![]() To pass this test, a connector must exhibit a 500 M Ohm resistance between connector sections at an applied voltage of 500 VDC. The connector may perform as expected at room temperature, but these tests evaluate whether the device will function over extreme temperatures.Įlectrical resistance. The specific solution would depend on whether the connector is sealed. Subjecting the components to immersion in automotive fluids and even salt water. Systematically stressing the connector mechanically This nearly 80-page document gives extensive – and precise – test information. To learn more about general requirements for connectors approved for automotive use, a great place to start is the USCAR2-7 specification by the Society of Automotive Engineers (SAE) and the United States Council for Automotive Research. This advantage lets companies like Toyota hold their suppliers to stringent quality standards. While these manufacturers are technically dependent on suppliers to maintain their reputations, the manufacturers make up a massive amount of the market share. Manufacturers like Ford, Toyota, GM, and many others “make” cars by gathering parts from a wide variety of suppliers and assembling them into a finished product. ![]() Maintaining Quality Automotive Components It’s no surprise that the electronics that make up your vehicle require extensive testing, including the connectors and cables that snake unseen through modern vehicles. Given their critical responsibility for our safety and overall well being, all automotive electrical components must be able to withstand freezing cold, blazing heat, and uneven terrain. The wires pass through a rubber seal on the back of each connector (the seal, seen on the right, has been pulled out for this picture).įor more information on wires, fuses, connectors and related topics, check out the links below.Automotive Grade Electrical Connectors: Unseen but Critical to a Car's Function One side of each connector has a round seal that keeps water from entering the space between the connectors once they are locked together. This seal fits firmly into the back of the connector. Each connector has a rubber seal through which all of the wires are fed. The seals prevent water from entering the connection once the connectors are locked together. The retainer keeps the pins and sockets in place. This piece makes it nearly impossible for the pins and sockets to work their way loose. ![]() It wedges against all of the plastic locking barbs so they can't release. The pin/socket retainer is a piece of plastic that slides into the connector from the front. ![]() This makes it harder to pull the wire away from the pin. Part of the pin wraps around the bare wire, while another part clamps onto the insulation. The pins are crimped to the wires using a special crimping tool. These are made very precisely so that the pins and sockets fit together with just enough force to ensure a good connection, but not enough force to make connecting and disconnecting too difficult. The pins and sockets are responsible for conducting electricity from one half of the connector to the other. All of these features are molded into the piece when it is made. There are numerous grooves to hold seals and make sure things fit together tightly. There are holes for the pins, and there are special barbs that lock the pins in place once they are inserted. There is a locking clip on the outside that holds the two halves of the connector together. The shell is an intricate piece that has a complicated shape.
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