned front rail system saving 23% mass while maintaining performance and safety targets



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Safety

USCAR’s Occupant Safety Research Partnership and international partners are designing the World SID II

Unique design harmonizes global requirements



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Research Partners

National Laboratories

Government Agencies

Suppliers

Universities


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ELECTRICAL WIRING COMPONENT APPLICATION PARTNERSHIP

Mission:– Facilitate and encourage cooperative research and development including

sharing of technologies and resources to develop common electrical connection systems and standard electrical components (e.g., motors, relays, and switches)

Staff:– Three full-time engineers, representing Ford, GM and DaimlerChrysler, located in

Southfield, MI (Presently considering a reorganization)

Harry Zaverzence /Jim Roberts (DaimlerChrysler)

Dan Jarmolinski (GM)

– http://www.uscarteams.org/

Formed:– June, 1994

Uniqueness:– Projects are not research oriented, but aimed at introduction of terminals, connectors, and

electrical components for specific model year

What is EWCAP?

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1. Develop common electrical connector specifications

2. Establish a standard “footprint” for electrical connections

3. Reduce the number of different connectors on a vehicle by using common device connection footprints

4. Establish and Catalog common families of “Best-in-Class” connection systems

USCAR / EWCAP Objectives

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BENEFITS Improve performance, reliability, and durability

Reduce development time

Commonization of “non-competitive” electrical devices

Reduces resource requirements on new systems

Reduces duplicate testing at suppliers

Assist in “Internationalization” of electrical components


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EWCAP

Projects

G.M.

FORD

YAZAKI

AUGAT

A.F.L.

UTACARDELL

OSRAM

EPC

AMP

INTERLOCK

D-C

DELPHI P.

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1. Develop common electrical connector specifications

SAE/USCAR-2: Performance Standard for Automotive Electrical Connector Systems

SAE/USCAR-3: Standard for Testing Automotive Miniature Bulbs

SAE/USCAR-4: Standard for Cigar Lighters and Power Outlets

SAE/USCAR-12: Wiring Component Design Guideline

SAE/USCAR-13: Standard for In-Tank Electric Fuel Pumps

SAE/USCAR-14: Specification for Testing Halogen Light Sources

SAE/USCAR-15: Specification for Testing Lamp Sockets

SAE/USCAR-17: Specification for Automotive RF Connector Systems

SAE/USCAR-18: FAKRA SMB RF Connector Supplement

SAE/USCAR-19: Coaxial Cable Connector Interface Square outer Conductor

SAE/USCAR-20: Field Correlated Life Test


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SAE/USCAR-21: Crimp Specifications

SAE/USCAR-23: Single Core Cables

SAE/USCAR-24: USCAR Inflator Technical Requirements and Validation

SAE/USCAR-25: Electrical Connector Ergonomic Requirements

SAE/USCAR-26: Finish Evaluation Electrical Ground Test Procedure

In Development:

USB Connector Performance Standard

Materials Color Chart and Standard

SAE/USCAR-22: Flex Cable & Flat Wire Specification

SAE/USCAR-27: Gas Discharge Light Source Subsystem

Precious Metal Plating Activity


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• Centerline Spacing

• Mating Shroud Dimensions

• Lock Feature Detail

• Index Feature Detail

2. Establish a standard “footprint” for electrical connections


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– Cigar Lighter

– Fuel Injector Conn.

– Oil Press Switch

– Light Bulb Housing

– Power Seat Motors

– ABS Controller Connection

– Mirror Connection

– Batteries

– Windshield Wiper Motors

– Power Outlet Connection

– Trailer Connectors

– A/C Pressure Switch

– Air Bag Initiator Conn.

– Horn Connector

– O2 Sensor Conn.

– Fan Motors

3. Reduce the number of different connectors on a vehicle by using common device connection footprints


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4. Establish and Catalog common families of “Best-in-Class” connection systems

Terminal Families:

0.64 mm Sealed Systems

0.64 mm Unsealed Systems






Hybrid Systems

Example of listing of 0.64mm unsealed systems from the USCAR website


The following terminals have been chosen and established to replace the numerous terminals currently in use.

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The EWCAP Difference

Uniqueness

– EWCAP drives OEM platform specific devices to be common commodities for the USCAR partners through the following items:

» Common specifications

» Common electrical interfaces

– Projects may be research oriented, but most often are aimed at introductions of terminals, connectors and electrical components .

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The EWCAP Difference (cont.)

Allows standardization

» Device manufacturer

» Terminal/connector supplier

» Wiring harness supplier

Improved quality from all areas including engineering, manufacturing and assembly.

Reduced component and fixture complexity.

Reduces engineering resources for new devices

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EWCAP Web Site

www.ewcap.uscarteams.org/

Content:– Parts list

– Part numbering system

– Footprint drawings

– Preferred connectors by device

– List of specifications

– List of current projects

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Connector Packaging Dimensions1.5 mm

CONFIG DRAWING # REVISION INDEX/

DRAWING PRIMARY DRAWING POLARIZATION STATUS USE SOURCE OPTIONS

1 X 4 150-U-004-1-Z01 A IN --- EPC A01,B01,C01,D01

Sample Catalog / Web Page

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17 specifications published

Over 100 engineering drawings showing 400 individual parts completed

Savings booked and projected:

$0$500,000

$1,000,000$1,500,000$2,000,000$2,500,000$3,000,000$3,500,000$4,000,000$4,500,000

2004 MY 2005 MY 2006 MY

DCX Saving

GM Savings

Ford Saving

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Airbag Initiator Example

Electrical connectors clearly not a purchasing factor

Average almost $2M savings in ’05MY for each company


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What Is USCAR Compliance?

A Device connection that meets the dimensional requirements (footprint) specified by USCAR, and…

A Harness connection that mates to a device which meets USCAR dimensional requirements and…..

When mated, a Connection System that meets the performance requirements of the SAE/USCAR 2 specification and…

A connection system that conforms to SAE/USCAR-12 Wiring Component Design Guidelines…

USCAR Compliance

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USCAR Does Not…….

Approve products

Certify products

Endorse products

Promote products

Verify performance of parts on their web

Verify the claims of products on their website

Publish Standards

Sell Standards

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2 Way 1.5 mm SealedIndex A

Knock Sensor

2 Way 1.5 mm SealedIndex B

Crank Sensor

3 Way 1.5 mm SealedIndex C (Gray)

3 Way 1.5 mm SealedIndex B ( Dk Gray)

5 Way Sealed 1.5 mm Index A (Gray)

5 Way Sealed 1.5 mm Index B (Black)

USCAR Compliant Device Connections

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30 Way SealedABS Connector

7 Way Sealed Trailer Tow Connector

2 Way Sealed Fuel Injector, Horn & Underhood Lamp Connector

3 Way Unsealed Cigar Lighter/Power Outlet Connectors

USCAR Compliant Device Connections

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USCAR 0.64 mm Connections

• Mates to USCAR standard 3.5mm footprint • Smaller package size• Mates to existing devices tooled for “pull-to-seat” connections• Uses same terminal design as the 4.5mm USCAR connectors

USCAR 3.5 mm Connections

USCAR Compliant 0.64 & 3.5mm Connections

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1 USCAR / EWCAP & USCAR Compliant Connections Prepared By John Yurtin Revised and Updated 4-5--05...

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