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We'd like to minimize the number of different connectors and components that exist in the car. It's terrible for inventory management and means we have a lot of board-specific parts and crimping.
Components
Taiping Liand Calder Kitagawa will fill this part out, describing the common components and sizes that they have identified and why.
Connectors
All of our connectors must be positive-locking and able to withstand high-vibration environments, ideally shrouded. Anything outside of an enclosure should be sealed and locking with strain relief.
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| Connector | Purpose | Max. Rated Voltage | Max. Rated Current | Max. Mating Cycles |
|---|---|---|---|---|
| Molex ClikCLIK-Mate | Wire-to-board: 1.25mm for signal and 1.50mm for power | 1.25mm: 50V 1.50mm: 100V | 1.25mm: 1A 1.50mm: 2A (3A with 2 circuits) | 30 |
| Anderson SB120 | HV power - note that this does not follow any of the rules | high | 240A | 10k |
| Hirose DF3 | Alternative to Clik-Mate (2mm pitch 2 circuit variant available) Not locking? | 250V AC? | 3A | 30 tin, 50 gold |
| M12-5 (DeviceNet) | CAN and power | 300V? | 4A (power) | |
| TE Deutsch | CAN, power, aux signal | |||
| Molex DuraClik | Wire-to-board (2mm) | 125V | 3A | 30 |
| Molex UltraFit (Gold Plated) | Wire-to-board: LV Power Connector | 400V | 12A | 200 |
After testing, the ClikCLIK-Mates 1.5mm will be a good choice for any signal wire-to-board connections required as long as we're satisfied with its lifespan. The 1.25mm versions extremely difficult to crimp and have a maximum wire size of 26 awg. The DuraCliks are a good alternative as they are designed explicitly for automotive use and support ISLs or TPAs for terminal retention and positioning.
We plan on powering all boards through the carrier board, so we want to find a high-current (10A) 2-pin connector for all LV power usage.
Follow-up
We have standardized on DuraClik ISLs for signal wires and Ultrafit TPAs for power. In addition, most of our components should be 0603.
We've also decided on Molex MX150Ls for panel-to-panel connectors as they seem to be the only connector family with options for panel-mount connectors in the 22-18awg range.
For HV connections, we've decided on Anderson SB120s over the TE HVP 800+ series because they're much easier to crimp. We may want to investigate sealing further.