汽車線束端子接插件應(yīng)用介紹課件

OUTLINE

IntroductionofCrimpConnectionTechnology

端子壓接技術(shù)介紹IntroductionofWaterProofTestforaSealedConnector

密封接插件防水測(cè)試介紹

IntroductionofConnector/Contact/SealApplicationSpec.

接插件/端子/密封件應(yīng)用規(guī)范介紹Introductionofcabledesign&layout導(dǎo)線設(shè)計(jì)和線束布置走向要求OUTLINEWhatIsCrimping?什么是壓接？page2Crimpingistheprocessofattachingaterminalontoawireundermechanicalpressure.壓接是在導(dǎo)線和端子接觸區(qū)域施加壓力使其成型，實(shí)現(xiàn)緊密連接的工藝ThesolderlessconnectionstartedfromAMPin1941.無(wú)焊連接技術(shù)最早源于AMP1941年提出

WhatIsCrimping?什么是壓接？page2RequirementsonaCrimpConnection壓接要求Inseparable,longtimereliableelectricalandmechanicalconnection

ofoneorseveralconductorsandthecrimpterminal.

在壓接端子與導(dǎo)線之間提供不可分離的,長(zhǎng)時(shí)間可靠的電氣和機(jī)械連接Easeofmanufacturingoftheconnection

壓接應(yīng)便于生產(chǎn)加工RequirementsonaCrimpConnecCrimpTypes端子壓接類型page4

Advantages優(yōu)勢(shì):OptimumdesignofCrimpBarrelfordesiredwiresizerangeandmaterialthicknessbycalculation.通過(guò)計(jì)算即可得出適合特定線徑范圍和料厚的壓接結(jié)構(gòu)FitsforseveralwiresizesonlybyadjustingCrimpHeight.僅調(diào)整壓接高度即可用于不同線徑壓接Terminalmanufacturingatlowcostbysequentialstampingdies通過(guò)連續(xù)沖壓生產(chǎn)實(shí)現(xiàn)低成本Easeoftermination,fullyautomatedpossible壓接自動(dòng)化Stableelectricalconnection,evenunderhazardousEnvironment.苛刻環(huán)境下性能穩(wěn)定CrimpTypes端子壓接類型page4AdvQualifiedCrimpedConnectionRequirement合格壓接的要求：

Wire導(dǎo)線:1.選用線徑符合壓接端子適用性要求2.剝線符合要求（長(zhǎng)度適合，不損鍍層，末端不

開(kāi)裂分叉）

Terminal端子1.按形式不同，分為開(kāi)筒式和閉筒式

2.按鍍層不同，分為鍍錫，鍍銀，鍍金，鍍鎳等

3.按是否含絕緣壓接或密封部分進(jìn)行區(qū)分

CrimpingTool壓接工具CrimpComponents壓接三要素QualifiedCrimpedConnection壓接準(zhǔn)備：端子選用CrimpComponents壓接三要素壓接準(zhǔn)備：端子選用CrimpComponents壓接三合格的剝線不合格的剝線壓接準(zhǔn)備：剝線要求CrimpComponents壓接三要素剝線長(zhǎng)度參考端子114使用規(guī)范合格的剝線不合格的剝線壓接準(zhǔn)備：剝線要求CrimpComCrimpingMachineandHandToolKits壓接設(shè)備和工具page8Alpha356Multi-FunctionalFully-AutomaticCrimpingMachine多功能全自動(dòng)端子壓接機(jī)Alpha477LeadMakerDoubleCrimpConnectionswithtwodifferentwiresAlpha477可同時(shí)壓接兩種不同線徑Thiskindofmachineissuitableforsamplemaking

常用于樣品制作HandToolKits手工壓接工具CrimpingMachineandHandToolCrimpApplicator壓接模具和刀片

page9CrimpApplicator壓接模具和刀片pageCommonCrimpTerminals常用壓接端子page10AMPMCPContactFamilyMCONContactFamilyDIA1,5/2,5mmMQSFamilyTimersContactFamilySensorFlatContactCommonCrimpTerminals常用壓接端子pCommonCrimpTerminals常用壓接端子page11DeutschCommonContactsCommonCrimpTerminals常用壓接端子pContactCurrentCarryingCapacity端子載流能力page12MQSAMPMCP1.5AMPMCP6.3AMPMCP2.8StandardPowerTimerMicroTimerJuniorPowerTimerFASTINFASTONMultilockPositivLockRoundcontactsDIA1,5mmupto7,5ASignalcurrentsupto50Aupto15Aupto40ASensorFlatcontactRoundcontactsDIA2,5mmMaxi

PowerTimerAMPMCP9.5upto90AMCON1.2MQSAMPSeal?size16“contactpage12ContactCurrentCarryingCapacWireDefinition導(dǎo)線page13Core:Material/Plating/Gaugesize/StrandquantityInsulation:Material/ODWireDefinition導(dǎo)線page13Core:DesignationofWireSizeforconductors導(dǎo)線尺寸定義Wiresectionsizecanbedefinedas:-mm2

CommonforEuropeanmarket-AWG

AmericanWireGaugetableofwiresizes,orderedinoppositedirectione.g.AWG24

0,205mm2 AWG161,3mm2noeasyconversiontomm2possiblecommonformagnetwireconversion:1mm2=1973,51CMA-CMA

CircularMilAreaDesignationofWireSizeforcTemperatureClassofTERaychemAutomotiveWirepage15TemperatureClassofTERaycheCrimpingProducts壓接產(chǎn)品page16Single-wireCrimp單線壓接Double-wireCrimp雙線壓接Multi-wireCrimp多線壓接CrimpingProducts壓接產(chǎn)品page16SConductor/InsulationCrimping芯線壓接與絕緣皮壓接page17Thereisadifferentiationtobemadebetweenaconductorcrimpandacrimpforaninsulationsupport.芯線壓接與絕緣皮壓接有一定的區(qū)別：Theconductorcrimpinsuresagoodconnectionbetweenthewireandtheterminal.芯線壓接保證了端子與電線的良好連接Theinsulationcrimpsupportsthewiretoreducetheaffectsofvibrationsandmovementontheconductorcrimp.絕緣皮壓接是為了減少震動(dòng)以及移動(dòng)對(duì)芯線壓接的影響Conductor/InsulationCrimpingProcessofF-Crimp壓接過(guò)程page18壓接刀具打開(kāi)，端子放置在下刀上，導(dǎo)線由手或機(jī)械設(shè)備送至合適的位置。上刀向下移動(dòng)，把導(dǎo)線壓入包筒。包筒隨上刀折彎，壓接成型。設(shè)定的壓接高度保證了壓接質(zhì)量。Theapplicationtoolisopened.Acontactispositionedontheanvil.Theleadisinsertedbyhandormechanically.Thecrimpermovesdownandpressestheleadintothecrimpbarrelandmakescontactwiththecrimpedges.Inthenextprocessingstagethecrimpedgesarerolled-round,theconductoriscompressedatthesametime,andthecrimpisformed.Thefinalpositionatagivencrimpingheightguaranteesthenecessarycompressionofthecon-ductortoformatightlycompressedcrimp.ProcessofF-Crimp壓接過(guò)程page1壓接過(guò)程中，導(dǎo)體受到套管的擠壓，在經(jīng)度和緯度兩個(gè)方向上均發(fā)生形變，形成冷焊：導(dǎo)體與套管表面的原氧化膜變形破裂導(dǎo)體與端子套管的純凈金屬表面充分緊密接觸擠壓變形過(guò)程中的微運(yùn)動(dòng)顯微鏡下，可觀察到金屬表面互相交融粘連BasicPhilosophyofCrimp壓接原理壓接過(guò)程中，導(dǎo)體受到套管的擠壓，在經(jīng)度和緯度兩個(gè)方向上均發(fā)生WirePositioning放線位置（后送料）page20前切料刀后切料刀下模WirePositioning放線位置（后送料）pageWirePositioning放線位置（側(cè)送料）page21下模端子支撐WirePositioning放線位置（側(cè)送料）pagepage22Thequalitativeassessmentofaconductorcrimp(usingtheexampleofanF-crimp)isdeterminedby.端子壓接質(zhì)量判斷有以下幾個(gè)方面：Visualinspection外觀檢測(cè)Measurementofthecrimpheight壓接高度測(cè)量Analysisofcrosssection壓接剖面分析Measurementofpulloutforce壓接保持力測(cè)量

EvaluationofaCrimpTermination端子壓接質(zhì)量判斷page22Thequalitativeassessmpage23Visualinspection外觀檢測(cè)Measurementofthecrimpheight壓接高度測(cè)量Analysisofcrosssection壓接剖面分析Measurementofpulloutforce壓接保持力測(cè)量

EvaluationofaCrimpTermination端子壓接質(zhì)量判斷page23EvaluationofaCrimpT端子壓接典型位置和術(shù)語(yǔ)

Bellmouth：鐘形口（喇叭口）Front：前部（鐘形口）Rear：后部（鐘形口）ContactBody：觸點(diǎn)本體CutoffTab：切斷突起LockingLance：鎖定針WireCrimp：導(dǎo)體壓接區(qū)InsulationCrimp：絕緣壓接區(qū)ConductorEnd：導(dǎo)體端部InsulationEnd：絕緣體端部Cable：線纜FeaturesofCrimpedTerminal端子壓接區(qū)域特征端子壓接典型位置和術(shù)語(yǔ)Bellmouth：鐘形口（喇叭口）F

端子壓接質(zhì)量判斷方法：外觀檢查

導(dǎo)體端部要求：

a.導(dǎo)體端部應(yīng)與導(dǎo)體壓接區(qū)域頂端平齊，最多不超過(guò)壓接區(qū)域頂端1mm（圖中a區(qū)域）

b.超過(guò)導(dǎo)體壓接區(qū)域端的導(dǎo)體部分不能阻礙端子的對(duì)配功能和鎖扣功能

c.若端子對(duì)配的連接器采用的是familyseal,則導(dǎo)體壓接區(qū)域頂端的導(dǎo)體部分長(zhǎng)度建議不大于0.5mm

絕緣層頂端要求：絕緣層頂端需在wirecrimp和insulationcrimp之間區(qū)域（圖中b區(qū)域）可見(jiàn)。abVisualInspection外觀檢查端子壓接質(zhì)量判斷方法：外觀檢查abVisualInspe導(dǎo)線截面積喇叭口長(zhǎng)度端子壓接質(zhì)量判斷方法：外觀檢查

壓接兩端喇叭口要求：

a.導(dǎo)體壓接區(qū)域后端需有喇叭口結(jié)構(gòu)，喇叭口長(zhǎng)度尺寸根據(jù)線徑?jīng)Q定。

b.導(dǎo)體壓接區(qū)域前端喇叭口可允許的最大值與后端一致。VisualInspection

外觀檢查導(dǎo)線截面積喇叭口長(zhǎng)度端子壓接質(zhì)量判斷方法：外觀檢查Vpage27端子壓接質(zhì)量判斷方法：外觀檢查

端部切斷突起（料頭）要求：

a.料頭必須可見(jiàn)，以保證端子沒(méi)有損傷。

b.料頭不應(yīng)影響端子正常插入塑殼和對(duì)配。c.料頭最大長(zhǎng)度不應(yīng)超過(guò)0.5mm，對(duì)于使用familyseal的連接器，料頭最大長(zhǎng)度不應(yīng)超過(guò)0.3mm，

料頭不能損傷密封圈。VisualInspection

外觀檢查page27端子壓接質(zhì)量判斷方法：外觀檢查Visupage28Visualinspection外觀檢測(cè)Measurementofthecrimpheight壓接高度測(cè)量Analysisofcrosssection壓接剖面分析Measurementofpulloutforce壓接保持力測(cè)量

EvaluationofaCrimpTermination端子壓接質(zhì)量判斷page28EvaluationofaCrimpT端子壓接質(zhì)量判斷方法：高度測(cè)量

導(dǎo)體部分壓接高度測(cè)量和公差要求：

a.導(dǎo)體壓接高度的公差由電線線徑?jīng)Q定。

b.導(dǎo)體壓接高度在生產(chǎn)過(guò)程中需持續(xù)管控。導(dǎo)線截面積壓接高度公差

CrimpHeightMeasurement壓接高度測(cè)量壓接寬度與壓接模具尺寸有關(guān)，壓接寬度

不作為生產(chǎn)控制尺寸。端子壓接質(zhì)量判斷方法：高度測(cè)量導(dǎo)線截面積壓接高度公差Cpage30壓高偏?。?mm)截面無(wú)孔隙好的電氣性能差的機(jī)械性能正常壓高截面無(wú)孔隙好的電氣性能好的機(jī)械性能壓高偏大(1.2mm）截面有小孔隙差的電氣性能較好的機(jī)械性能壓高偏大(1.3mm)截面有較多孔隙差的電氣性能差的機(jī)械性能CrimpHeightandPerformance壓接高度與性能對(duì)比page30壓高偏小（1mm)正常壓高壓高偏大(1.2mmpage31CrimpPerformanceCurve壓接高度與性能對(duì)比Mechanicalandelectricalperformancevarywiththecorecrimpheight.page31CrimpPerformanceCurvepage32Visualinspection外觀檢測(cè)Measurementofthecrimpheight壓接高度測(cè)量Analysisofcrosssection壓接剖面分析Measurementofpulloutforce壓接保持力測(cè)量

EvaluationofaCrimpTermination端子壓接質(zhì)量判斷page32EvaluationofaCrimpT端子壓接質(zhì)量判斷方法：剖面檢測(cè)為檢查端子壓接的質(zhì)量，經(jīng)常要做壓接剖面檢測(cè)，檢測(cè)剖面的要求是：

a.剖面的切割方向需是垂直方向

b.剖面位置需在wirecrimp中間，且需避開(kāi)serration（齒狀突起）

c.做剖面時(shí)，需在端子周圍和內(nèi)部灌入人工合成膠，避免端子和導(dǎo)線移動(dòng)偏移

d.切割后需要進(jìn)行表面研磨和酸蝕，便于觀察檢驗(yàn)合理剖切位置serrationCrossSectionAnalysis

剖面分析端子壓接質(zhì)量判斷方法：剖面檢測(cè)合理剖切位置serrationMakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事項(xiàng)Processofcrosssectionmaking剖面制作基本流程Purpose:Aclearoutlineandgoodseparationofthecrimpbarrelandthesinglestrandshastobeobtained.目的：看到截面清晰的輪廓，并且能清楚的分辨出端子壓接部分和電線導(dǎo)體。Errorsatthepreparationofcrosssectionleadtopoororevenimpossibleabilitytojudgethem.

不良的截面制作可能會(huì)影響截面判定結(jié)果，甚至無(wú)法進(jìn)行判定。TerminalCutting切割端子Polishingsectionsurface切割表面拋光Etchingsectionsurface表面酸蝕MakingofCrossSection/ThedMakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事項(xiàng)page35Crossperpendiculartothelongaxisinthemiddleandofthecrimpbarrel,butavoidingbeinginsideofaserration.切割端子：剖切面和底面垂直；

在壓接區(qū)域中部；

避開(kāi)serration；Duringthecuttingandpolishing,donottoopenthecrimpbarrelwings.切割和拋光時(shí)卷曲部分被破壞；Duringpolishingcarehastobetakentoavoidtheouteredgetoberounded.Otherwisenosharpoutlinecanbedisplayed.拋光時(shí)，周邊形成圓角MakingofCrossSection/ThedMakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事項(xiàng)

Allstrandsshouldbedeformed.電線的每根導(dǎo)體有明顯的壓縮Materialthicknessmustbeatleast?ofthenominalmaterialthicknessofthecrimpbarreltoavoidoverpressing.壓縮量較大時(shí)，端子底部會(huì)被壓縮。為防

止過(guò)量壓縮，要求底部厚度必須≥端子原

始厚度的?。Whenetchingispoor,thereisnoclearseparationofinnercontourandofthesinglestrands酸蝕不佳，端子和電線導(dǎo)體無(wú)法清晰可辨Crimpbarrelmustbeclose(?tbut0.1mmmin).Opencrimpbarrelsarenotacceptable.端子兩邊完全閉合，并有一定的支撐長(zhǎng)度MakingofCrossSection/ThedMakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事項(xiàng)Theremustbeavisibledistanceofthecrimpwingendstothebottomaswellastothesideofthecrimpbarrelinnerwall.卷邊與側(cè)面或者底面有可見(jiàn)的距離

Maximumallowedsupportangleis30o卷邊重合后，支撐角≤30o如果重合線不是直線，取輪廓最外部的兩點(diǎn)來(lái)確認(rèn)支撐角度。Ifthetouchinglineofthecrimpwingsisnotstraight,alinethroughtheoutermosttouchingpointsisusedtoevaluatethesupportangle.MakingofCrossSection/ThedMakingofCrossSection/Thedo'sanddon'ts剖面制作方法及注意事項(xiàng)flashheight<tflashwidth<?twhenflashheight<?tforlongerflashthewidthmustnotexceed?t注意毛邊的厚度和寬度Tearsorcracksattheinnerorouterwallofthecrimpbarrelareunacceptable.不允許有壓接裂痕otherfailures:-Strandcrimpedatouterwall-Insulationbeingcrimpedincrimpbarrel其余不良

-有電線導(dǎo)體未被壓入端子-有電線絕緣皮被壓入導(dǎo)體部分MakingofCrossSection/Thed端子壓接質(zhì)量判斷方法：剖面檢測(cè)

剖面檢測(cè)參數(shù)是：① CH壓接高度；根據(jù)產(chǎn)品規(guī)范定義② CB壓接寬度（名義）；根據(jù)產(chǎn)品規(guī)范定義③ CBm可測(cè)量壓接寬度；=1*CB~1.1*CB④ W支撐角度；≤30o⑤ L支撐長(zhǎng)度；≥?*S(0.1mmmin.)⑥ R側(cè)底部距離；≥1*S⑦ GH毛邊高度；≤1*S⑧ GB毛邊寬度；

GB≤?*S,ifGH<?*SGB≤?*S,ifGH≥?*S⑨ SB底部厚度；≥?*SS=端子材料厚度

EvaluationofCrossSection剖面檢測(cè)端子壓接質(zhì)量判斷方法：剖面檢測(cè)Evaluationofthesedimensionshavetobemeasuredviamicroscopephotographexamples…通過(guò)顯微鏡檢測(cè)相應(yīng)尺寸

EvaluationofCrossSection剖面檢測(cè)thesedimensionshavetobemeDocumentationacc.CrimpTechnology壓接使用規(guī)范114-xxxxx:XXXCONTACTSYSTEMAPPLICATIONSPEC(特定端子使用規(guī)范）114-18022:GENERALGUIDELINESFORAPPLICATIONOFCONTACTSWITHOPENCRIMPBARRELS

（開(kāi)口壓接端子的應(yīng)用總則）114-18022-10:MAKINGANDEVALUATIONOFCRSSSECTIONSFORF-CRIMPTEMINATIONS

（F型壓接的剖面制作及評(píng)估）DINEN60352-2:CRIMPCONNECTIONS,SOLDLESSELECTRICALCONNECTIONS

（壓接，非焊接連接）Documentationacc.CrimpTechnExamplesforCrossSections–goodsamples剖面樣品Nocavitiesarevisible無(wú)孔隙Symmetric截面對(duì)稱Compactionofallstrands所有導(dǎo)線都應(yīng)被壓實(shí)Wingstouchonlyconductor翼端只接觸導(dǎo)線Terminalstockfreeofcracks/breaks端子無(wú)裂紋Corewings“Locked”(NoGap)attopofcrimp.端

子兩邊完全閉合，并有一定的支撐長(zhǎng)度ExamplesforCrossSections–ExampleforCrossSections–badsamples不良的剖面樣品unsymmetricalrollinwiresizetoosmalltears/bulgingCrimpheighttoohighCrimpheighttoolow/overpressedExampleforCrossSections–bpage44Exampleforcrosssections–badsamples其他不良剖面page44Exampleforcrosssectipage45Visualinspection外觀檢測(cè)Measurementofthecrimpheight壓接高度測(cè)量Analysisofcrosssection壓接剖面分析Measurementofpulloutforce壓接保持力測(cè)量

EvaluationofaCrimpTermination端子壓接質(zhì)量判斷page45EvaluationofaCrimpTMeasurementofPullOutForce壓接保持力測(cè)量destroyingWirepulloutforce

(withinsulationcrimpopened)

Requirement:acc.DINEN60352-2(upto10mm2)acc.VDE0220(for>10mm2)

>60N/mm2wiresectionMeasurementofPullOutForce端子壓接質(zhì)量判斷方法：絕緣壓接檢查絕緣層壓接要求：端子的絕緣皮處一般有3種壓接方式，其壓接截面見(jiàn)下圖，其壓接要求分別是：a.Fcrimp壓接處兩端接觸b.overlapcrimp壓接處交疊長(zhǎng)度大于等于一個(gè)板材厚度c.wrapcrimp壓接處相交長(zhǎng)度大于等于一個(gè)板材厚度d.經(jīng)過(guò)一個(gè)循環(huán)的折彎實(shí)驗(yàn)，絕緣皮壓接處不能松脫導(dǎo)線絕緣層端子折彎角30?折彎長(zhǎng)度50mm

InsulationCrimping絕緣皮壓接DIN41611T3端子壓接質(zhì)量判斷方法：絕緣壓接檢查導(dǎo)線絕緣層端子折彎角30?page48ExampleforCrossSections–badsamples不良的剖面page48ExampleforCrossSectiOUTLINE

IntroductionofCrimpConnectionTechnology

端子壓接技術(shù)介紹

IntroductionofWaterProofTestforaSealedConnector

密封接插件防水測(cè)試介紹

IntroductionofConnector/Contact/SealApplicationSpec.

接插件/端子/密封件應(yīng)用規(guī)范介紹OUTLINEConstructionofthecode1stnumberindicatestheprotectionofsolidobjectsandmaterial2ndnumberindicatestheprotectionofliquid(water)Additionalnumber:againstaccesstohazardouspartsSupplementaryinformationDegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)ConstructionofthecodeDegreeDegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)DegreesofProtectionagainstIPX.0 Nonprotected,NospecialprotectionIPX.1 ProtectedagainstfallingwaterEquivalentto3-5mmrainfallperminuteforadurationof10 minutes.Unitisplacedinitsnormaloperatingposition.IPX.2 Protectedagainstfallingwaterwhentiltedupto15degrees.Sameas(1)abovebutunitis testedin4fixedpositions-tilted15degreeineachdirectionfromnormaloperating position.IPX.3 Protectedagainstsprayingwater,Watersprayingupto60degreesfromverticalat10 liters/minatagagepressureof50-150kN/m2for5min.IPX.4(K) Protectedagainstsplashingwater.Sameaslevel3butwaterissprayedatallangles(andincreasedpressure).IPX.5 ProtectedagainstwaterjetsWaterprojectedatallanglesthrougha6.3mmnozzleataflowrateof12.5liters/minatagagepressureof30kN/m2for3minutesfroma distanceof2.5~3meters.IPX.6(K) Protectedagainstheavyseas.Waterprojectedatallanglesthrougha12.5(6.3)mmnozzleata flowrateof75(100)liters/minatagagepressureof100(1000)kN/m2for3minutesfromadistanceof2.5~3meters.IPX.7 Protectedagainstwaterimmersion.Immersionfor30minutesatadepthof1meter.IPX.8 ProtectedagainstwatersubmersionTheequipmentissuitableforcontinuoussubmersioninwaterunderconditionswhichareidentifiedbythemanufacturer.IPX.9K ProtectedagainsthighpressureJet.Waterjetsfromnozzlesshallexhibitfollowing characteristics: -Temperature80±5°C -Flowrate14-16l/min -Pressure8000-10000kPameasuredasnearaspracticabletonozzleDegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)IPX.0 Nonprotected,Nospecpage53DegreesofProtectionagainstWater(GB4208)防水等級(jí)(GB4208)page53DegreesofProtectionapage54DegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)IPX.1/IPX.2page54DegreesofProtectionapage55DegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)IPX.3/IPX.4/IPX.4Kpage55DegreesofProtectionapage56IPX.5/IPX.6/IPX.6KDegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)page56IPX.5/IPX.6/IPX.6Kpage57IPX.7/IPX.8/IPX.9KDegreesofProtectionagainstWater(IPCodeDIN40050)防水等級(jí)(DIN40050)page57IPX.7/IPX.8/IPX.9Kpage58SensorConnector1visualinspection2contactresistance3watertightsealing(airblowingupto98kPa)4thermalshock(-50to+120°C,100h)5contactresistance6watertightsealing(airblowingupto29.4kPa)7watertightsplash(IPX.9K)Superseal1.5

Group1Group21visualinspectionvisualinspection2insluationresistanceheataging(125°C)3IPX.6K/IPX.9Kwaterresistance(30min,0.01barpressure)4insluationresistanceinsulationresistanceMCON1.2Connector1visualinspection2rapidchangeoftemperature(-40-130°C)3protectionagaistwater(airblowingupto600mbar)4IPX.4K/IPX.9KHDSCSConnector1visualinspection2pre-aging(120/-40°C,500h/120°C,120h/140°C)3IP67/IP69K4visualinspectionSuperseal1.0mmConnector

Group1Group21visualinspectionvisualinspection2insulationresistanceIPX.9K(leakcurrent)4sealingtest:

airblowupto98kPa,leakcurrent(28V,100uA)

5visualinspection

154P(94+60)Connector1visualinspection2IPX.9K3thermalshock(-40to+130°C)4IPX.9K5waterbathtest(airblowupto60kPa)6waterimmersionaftertemperaturechangeSealingTestforCommonConnector常用連接器防水測(cè)試page58SensorConnector1visualValidationofSealingBehavior驗(yàn)證密封性能Analyzethesealshape,contactpressurebyCAE.CAE模擬接觸壓力Measurethesealingpressurebytests.實(shí)驗(yàn)室進(jìn)行氣密性測(cè)試Stress&ContactPressureValidationofSealingBehaviorDifferentTypesofSealsinConnector連接器中的密封圈02October2023Wire/CavitySeals:SWSFamilySealPeripheralSeals:RadialSealFaceSealLshapedperipheralsealDifferentTypesofSealsinCointerferenceSINGLEWIRESEALpositioningTheSWSisplacedonthewireatadefineddimensionthroughanautomated/annualprocess.Tofacilitatethisoperation,oil(about2%)isaddedtothebasematerial.ThewiresizeisdeterminedbytheholedimensionsoftheSWS.將電線穿入SWS通常SWS帶有硅油以便裝配適用的線徑由SWS內(nèi)孔尺寸決定interferenceSINGLEWIRESEALpoSingle

WireSealThecontactbarrelsmustcloseandretaintheSWSwithoutgeneratingcutsonthesurfaces;TheSWSmustbealignedwiththecontactcenterline.確保SWS被端子包筒包牢；避免SWS被刺破SWS中心須與端子中心對(duì)齊SingleWireSealThecontactbaThesealcrimpedontothecontactisinsertedintothecavity.Thedifferencebetweenthedia.ofthelipsoftheSWSandthecavitydia.providescompressiononthesiliconewhichgeneratestwoadditionaleffects:FrictionwhenthecontactisinsertedintothecavityAdditionalclosurepressureonthewireinterface裝入SWS,通過(guò)對(duì)硅膠的壓縮達(dá)到密封功能CavityPlugsareusedtosealunusedcavitieswithadistancetothetop.未用孔位使用盲堵密封,確保與HSG端面有一段距離CavityPlugSingle

WireSealThesealcrimpedontothecontHowtoFindSuitableSWSforaConnector?如何找接插件對(duì)應(yīng)的密封圈?SmallTip1:tofindoutonaconnectordrawingweprovided查找接插件圖紙Otherusefulinfo.couldalsobefound:SuitablecontactforthisconnectorSuitablewirerangeforthisconnectorCounterpartMatingcomponentsforthisconnector其他有用信息如：接插件端子，適用線徑范圍，對(duì)配件，其他各種組件通常亦可在圖紙上找到HowtoFindSuitableSWSforaSmallTip2:tofindoutonacontactdrawing/catalogweprovided查找端子圖紙或產(chǎn)品目錄手冊(cè)SuitableSWSindicatedonterminaldrawingSuitableSWSindicatedonproductcatalogHowtoFindSuitableSWSforaConnector?如何找接插件對(duì)應(yīng)的密封圈?SmallTip2:tofindoutonaSmallTip3:tofindoutonrelated114spec查找端子使用規(guī)范HowtoFindSuitableSWSforaConnector?如何找接插件對(duì)應(yīng)的密封圈?SmallTip3:tofindoutonreFamilysealPolarizationplateLongitudinalsectionThefamilysealmustbeintegratedintotheconnector.Familyseal通常是預(yù)先組裝在接插件里Thepolarizationplateisnecessarytoguidethecontact.Familyseal保護(hù)蓋可用于端子導(dǎo)向

FamilySealandUsableContacts

SealPlugFamilySealFamilysealPolarizationplateLMQScleanbodyMQSstdversionThecontactsuitableforagrommetmustbefreeofanycut(sharp)edgesinallprofiles→designandstampingprocessaremorecomplex.用于Familyseal的端子表面不能有任何的尖刃，以免割破密封圈。這種端子稱為CleanbodyFamilySealandUsableContactsFamilySeal和所適用端子

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