How to select 48 V connectors for medium-voltage automotive architectures
separate connectors for each voltage level, avoiding the integration of both voltages within the same connector. Additionally, the automotive industry has adopted light blue color coding for 48 V connectors to clearly differentiate them from 12 V connectors. The origin of this color coding dates back to electric forklifts, which have long used batteries of varying voltages. Color guidelines were established to prevent errors, leading to the widespread adoption of blue for 48 V connectors across various industries. This system works in tandem with the established use of orange connectors and wiring, which signify high-voltage systems. This color coding clearly indicates components that require specific safety precautions, ensuring that they are not handled without appropriate
by USCAR-21, which stipulates the test methods and criteria for cable-to-terminal electrical crimps in automotive applications. A key aspect of USCAR-21 is pull testing, which involves applying a consistent pull rate to a crimped connection to assess its tensile strength. This testing ensures the crimp can endure the mechanical stresses it will face during its service life. The specification also highlights the necessity of using precise tooling and process settings during crimping. Additionally, it is advisable to seek connectors certified to GMW3191, a comprehensive standard formulated by General Motors. This standard outlines the testing and validation requirements for automotive electrical connectors, confirming their reliability and durability in demanding conditions.
Molex MX150 assembly and service considerations To complete a connector assembly, the wiring must first be terminated. With the MX150 male connector assembly, for example, the wire harness must be terminated into a 330000001 blade. Similarly, the wiring must be terminated into a 33001 or 33012 series rectangular connector contact for the female receptacle. In either case, the terminated wires must be pushed into the connecter until they are secured. If a circuit position must be left empty, the gap should be filled on the male side with the 343450001 cavity plug. To aid in this termination process, Molex offers the 0638115900 manual crimping tool (Figure 3). This device ensures a secure connection between the wire and blade or rectangular contact.
safety training and personal protective equipment (PPE).
Manufacture and serviceability considerations
The risk of arcing in mid-voltage connectors necessitates that they be designed for reliable manufacturing and servicing. This requirement is addressed
Figure 3: The 0638115900 manual crimping tool ensures a secure connection between the wire and blade or rectangular contact. (Image source: Molex)
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