TP2 -

DESIGN GUIDELINES FOR CONNECTORS

Optimization of automated connector assembly

The overall design guidelines from sub-project 1 (SP1) are supplemented in sub-project 2 (SP2) by specific design guidelines for connectors. Due to the variance in the field of connectors, consisting of current-carrying contact parts and insulation elements such as seals and housings, detailed design guidelines will be drawn up. Synergy effects with the existing sub-projects, especially between SP1 and SP2, are to be used to develop suitable design guidelines and enable the 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 costs involved. The degree of automation depends on the type of cable harness selected (HV - high-voltage, LV - low-voltage or KSK - customer-specific cable 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 guidelines for connectors that facilitate or enable automation.

Current focus of work

One focus is the development of further design guidelines for connectors and their structural comparison with the design guidelines from SP1 (design rules for the automation of the wiring harness). Approaches for new design guidelines that could not be finalized for the first version of the standard are being revised and prepared for updating the standard.

In addition, the existing design guidelines 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 guidelines with the other application levels high-voltage in sub-project 4 and high-frequency in sub-project 5. The aim is to develop as few different design guidelines as possible but as many as necessary.

Outlook

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.