The connection problem of automotive connectors

Improper insertion of connectors during wiring installation into automobiles at assembly plants may result in connector failure. To overcome this problem, design engineers have developed various connector locking devices, one example of which is the Spring Lock developed by FCI. When the two halves of the connector are plugged together, the spring device will be compressed. If properly plugged in, the connector spring lock will come into play, allowing the two connectors to be joined together. If the connector is not fully inserted, the spring will spring open two halves (when the installer releases the connector), indicating a connection failure. Another approach is to use a plug-in auxiliary device to simplify the insertion process of larger connectors. FCI's new ErgoMate? The technology adopts a gear type cam and slider device. This slider device enables a fluid power to be obtained from the assembler when the connector is plugged in, eliminating the need for a typical connector to drive a secondary joystick or slider. Compared with other methods, due to the cam, the insertion force of the connector can be reduced by 40%. FCI's latest APEX 24 way Hybrid connector utilizes this technology. When the efficiency design is improved, assembly becomes simple and easy to implement, and the connection stability also increases accordingly. FCI has solved another issue related to the cable connection of the airbag ignition module. In the past 20 years, a large number of smoke and fire signal devices (airbags and seat belt pre tensioners) have been produced, but some of these devices are difficult to access during the automotive assembly process, which requires safety burst tube connectors and sockets. FCI's solution proposes a new type of anti skew plug connector interface - MCCAK-2. Explosive tube connectors are electrical connectors designed specifically for in car smoke and fire signal devices. These connectors are very compact and typically come with signal filtering devices such as ferrite or coils for signal processing. When the connector is inserted or removed from the airbag, the use of special short-circuit contacts can prevent accidental triggering of the airbag due to parasitic signal input. Due to the use of advanced safety applications such as pedestrian protection devices, this connection is more complex, requiring a sealed explosive tube connector solution. It is very important to seal the electrical contacts of the connector when applied to the exterior of the car and under the hood. For connector manufacturers, providing low-cost, stable, and easy to assemble submersible connector solutions is a highly challenging task. In high-density or multi pin systems, using gasket seals or porous sealing rings is a standard practice. When designing such seals, there are two main issues that must be addressed. Firstly, it is necessary to insert the terminal through a sealed hole, which means that a square or rectangular terminal needs to pass through a circular sealed hole. This requires controlling the composite insertion force of the terminals to prevent cable bending. Secondly, different wire diameters have requirements for sealing. Usually, this forces the use of seals with smaller sealing holes and greater elasticity to accommodate different wire diameters, which increases the likelihood of seal damage or tearing. The CMC series connectors designed specifically for engine management systems by FCI, drawing inspiration from submarine methods, are an innovative sealing method. Assemble the sealed cable (with terminals) into the connector, and then use a wiring cover to further compress the seal. In this way, only a small sealing pressure or force is generated during the assembly process, and a larger sealing pressure or force can be obtained in practical applications. All these innovative developments demonstrate the determination of connector designers and manufacturers to continuously provide new products for increasingly demanding markets. As a leader in the global automotive connector industry, FCI has a long history of innovation and will continue to strive to improve the reliability of automobiles, ultimately satisfying customers.