TP2 –

Design rules for connectors

Optimization of automated connector assembly


Dr. Jens Haun

Kostal Kontakt Systeme GmbH

Dr. Haun is head of pre-development


Optimization of automated connector assembly

The overall design rules from sub-project 1 (TP1) are supplemented in sub-project 2 (TP2) by specific design rules for connectors. Due to the variance in the sub-area of connectors, consisting of current-carrying terminals and insulation elements such as seals and housings, detailed design rules will be developed. Synergy effects with the existing sub-projects, especially between TP1 and TP2, will be used to develop suitable design rules and enable automated production and use of connectors.


Initial situation and motivation

The majority of connector assembly is currently carried out manually. Only crimping can be automated thanks to a good balance between the degree of automation and the cost. The degree of automation depends on the type of wire harness selected (HV - high voltage, LV - low voltage or KSK - customer-specific wire harness), with the KSK representing the most demanding production effort. The variety of parts available on the market makes automation difficult. There is a lack of industry-wide recognized and implementable design rules for connectors that favor or enable automation.


Current focus of work

One focus is the development of further design rules for connectors and their structural comparison with the design rules from TP1 (design rules for the automation of wire harnesses). Approaches for new design rules that could not be finalized for the first version of the standard will be revised and prepared for the update of the standard.
In addition, the existing design rules from DIN 72036 are to be further refined and updated with the knowledge gained from the application of the standard. The aim is to incorporate user feedback and incorporate it into the update of the standard.
A new challenge is the coordination of the LV design rules with the other application levels high voltage in subproject 4 and high frequency in subproject 5. The aim is to develop as few different design rules as possible but as many as necessary.



By eliminating design features that are required for manual processing, the aim is to find potential for simplification, provided that certain components are processed exclusively automatically.