1
Terminal Sizes
CTIS # 29956
Prepared By John Yurtin
Updated 4-25-2005
Connection Systems Training
2
The first step in supporting the customer is to clearly know your product. Understanding the reasons for all the different terminal sizes is absolutely necessary to choose the right terminal for any application
This training should help you understand the different terminals we produce, why they exist and how to choose the right product.
Excellence
Focus: Your customer
Method: Innovation and continuous improvement
3
“Hello!
Welcome to this terminal systems training
session!
Understanding all the different terminal
systems we produce today is a big challenge. I hope
this session will give you a better knowledge of Delphi’s
various connections.
I plan time for questions at the end of the session,
however, please feel free to ask questions at any time.”
John Yurtin
4
Thermo Nalius Ringus
5
1946 Chevrolet Wire Harness
6
Over 2400 TerminalsOver 2400 TerminalsOver 2400 TerminalsOver 2400 Terminals
Today’s “High End” Vehicle Wiring
7
500 to 2400 Terminals / Vehicle
“Over 126 Billion Terminals / Year”
Over 63 Million Vehicles / Year
Automotive Connections “101”
8
7,200,000 7,200,000 TerminalsTerminals
2 Hours of Delphi Production
9
Pack-Con I
Pack Con II & IV
56 Series
58 Series
59 Series
Com Pack I, II, & III
Edge board (Fork, ECM & Bow Types)
188 Series (4.7mm)
Twin Lock
ACT Series
ES-Kontakt
0.64mm Buchsenkontakt
Pin Grip
Weather-Pack
Metri-Pack 150 - 630
Micro-Pack 100 & 100W
Ducon
Micro-Pack 064
Ring/Spade
Micro-Timer
DS Series
DFK Series
HVF & HVF II
VF Series
SF Series
Faston
AF Series
Pack Con III & IV
Edge board (Pack-Con Types)
Micro 64
Micro HVT (unsealed)
GT
800 Maxi
ATS
MTS 064
DSQ
2.8 BTS
090 II Series
070 Series
040 III Series
250 Series
W Series
Power-Pack
DHD Heavy Duty
ZRT
BFC 1.8
YESC
187 Series
Micro 050 Series (Toyota)
GT 1.5, 2.8 & 6.3 with FBT
Flex-Pack 0.64, 1.2, 1.5 & 2.8
2.8 & 6.3 PCB
1.5 & 2.8 ETS
1.2 Optima
0.64 MTSB
Micro HVT 1.2
090 II with FBT
1mm Deutsch Replacement
.5 mm Blade-on-Beam
.8 mm Blade-on-Beam
6mm vane - Motorola
Develop Introduce and Grow Maintain Exit
Terminal Systems Portfolio
10
How many terminal types do we need?
11
• Electrical Requirements
Power / Signal / Voltage / Current….
• Mechanical Requirements
• Environmental Requirements
• Mating Devices
• Standards
National / International / OEM / Organization……
• Preferences
Pin / Blade / One Piece / Two Piece…
Materials and plating…
• And Every Combination of These
As many as it takes!!
12
Metri-Pack Terminal Proliferation
150, 280,480,630,800 M&F 10
Various Crimp Configurations 50
Sealed and Unsealed 100
Add 150 Pull-To Seat versions 160
280 Slotted Pull to seats 169
Design Variations (e.g. Nose Guards) 287
Material Options 565
Plating Options 680
13
Blade / Pin Standards
14
ISO Standards
15
USCAR Standards
The USCAR organization has standardized on 4 terminal sizes:
– 0.64 X 0.64– 1.5 X 0.8– 2.8 X 0.8– 6.3 X 0.8
USCAR also specifies the material and plating requirements.
16
SAE Standards
17
Terminal Sizes (slide 1 of 3)
0.50 0.64 0.8 1.0 1.2 1.5 1.8Micro 050 Toyota
Micro-Pack .64
Micro-Pack 100W
150Metri-Pack 070 Series
.5 Ducon .64 Ducon .8 Ducon Micro-Pack 100
1.5 Ducon BFC 1.8
Micro 64 040 III 150 GT
Micro HVT Micro HVT Micro HVT Micro HVT DSQ 1.5
.5mm Blade-on-Beam
.8mm Blade-on-Beam
Optima 150 GT (FBT)
MTS/MTSB 1mm P&S BTS 1.5
Buchsen-kontakt
CTS 1.2 CTS 1.5
.64 Kaizan Replacement
1.5 ZRT
.64 Flex-Pack 1.2 Flex-Pack 1.5 Flex-Pack
18
2.0 2.3 2.8 3.0 3.75 4.8 5.2Weather-Pack 090 II Series 280 Metri-Pack Pack-Con I 187 Series Pack-Con II
090 II (FBT) DS Series 188 Series
DSQ Series 188 Pack-Con
ZRT 2.8 480 Metri-Pack
HVF Series 4.8 Ducon
2.8 Ducon
2.8 Flex-Pack
280 GT
280 GT (FBT)
ATS
2.8 BTS
2.8 CTS
Terminal Sizes (slide 2 of 3)
19
5.7 6.3 8.0 9.5 15 20Pack-Con III,
IV & V56 Series 59 Series 9.5 Ducon Power Pack
1500 SeriesPower Pack 2000 Series
58 Series 800 Maxi
SF Series Maxi-Fuse
630 Metri-Pack
800 Metri-Pack
6.3 Ducon
630 GT
630 GT (FBT)
VF Series
Terminal Sizes (slide 3 of 3)
20
0.50 Ducon
0.5 mm Terminals
21
Micro-Pack 0.64
MTS
MTS B
Buchsenkontakt
Micro-64
Micro HVT
0.64 mm Terminals
22
Ducon 0.8 Micro HVT
0.8 mm Terminals
23
040-III
Micro-Pack 100
Micro-Pack 100W
Micro HVT
1.0 mm Terminals
24
CTS 1.5BTS 1.5
DSQ 1.5
Micro HVT
1.2 mm Terminals
Optima 1.2
25
CTS 1.5BTS 1.5
DSQ 1.5
Ducon 1.5150 GTMetri-Pack 150
1.5 mm Terminals
26
1.8 mm Terminals
BFC 1.8
27
090-II
2.3 mm Terminals
28
DSQ 2.8
ATS 2.8
Ducon 2.8Metri-Pack 280
280 GT
DS Series
VF 2.8
2.8 mm Terminals
BTS2.8
29
Ducon 4.8187 Series480 Metri-Pack
4.8 mm Terminals
30
56 Series
VF SeriesDucon 6.3SF Contact
630 Metri-Pack58 Series
6.3 mm Terminals
GT
31
59 Series Maxi Fuse800 Metri-Pack
8.0 mm Terminals
32
Ducon 9.5
9.5 mm Terminals
33
15 mmPower-Pack
20 mmPower-Pack
15 & 20 mm Terminals
34
One-Piece, Tangless, Non-Oriented Terminal
Square Peg in a Round HoleMinimum 3 point contact is maintained
in all terminal orientations by design
Internal contact arms are protected by outer barrelTerminal-to-connector locking accomplished on outer barrelNon-oriented design facilitates harness manufacture
Mating Pin• USCAR or ISO Standard 0.64mm
Square or 0.8mm Round
Production Crimp• Mechanically and electrically
validated• 0.35mm²/0.50mm² and 0.80mm²
2 Moving Contacts
Stationary Contact
Female Terminal• 0.007” thick, CDA 425 hard
•Palladium/gold flash electroplate
Micro-64 Terminal SystemMicro-64 Terminal SystemMicro-64 Terminal SystemMicro-64 Terminal System
35
Application
•FFC/FPC Connection•Device Connection
Features
•Two piece female terminal design•Mating part: 0.64 x 0.64 male terminal•FPC Crimp •MQS (Tyco) cavity compatible
Target Customers•OPEL, VOLVO, PSA,FIAT, RENAULT, TIER 1
Expected Volumes per Year•SOP: August 2001•2002 5 Mio. parts •2003 20 Mio. parts•2004 20 Mio. parts
Stage of Development•Parts available and validated
MMicro icro TTerminal erminal SSystem 0.64ystem 0.64MMicro icro TTerminal erminal SSystem 0.64ystem 0.64
MTS 0.64
36
Application
•Inline Connection
Features
•Three piece male terminal design•Mating part: 0.64 x 0.64 female terminal•Unsealed •MQS (Tyco) cavity compatible
Target Customers•OPEL, VOLVO, DC, FIAT, RENAUT, PSA, TIER 1
Expected Volumes per Year•SOP: Oct. 2002•2003 40 Mio. parts •2004 80 Mio. parts•2005 80 Mio. parts
Stage of Development
•Tooling in process
MMicro icro TTerminal erminal SSystem 0.64ystem 0.64MMicro icro TTerminal erminal SSystem 0.64ystem 0.64
MTS 0.64
37
Application
•Engine Compartment Connection•Device Connection
Features
•Two piece female terminal design•Mating part: 0.64 x 0.64 male terminal•Clean body for blocksealing systems
Target Customers•OPEL, FIAT, VOLVO, PSA, RENAULT, VW, DC
Expected Volumes per Year•SOP Oct. 2002•2003 120 Mio. parts •2004 200 Mio. parts•2005 200 Mio. parts
Stage of Development
•Prototypes available
MMicro icro TTerminal erminal SSystem Blockseal 0.64ystem Blockseal 0.64MMicro icro TTerminal erminal SSystem Blockseal 0.64ystem Blockseal 0.64
MTS 0.64 B
38
Application
•In-Lines and Device Connection•2.54 mm Centerlines
Features
•One piece terminal designs•Female terminal mates to:
0.64 x 0.64 male terminal0.80 x 0.64 male terminal1.00 x 0.64 male terminal1.20 x 0.64 male terminal
Target Customers•First Application GMT201 Headlamp Conn
•Stage of Development•Female in Production•Male terminal in development (1.0 x 0.64)•Validation Complete to USCAR
HVT Unsealed Female
HVT Unsealed Male
Micro HVT 1.2 mm
39
Application
•Engine Compartment Connection•In-Line & Device Connection
Features
•One piece terminal designs•Female terminal mates to:
0.64 x 0.64 male terminal0.80 x 0.64 male terminal1.00 x 0.64 male terminal1.20 x 0.64 male terminal
•Clean body for blocksealing systems•Cavity compatable with Kostal MLK 1.2
Target Customers•First application Daimler Chrysler ECM
Stage of Development
•Production Tooling Near Completion
HHighigh V Valuealue T Terminal erminal SSystem (Sealed)ystem (Sealed)HHighigh V Valuealue T Terminal erminal SSystem (Sealed)ystem (Sealed)
HVT Sealed Female
40
Closed Box TerminalContact gap is optimized for 0.64 mm thick blade,
but mates to a 0.8 mm thick blade (devices)
Secondary Contact Support Supports the primary contact, giving the
advantages of a two-piece terminal in a one-piece design
Tangless DesignIn conformance with SAE/USCAR
design guidelines
-40°C to 125°C operating range (USCAR Class III)155°C terminal exists for high temp applications (Class IV)
Indexing Tab
Approximately 10.4 billion 150 GT terminals with this interface are currently in service
GT Standard Terminal System 1.5GT Standard Terminal System 1.5GT Standard Terminal System 1.5GT Standard Terminal System 1.5
41
Closed Box TerminalContact gap is optimized for 0.8 mm thick blade on USCAR-standard devices
Tangless DesignSame basic geometry as thestandard GT female terminal
Indexing TabUnique from that on standard GT female terminal- Terminal will not plug to a connector designed for standard female terminal
This interface geometry has been in production since MY02– Used on GMT360/370
» 40 places – BEC to BCM flex circuit jumper
GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5
42
Flex-Pack Connection System Proposal
– New low cost connection system that performs to USCAR and Toyota 1000G requirements
Goal– Reduce connection system cost by 15% to 20% from current systems cost.
– Offer innovation- closer centerlines with larger cable, high terminal retention forces with one piece plastic, optimize normal force on contacts while maintaining engage force requirements, mating blade lead-in.
Flex Beam Cavity
Develop Flex-Pack 0.64 Terminal
Develop Flex-Pack 1.2 Terminal
Develop Flex-Pack 1.5 Terminal
Develop Flex-Pack 2.8 Terminal
For 4.8, 6.3, and 9.5, use existing GT/MP and Ducon. (low volumes)
Develop
Optimize
Modify existing GT 1.5 Terminal
Modify existing GT 2.8 Terminal
Modify existing GT 6.3 Terminal
Interim Step ADP
ADPPDP
43
One piece female connector housing, NO spacer/PLR or secondary lock required (tangless terminal system)
Superior terminal to connector retention
– No flexible lock features
Good tactile and audible plug: Inertia style plug
Tighter row to row packaging than typical tangless terminal systems- Works in Europe
Mating blade lead in integral to connector housingIntegrated Blade Lead In
Flex Beam (Spring)
Cantilever Lock(Flexible)
Flex Beam Technology
Typical Tangless Terminal Cavity Flex Beam Technology
Rigid Lock
PLR or SecondaryPiece
Blade Lead Inon PLR
Conn HousingConn Housing
44
Flex Beam Technology
Marrying Product/Process Build Holder utilizes two ring out pins
– Terminal contacts pins 90° with respect to plugging direction
– One or two ring out pins can be used depending on build process
Ring Out PinsBuild Holder
Terminal to Pin contact 90° from axis of plug
45
GT Terminal with Flex Beam Technology
GT 150 Terminal Redesign (first step)» Smoothing box to evaluate matt seal applications
» Wedge feature for added terminal retention
» Evaluating contact
280 and 630 ESD’s in design
Basic electrical contact remains same
Wedge Featureadded to increase terminal retention
46
100% closed mating blade lead in integral to connector housing
Non-orienting terminal, symmetric
to blade
Plug through matte (block) seal
New double spring terminal contact
Roll out– 1.2, 1.5, 2.8, 6.3/8.0
– 0.64 being evaluated
Blade Lead In100% enclosed
Hold Down Beam
Terminal Lock
Flex Beam TechnologyNext Generation- Flex Pack
Built in Interferencebetween Terminal and Beam
Ring out pin cavities
47
Integrated Blade Lead In
Hold Down Beam
Terminal Lock
Flex Beam Cavity – “Enhanced Cavity Design”
One piece female connector housing, NO spacer or secondary lock required
Superior terminal retention. Retention force averages above 120N’s (Toyota Spec: 100N min)
Packaging advantage–Adapts to European device footprint
Mating blade lead in integral to connector housing
48
VF Series Terminals ( Vier Feder) Description
– Terminal System 1.5, 2.8, 6.3 (4.8) Series
– Sealed and unsealed available
– Brand Names
» DS (Double Spring)
» VF (Vier-Feder)
» HVF (Hochleistungs Vier-Feder)
» DSQ (Double Spring Quadlock)
» ATS (Active Terminal System)
– HVF available with FPC Crimp Value
– Cavity compatible with Industry standard connectors
– Good electrical and mechanical performance combination
– ATS with high vibration performance due to S-Spring element
– 1,5 Male Terminal is universally usable Status
– All Terminal Versions in production including several connector systems
– New connector developments in process
49
Application
•Inline Connection•Device Connection
Features
•Two piece female terminal design•Mating part: 1.2/1.5 x 0.8 male terminal•Unsealed and Sealed•Cavity compatible to Tyco Micro-Timer
Target Customers•OPEL, FIAT
Status•In Production
DSQ 1.5
DSQ 1.5 (Double Spring Quadlock)
50
Application
•Device Connection•Inline Connection
Features
•Two piece female terminal design•Mating part: 1,5 x 0.8 blade •Sealed and Unsealed•Sicma 2 & 3 (FCI) cavity compatible
Target Customers•PSA, Renault, FIAT
Stage of Development
•Tooling in process
BTS 1.5
BTS 1.5 (Block Seal Terminal System)
51
Optima 1.2
Features:•2 Piece Terminal System•Blockseal /Unsealed and Single Wire•Cavity compatible to MLK & MCP•Centerline 2,54 mm, two rows•One Part for 2 Gap Sizes 0.6 & 0.8 mm
Version: 1.2 mm FemaleCustomer: AllApplication: StandardStatus: DevelopmentInnovation: Patent application
52
BTS 2.8 (Block Seal Terminal System)
Features:•2 Piece Terminal System•Blockseal / Unsealed Terminal•Cavity compatible to FCI Sicma
Version: 2,8 mm, FemaleCustomer: PSA / RenaultStatus: Patent Filed
53
BFC 1.8 Terminal
Application
• Inline Connections• 0.5mm2 - 2.5mm2 versions• Unsealed versions only
Features
• One piece female terminal design• Mating part: 1.8 x 0.8 male terminal
• Cavity Compatable with Tyco 070 Series Micro-Lock or Mini-MIC terminals
• (BFC is Portuguese for "Baixa Força de Conexão" (Low Engage Force).
Customers• Ford and Fiat
Status:
• In Production (Brazil)
54
CTS 1.5 (Compact Terminal System)
Product Description
– 1,5 Terminal size, sealed and unsealed
– Successor of the Timer terminals
– Terminal is cavity compatible with QKK (VW) and MCP (rest of the world)
Value Proposition
– One terminal part number for mating tab 0,6 and 0,8 mm
– highest vibration performance and low insertion force based on 2 piece CTS terminal design
Status
– In Production
55
Application
•Inline Connections
Features
•Two piece female terminal design•Mating part: 2.8 x 0.8/0.6 male terminal
•Support spring from the front•Spacer at the body terminal to define the gap size•Soft spring rate
Target Customers•All
Stage of Development
•Concept Only
CTS 2.8 (Compact Terminal System)
56
Application
•Inline and Devices
Features
•Two piece female terminal design•1.) Mating part: 1.5 x 0.8 male terminal•2.) Mating part: 2.8 x 0.8 male terminal
• Cavity compatible to GT-System
Target Customers•European Customers
Expected Volumes per Year•SOP: tbd
Stage of Development
•Concept study in process
ETS 2.8
ETS 1.5 & 2.8 (European Terminal System)
57
Application
•Inline Connection•Bus Electrical Centers (BEC)
Features
•Two piece female terminal design•Mating part: 2.8 x 0.8 male terminal•Unsealed•4-side-shoulder for secondary locking•Cavity Compatible with Tyco Junior Power Timer
Target Customers•OPEL
Status
•In Production
DSQ 2.8
DSQ 2.8 (Double Spring Quadlock)
58
Application•Engine Compartment Device Connections•High Vibration Applications
Features•Two piece female terminal design•Mating part: 2.8 x 0.8 male terminal•Fretting Corrosion Resistant•Flewxible section between core crimp and body absorbs vibrations.•Sealed System
Target Customers•OPEL, FIAT
Status•ProductionATS S-Spring performance
ATS 2.8 (Active Terminal System)
59
Application
•Terminal for Maxi Fuses•Unsealed terminal
Features
•Two piece female terminal design•Mating part: 8,0 x 0.8 fuse blade
Target Customers•VW, Audi
Stage of Development•Development on hold
Maxi Fuse 8.0
Maxi Fuse 8.0
60
Features:
– One piece terminal system
– Soldering Terminal
PCB Terminals
Version: 2,8 and 6,3 mm
Customer: All
Application: IBEC
Stage of Development: Concept
Innovation status: Patent application
Availability of parts: No
PCB Terminals
61
Ducon Series Terminals
Description– High performing terminal system
– Sealed and unsealed
– Blade sizes 0.64, 0.8, 1.5, 2.8, 4.8, 6.3, 9.5, and 9.5 HT
Status– In production since 1989
– Copied by Kostal SLK
– Plan to optimize the manufacturing process during 2005 for cost reduction
Value Proposition High electrical performance
High energy, high voltage capability
Excellent temperature and vibration
resistance
Robust two piece design
Multiple contact point technology
62
– Silver Plated Copper Alloy
» 2 Piece Terminals
» Offers Low Electrical Resistivity and High Thermal Conductivity
» Uses “Vane” contacts
» Designed for straight or Right Angle Mating
Inline connection
Right angle connection
Power-Pack Terminals
63
1500 Series
2000 Series
10 vane Insert
8 vane Insert
Power-Pack Terminals
– Passed Current Cycling
» 400A for 12s
» 200A for 12s
» 50A for 12s
» 20 Cycles
– Successfully used at 230A continuously