1. 1 USCAR / EWCAP & USCAR Compliant Connections Prepared By John Yurtin Revised and Updated 4-5--05 CTIS # 29955 Connection Systems Training

2. 2 Working together with customers, suppliers and competitors can result in improved products for the customer. Understanding this relationship within standards activities is essential to this process. This training will help you understand the USCAR activities and how it can benefit our business Excellence Focus: Your Customer Style: Teamwork

3. 3 The USCAR Organization The USCAR / EWCAP Organization USCAR/EWCAP Objectives USCAR Compliance Requirements USCAR Compliant Connections Delphi’s Continuing Commitment to USCAR Agenda Southfield Town Center 1000 Town Center Drive Suite 300 Southfield, MI 48075

4. 4 United States Council for Automotive Research (USCAR) is the umbrella organization for collaborative research among DaimlerChrysler Corporation, Ford Motor Company and General Motors Corporation. http://www.uscar.org/ Sharing technology for a stronger America What Is USCAR?

5. 5 USCAR AS UBRELLA FOR BIG THREE RESEARCH  Collective research-and-development work among the Big Three has been underway since 1988.  USCAR was formed in 1992 to help coordinate administrative and information services for existing and future Big Three research consortia devoted to tackling shared technological and environmental concerns.  Incentive came after famous visit of President Bush and the Big Three Auto company presidents to Japan to try to limit imports. USCAR, an Umbrella for Big Three Research

6. 6 The USCAR Organization USCAR Council USCAR Leadership Group Advanced Powertrain Manufacturing Energy Storage Environmental E/E Fuel Cell Hydrogen Materials Safety Sharing technology for a stronger America

7. 7 USCAR Objectives  The main objectives of USCAR are: –Monitor current joint research projects and consortia; –Consider and recommend new joint research and development projects and consortia; –Interact with other organizations (Society of Automotive Engineers, etc.), supplier companies and governmental agencies; –Share results of joint projects with member companies; –Seek and recommend funding from public and private sources for joint research and development, and –Provide facilities and administration for consortia.

8. 8 Consortia / Technical Teams / Working Groups  ACC – Automotive Composites Consortium  ERC – Environmental Research Consortium  EWCAP – Electrical Wiring Applications Partnership  LEP – Low Emissions Partnership  LEPC – Low Emissions Paint Consortium  OSRP – Occupant Safety Research Partnership  SCAAP – Super Computer Automotive Applications Partnership  USABC – United States Advanced Battery Consortium  VRP – Vehicle Recycling Partnership  USAMP - United States Automotive Materials Partnership

9. 9  Freedom Car & Fuel Partnership –Advanced Combustion & Emissions Control –Electrochemical Energy Storage Team –Electrical & Electronics –Fuel Cells –Materials –Vehicle Systems Analysis Tech Team –Hydrogen Storage –Hydrogen Codes & Standards  U.S. A-Team –Manufacturing Competitiveness Consortia / Technical Teams / Working Groups

10. 10  Electrical Power Systems (Formerly 42 Volt)  Manufacturing  Transmissions Consortia / Technical Teams / Working Groups

11. 11 Partnering Adds Value  Accelerates technical development  Provides common voice to supply base  Increases value of research investments  Improves quality and reduces cost for noncompetitive technologies  Addresses more than single company can accomplish alone Sharing technology for a stronger America

12. 12  Freedom from foreign petroleum dependence  Freedom from pollutant and carbon dioxide emissions  Freedom for Americans to drive where they want, when they want in the vehicle of their choice  Freedom to obtain fuel affordably and conveniently FreedomCAR & Fuel Partnership Sharing technology for a stronger America

13. 13 Technology Solutions for the Automobiles of Today and Tomorrow Sharing technology for a stronger America

14. 14 … thus, the need to continue R&D for all technologies Freedom CAR Technology Alternatives No single global technology solution has yet emerged… Near TermMid TermLong Term Specific Benefit Deployment Timeframe Advanced Gasoline ICE Hybrid Powertrain Diesel ICE Today Fuel Cell Hydrogen ICE Deployment Development Sharing technology for a stronger America

15. 15 Strategic Partnerships  Increase competitiveness of United States manufacturing base  Digital tools  Plant floor controllers  Ergonomics US A TEAM (U.S. Alliance for Technology and Engineering for Automotive Manufacturing) Sharing technology for a stronger America

16. 16 Low Emissions Partnership Engine Benchmarking  Why run the same tests three times when once will do?  Partners exchanged data sets on 38 of their own engines  Each partner saved close to $2M  How each company applies that data becomes competitive Advancing Technology with Collaboration Sharing technology for a stronger America

17. 17 Advancing Technology with Collaboration Vehicle Recycling Partnership  Promotes technical and economic feasibility for recycling  Collaborates with Argonne National Laboratory on Plastics Recycling Sharing technology for a stronger America

18. 18 Lightweight Materials  Redesigned front rail system saving 23% mass while maintaining performance and safety targets Advancing Technology with Collaboration Sharing technology for a stronger America

19. 19 Safety  USCAR’s Occupant Safety Research Partnership and international partners are designing the World SID II  Unique design harmonizes global requirements Sharing technology for a stronger America Advancing Technology with Collaboration

20. 20 Research Partners  National Laboratories  Government Agencies  Suppliers  Universities Sharing technology for a stronger America

21. 21 ELECTRICAL WIRING COMPONENT APPLICATION PARTNERSHIP  Mission: –Facilitate and encourage cooperative research and development including sharing of technologies and resources to develop common electrical connection systems and standard electrical components (e.g., motors, relays, and switches)  Staff: –Three full-time engineers, representing Ford, GM and DaimlerChrysler, located in Southfield, MI (Presently considering a reorganization) Harry Zaverzence /Jim Roberts (DaimlerChrysler) Dan Jarmolinski (GM) –http://www.uscarteams.org/http://www.uscarteams.org/  Formed: –June, 1994  Uniqueness: –Projects are not research oriented, but aimed at introduction of terminals, connectors, and electrical components for specific model year What is EWCAP?

22. 22 1.Develop common electrical connector specifications 2.Establish a standard “footprint” for electrical connections 3.Reduce the number of different connectors on a vehicle by using common device connection footprints 4.Establish and Catalog common families of “Best-in- Class” connection systems USCAR / EWCAP Objectives

23. 23 BENEFITS  Improve performance, reliability, and durability  Reduce development time  Commonization of “non-competitive” electrical devices  Reduces resource requirements on new systems  Reduces duplicate testing at suppliers  Assist in “Internationalization” of electrical components USCAR / EWCAP Objectives

24. 24 EWCAP Projects G.M. FORD YAZAKI AUGAT A.F.L. UTACARDELL OSRAM EPC AMP INTERLOCK D-C DELPHI P.

25. 25 1.Develop common electrical connector specifications SAE/USCAR-2: Performance Standard for Automotive Electrical Connector Systems SAE/USCAR-3: Standard for Testing Automotive Miniature Bulbs SAE/USCAR-4: Standard for Cigar Lighters and Power Outlets SAE/USCAR-12: Wiring Component Design Guideline SAE/USCAR-13: Standard for In-Tank Electric Fuel Pumps SAE/USCAR-14: Specification for Testing Halogen Light Sources SAE/USCAR-15: Specification for Testing Lamp Sockets SAE/USCAR-17: Specification for Automotive RF Connector Systems SAE/USCAR-18: FAKRA SMB RF Connector Supplement SAE/USCAR-19: Coaxial Cable Connector Interface Square outer Conductor SAE/USCAR-20: Field Correlated Life Test USCAR / EWCAP Objectives

26. 26 SAE/USCAR-21: Crimp Specifications SAE/USCAR-23: Single Core Cables SAE/USCAR-24: USCAR Inflator Technical Requirements and Validation SAE/USCAR-25: Electrical Connector Ergonomic Requirements SAE/USCAR-26: Finish Evaluation Electrical Ground Test Procedure In Development: USB Connector Performance Standard Materials Color Chart and Standard SAE/USCAR-22: Flex Cable & Flat Wire Specification SAE/USCAR-27: Gas Discharge Light Source Subsystem Precious Metal Plating Activity USCAR / EWCAP Objectives

27. 27 Centerline Spacing Mating Shroud Dimensions Lock Feature Detail Index Feature Detail 2. Establish a standard “footprint” for electrical connections USCAR / EWCAP Objectives

28. 28 –Cigar Lighter –Fuel Injector Conn. –Oil Press Switch –Light Bulb Housing –Power Seat Motors –ABS Controller Connection –Mirror Connection –Batteries –Windshield Wiper Motors –Power Outlet Connection –Trailer Connectors –A/C Pressure Switch –Air Bag Initiator Conn. –Horn Connector –O 2 Sensor Conn. –Fan Motors 3. Reduce the number of different connectors on a vehicle by using common device connection footprints USCAR / EWCAP Objectives

29. 29 4. Establish and Catalog common families of “Best-in- Class” connection systems Terminal Families: 0.64 mm Sealed Systems 0.64 mm Unsealed Systems 1.5 mm Sealed Systems 1.5 mm Unsealed Systems 2.8 mm Sealed Systems 2.8 mm Unsealed Systems 6.3 mm Sealed Systems Hybrid Systems Example of listing of 0.64mm unsealed systems from the USCAR website USCAR / EWCAP Objectives The following terminals have been chosen and established to replace the numerous terminals currently in use.

30. 30 The EWCAP Difference  Uniqueness –EWCAP drives OEM platform specific devices to be common commodities for the USCAR partners through the following items: »Common specifications »Common electrical interfaces –Projects may be research oriented, but most often are aimed at introductions of terminals, connectors and electrical components.

31. 31 The EWCAP Difference (cont.)  Allows standardization »Device manufacturer »Terminal/connector supplier »Wiring harness supplier  Improved quality from all areas including engineering, manufacturing and assembly.  Reduced component and fixture complexity.  Reduces engineering resources for new devices

32. 32 EWCAP Web Site  www.ewcap.uscarteams.org/ www.ewcap.uscarteams.org/  Content: –Parts list –Part numbering system –Footprint drawings –Preferred connectors by device –List of specifications –List of current projects

33. 33 Connector Packaging Dimensions 1.5 mm CONFIG DRAWING # REVISION INDEX/ DRAWING PRIMARY DRAWING POLARIZATION STATUSUSE SOURCE OPTIONS 1 X 4 150-U-004-1-Z01 A IN --- EPC A01,B01,C01,D01 Sample Catalog / Web Page 33

34. 34 17 specifications published Over 100 engineering drawings showing 400 individual parts completed Savings booked and projected:

35. 35 Airbag Initiator Example  Electrical connectors clearly not a purchasing factor  Average almost $2M savings in ’05MY for each company Sharing technology for a stronger America

36. 36 What Is USCAR Compliance? A Device connection that meets the dimensional requirements (footprint) specified by USCAR, and… A Harness connection that mates to a device which meets USCAR dimensional requirements and….. When mated, a Connection System that meets the performance requirements of the SAE/USCAR 2 specification and… A connection system that conforms to SAE/USCAR-12 Wiring Component Design Guidelines… USCAR Compliance

37. 37 USCAR Does Not…….  Approve products  Certify products  Endorse products  Promote products  Verify performance of parts on their web  Verify the claims of products on their website  Publish Standards  Sell Standards

38. 38 2 Way 1.5 mm Sealed Index A Knock Sensor 2 Way 1.5 mm Sealed Index B Crank Sensor 3 Way 1.5 mm Sealed Index C (Gray) 3 Way 1.5 mm Sealed Index B ( Dk Gray) 5 Way Sealed 1.5 mm Index A (Gray) 5 Way Sealed 1.5 mm Index B (Black) USCAR Compliant Device Connections

39. 39 30 Way Sealed ABS Connector 7 Way Sealed Trailer Tow Connector 2 Way Sealed Fuel Injector, Horn & Underhood Lamp Connector 3 Way Unsealed Cigar Lighter/Power Outlet Connectors USCAR Compliant Device Connections

40. 40 USCAR 0.64 mm Connections Mates to USCAR standard 3.5mm footprint Smaller package size Mates to existing devices tooled for “pull-to-seat” connections Uses same terminal design as the 4.5mm USCAR connectors USCAR 3.5 mm Connections USCAR Compliant 0.64 & 3.5mm Connections