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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
Sharing technology for a stronger America
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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
Consortia / Technical Teams / Working Groups
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Electrical Power Systems (Formerly 42 Volt)
Manufacturing
Transmissions
Consortia / Technical Teams / Working Groups
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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
Sharing technology for a stronger America
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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
Sharing technology for a stronger America
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Technology Solutions for the Automobiles of Today and Tomorrow
Sharing technology for a stronger America
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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
Sharing technology for a stronger America
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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)
Sharing technology for a stronger America
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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
Sharing technology for a stronger America
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Advancing Technology with Collaboration
Vehicle Recycling Partnership Promotes technical and
economic feasibility for
recycling
Collaborates with Argonne
National Laboratory on
Plastics Recycling
Sharing technology for a stronger America
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Lightweight Materials
Redesigned front rail system saving 23% mass while maintaining performance and safety targets
Advancing Technology with Collaboration
Sharing technology for a stronger America
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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
Sharing technology for a stronger America
Advancing Technology with Collaboration
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Research Partners
National Laboratories
Government Agencies
Suppliers
Universities
Sharing technology for a stronger America
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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
USCAR / EWCAP Objectives
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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
USCAR / EWCAP Objectives
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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
USCAR / EWCAP Objectives
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• Centerline Spacing
• Mating Shroud Dimensions
• Lock Feature Detail
• Index Feature Detail
2. Establish a standard “footprint” for electrical connections
USCAR / EWCAP Objectives
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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
USCAR / EWCAP Objectives
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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
1.5 mm Sealed Systems
1.5 mm Unsealed Systems
2.8 mm Sealed Systems
2.8 mm Unsealed Systems
6.3 mm Sealed Systems
Hybrid Systems
Example of listing of 0.64mm unsealed systems from the USCAR website
USCAR / EWCAP Objectives
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
Sharing technology for a stronger America
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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
Recommended