When we imagine the tens of thousands of components in a vehicle – each carefully selected and assembled in a system or sub-system to supply power, transmit or process signals within sections of the car to activate a vehicle response or to perform a series of functions and making sure it works – the sheer task of the automotive designer or electronics engineer is no mean feat. Automotive engineers are employed by car and truck makers, or parts suppliers to design and build individual parts or systems, or even possibly the entire vehicle. Anything from engine design, aerodynamics, thermodynamics, performance and fuel-efficiency to safety features, infotainment or vehicle ergonomics will be an area that requires in-depth knowledge of those applications and the technologies associated with designing and manufacturing them.
This article highlights Molex’s MX150 connector family and features that help the design engineer make informed decisions when choosing an appropriate interconnect for the application they could be working on . These could include vehicle transmission, head/tail lamps, body harnesses, wipers, washers, defoggers, speedometers, A/C modules, turn signals, airbag harnesses, speakers, door connectors, brake modules, horn and more.
Connector designs with vehicle assembly and manufacturing considerations
Decades of collaboration with top-tier automotive and commercial vehicle makers around the world has given Molex the understanding of their connectivity needs. Recognizing their need for cost-efficient manufacturability in all aspects of interconnect design, functionality, performance and reliability, concept models were developed in the early stages of design and improved to enable easy usability and quick implementation.
The MX150 connector solution was developed with manufacturing considerations early in its design stage. The MX150 connector was based off the 1.50mm ISO Blade-type terminal system in pre-Tin, Selective Gold and pure Silver contact finishes, and designed around giving users superior space-savings over traditional USCAR connectors. Design Engineers had the flexibility of choosing compatible male and female connectors and terminals with plating of choice to meet their needs.
Space and mass savings are ever more crucial for internal combustion engine (ICE) powered and battery powered electric vehicles, due to challenging EPA regulations and the need to reduce battery size. The MX150 is a product family that is constantly evolving to offer a wide range of circuit sizes and hybrid connector options.
In a typical wire-to-board configuration for example, The MX150’s preassembled, submersible connector system simplifies device tooling by incorporating USCAR-specified interface geometry directly into the sealed headers. The MX150 connector’s preassembled Terminal Position Assurance (TPA) housings help ensure crimped terminal leads are properly locked into the connector for added contact reliability. If the crimp terminal is not locked, the TPA will not fall into the final locking position and the connector system will not be locked.
Molex offers an optional Connector Position Assurance (CPA) feature that, when used, ensures a fully mated system, preventing any accidental disconnect.
The MX150’s rugged, environmentally sealed connector (receptacle) interface is optimized to meet IP6K7 and IP6K9K sealing requirements, enabling it to support both low-level signal and power applications up to 22.0A. The sealed MX150 connector supports an operating temperature class of -40 to +150°C (for Ag) with excellent electrical performance even at V3 vibration class, making it suitable for automotive, commercial, industrial or recreational vehicles as well as construction and marine equipment uses.
The MX150 connectors are proven and industry-tested offering with excellent warranty performance. The product’s highly engineered connector housings, sealing technology, and position assurance designs – all combine to ensure the highest-quality connections for use in harsh environments, making this product a go-to solution for designing automotive parts.
Choose a dual-seal interconnect system when operating at high-current, high-temperature conditions
Equally vital to the reliable functioning of the interconnect system running at high-current and high-temperature conditions is the selection of its seal support system. The type of seals you choose will determine the level of connection performance that best meets your expectations.
The MX150 series of sealed single-row and dual-row connectors uses Mat seal technology for the MX150 (1.50 mm) terminals. The use of Mat seal technology eliminates the need for individual cable seals, resulting in a reduced package size and greater space savings (a critical factor for space-tight applications), and costs associated with maintaining additional inventory (which inevitably increases with increasing circuit size or the number of wires used). The mat-seal incorporates a single silicone-based seal with individual wire openings allowing for a tighter overall pitch and smaller package size.
In a wire-to-board application, the solder-tail and compliant-pin electrical interfaces provide module design flexibility and lower applied costs by eliminating the need to purchase, handle and crimp individual wire seals. A grommet cap (for standard connectors) protects, securely retains and provides strain-relief to the wire-seal interface.
The sealing geometry of the ring seal incorporates spray shield to meet IP6K7 and IP6K9K requirements. A truly sealed connector system, the MX150 header system has been tested and confirmed to perform under submersed conditions in various fluids.
The MX150 sealed connector’s single-piece 3.50 mm pitch housing eliminates unnecessary and costly assembly operations while delivering a more compact connector. Additionally, the single- and dual-row back-shells or wire-dress covers available in 2-, 3-, 6-, 8-, 12-, 16- and 20-circuit sizes provide additional protection of the back wires of the connector, securing the cable bundle while offering strain relief.
Ease and speed of assembly is one hallmark feature of the MX150 connector system. The MX150’s connector housing comes with four polarization and color options, making visual identification and assembly both quick and easy. Convenience is also an important selling point of the MX150 interconnect system. A clip-slot feature comes standard on blade connectors and is optional on receptacles. The standard MX150 connector uses USCAR 11.00mm clip slot to provide a simple and easy method for securing connectors to a mounting surface for a variety of applications.
Panel-mounted connectors in 2×3 and 2×6 configuration along with a 20-way V0 version is available.
Also available are Twist-Lock Sealed Bulkhead Connectors. These ensure simplified and reliable connector mating and assembly while providing superior sealing and electrical performance in rugged, exterior automotive applications. MX150 Twist-Lock Sealed Bulkhead Connectors simplify connector assembly by eliminating the need for additional fasteners. These connectors employ ring-seal technology to meet industry-standard sealing requirements.
Molex offers Flashover options (i.e., custom void patterns) for greater design flexibility if needed.
MX150 hybrid sealed connector system reduces package size and costs
For Mat-sealed systems, Molex offers 4 series of Hybrid Receptacle Connectors (34985, 160076, 160078, 160111) spread over 4 circuit sizes (8, 10, 12 and 16-way). These come in a combination of keying design, CPA and Clipslot options; with resin colors that are Black, Gray (Dark), Gray (Light), Stone Gray or Yellow. These parts are grouped in 3 application configurations: Power, Wire-to-Board and Wire-to-Wire.
Molex also offers Hybrid Blade Connectors (34986, 160112) for Power and Wire-to-Wire configuration applications. These come in 12 and 16-way designs. The resin color options for these parts are Black, Gray (Dark), Gray (Light), Natural, Stone Gray and Yellow.
The parametric parts search engine in the Molex website will help the customer filter and select their desired design configurations.
Tin, silver and gold-plated crimp terminals offer best match price-to-performance options
Tin, Silver, and Gold-plated versions are available for the MX150 blade and receptacles mat seal and cable seal terminals and these offer reliable and economical connectivity choices. These terminals are validated to meet USCAR-21, USCAR-2, and GMW3191 specifications.
Supporting current ratings up to 22.0A, the terminals withstand Class 3 (-40 to +125°C) for Tin, and Class 4 (-40 to +150°C) temperatures for Silver, providing superior performance, while the wires comply with GM, Ford, PSA, and JASO specifications to meet the requirements of major automotive manufacturers.
The MX150 standard and M3 grip terminals are packaged in reels (terminals are not packaged with connectors), and used with Series 33471, 33472, and 34985 receptacle connectors and Series 33481, 33482, and 34986 blade connectors.
The Molex MX150 web overview offers a quick way to filter out the required part and part details which come complete with sales drawings, product specifications and related engineering documents.
Conclusion
The importance of implementing a rugged, reliable and industry-recognized sealed interconnect solution in automotive or commercial vehicles whether for routine or rigorous operations can in no way be overstated. The suitability of the MX150 interconnect solution for a specific application has a vital role to play in the safety of the driver, its passengers and other road users – particularly in harsh weather conditions. The MX150’s sealed connector system complies with USCAR-20 (FCLT)/USCAR-2 Rev.4/USCAR-21 standards, making it suitable for use with on-engine, high-vibration, under-hood and under-chassis environments as well as a host of other applications. Designed with features that make for easy assembly, the MX150 connector system helps automotive makers lower overall production costs.
With more than 30 years of experience serving leading automakers and suppliers in the automotive industry, Molex is furthering its mission to design and deliver critical electronic, power and signal, and connectivity solutions that form the central nervous system of tomorrow’s electrified vehicles.