Why Do Automotive Connectors Fail?

Wiring harnesses are the central nervous systems of modern vehicles. They’ve evolved far beyond simple bundles of wires and encroach on every system and every panel in both body and chassis. Conductors now carry data as well as power, but the common element is the need to terminate those conductors in some kind of electrical connector. They are normally trouble-free, but when they fail, the result is at best inconvenient and at worst, crippling to the motor vehicle. Why do they fail? Jim Anderton shows us one connector that simply didn’t measure up.

ABOUT END OF THE LINE:
Manufacturing veteran James Anderton expresses his compelling and unique opinions about the state of the manufacturing sector. He shares his thoughts and insights to help engineering and manufacturing professionals navigate through the challenges of world events, the blending old with new technologies, evolving processes, gaps in skilled labour, in an effort to help maximize productivity of their daily operations.

James is a former editor of trade publications in the automotive, metalworking and plastics industries with contributions to a wide range of print and on-line publications. He also brings prior industry experience in quality and manufacturing for a Tier One automotive supplier.

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ENGINEERING.COM TV:

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STEM GAMES:

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#Automotive_Connectors #Car_Wiring_Harness

[KrustyKlown]

3:05 "can a major OEM simulate"... they don't, but the companies who make those connectors CERTAINLY do "simulate" all use stresses, based on OEM required performance specifications. FYI - Honda buys their connectors from the same companies who sell to all OEMs. (OEMs do NOT design or make their electrical connectors). ... an OEM must buy the right connector for the job.

[carlosdeandro]

Problems:
1 - EXPENSIVE !!!
2 - Difficult access (even for professionals).
3 - Poorly standardized (even with specific characteristics it would be possible to globalize these models, but each vehicle uses a more bizarre set of connectors than the other, making it more expensive and making access VERY difficult for ordinary people and even workshop professionals).

It is necessary to standardize these connectors and terminals globally, so that access is common to anyone and, consequently, the price has good stability and is much lower than it is currently. That's possible because the necessary characteristics are not so that specific as to prevent an better global standardization.