Collective Thermal Behavior of Multiple Terminals in an Automotive Electrical Connector 2016-01-0105

This technical paper aims to provide a framework for simulating the thermal behavior of an automotive electrical connector with the current flow across each terminal. An automotive electrical connector uses multiple terminals fitted in the respective cavity of a connector. Temperature at terminal increases with the current flow level across it. This temperature rise occurs due to resistive heat loss in the terminal. Due to this, temperature in the surrounding cavities also rises; hence, the current carrying capacity of those cavities reduces. Analysis of similar scenarios for design alternatives and design decisions is important to develop reliable and optimized solutions. The reliable and optimized solution helps to save the cost.

There is a large variation of different terminals used in the wiring harness, and there are various parameters attributing to this variation (shape, size, material, plating etc…). For simulation, developing models for each terminal variation is very complex. Hence, this paper discusses a method, which utilizes manufacturer’s curve as an input to capture all possible variations of a terminal (shape, size, plating etc…), and additionally the effect of different wire-terminal combinations also. After initial development of the framework, any terminal can use this framework (with proper characterization of specific series)

The basis of this paper is study done on 9-cavity connector. Study of central cavity ensures covering all different detections. This study is for harness-to-harness interconnection, packaged in an environment with laminar heat flow. It is possible to use different features of various automation tools but the method is inherently independent. Mathematical modelling techniques can also be used to achieve the same results.