GenBoard currently uses two EconoSealIII connectors
ECM connector aspects
For next generation, we're looking for other types (although EC18 and EC36 would work):
- We should remain on the lookout for other automotive specification connectors
- optimizing size
- Box-height is a bit prohibitive with EconoSealIII
- I noticed that 100mm board maxsize would seriously limit our choice. 114mm is much better.
- 10A is ideal for the few high-power pins, but for most pins, smaller centerline would be welcome (the combo-design SAAB is perfect in this way).
- reliability (several good choices, sealed is a good idea)
- availability (usual: 2 months, MOQ: 60 .. 150)
- price - note that a very good ARM processor can be obtained for the price of a connector solution. The connector-saga suggests that it's better to have a very few powerful units (pincount=35 or 70) rather than many lower-pincount units (unless one likes DSUB :-) VemsFrontier/Boards should be in the ballpark, if boards's bigger size is increased to 114mm so that the tyco 2-825213-5 junior-timer header fits.
Good candidates for future ECMs are
- the timer series
- [SAAB mixed timer connectors] see below. Looks like the best choice for a v3-like full-featured ECM.
- low profile 35 pin junior timer: 2-825213-5 Looked like a very good choice before we found it's probably non-sealed. Boardsize >= 114mm. Very little board area wasted. Note that [fciconnect 43132000] looks very similar, actually the fciconnect also has a little step where the tyco lacks it for 9mm on the 2 sides. Pins are 2.8x0.8mm (which is same as tyco junior power timer)
- or ampseal
- unless molex shows us something.
- Econoseal 1mm series for example 60 pin PN [3-1437285-2]
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Mixed timer - many microtimer and a few junior timer pins from SAAB-Tyco - not as good as it seemed first
These are negotiated to be available. After closer investigation, they don't look as good as first. There are only 2 JPT pins with ignition capable clearance. The footprint is not so much better than EC36 (for EC36 one line is closer to the edge). We cannot justify spending thousands of EUROs (and all the logistics nightmare) for questionable benefits. EC36 is million times better when we decide about flying-loom version (should ArmUfo be late or something)
- [SAAB42 family parts "comparison"]: 36 microtimer + 6 junior power timer pins. Note that this is very boardspace efficient. There are 3 JPT pins on both sides. The upper row of MPT have ignition compatible clearance.
- [search page at last point] and
- [SAAB42 board hearer].
- [9 types of receptacles] click on compare parts. Note that 9 for CuSn material only! What material do we want? Click on CuSn to see other materials. Which recaptacles do we actually want?
There is quite a few receptacles to choose from, but after choosing single piece instead of real+single piece I'm down to 5 types for the Junior-Power-Timer.
The questions we need to ask(junior-power-timer):
Which wire size do we want? For power-junior-timer I'd say 1.5-2.5sq.mm even if this will cause us to have two stocked junior-power-timer recaptacles (0.5-1.0sq.mm for the injector connectors and the WBo2 connector.)
Do we want to use a seal?I'd say that we don't need to seal each wire of the ECU connector.
There is only two isolation sizes, both effectively the same. (2.11-3.11 or 2.0-3.0)''
Which plating do we want? Most likely selective gold plate, all parts is gold plated. Going with selectable gold plating also eliminates the isolation thickness choice and leaves us with one part #
The 1.5-2.5 sq.mm, 2-3mm isolation, non sealed, selective gold plated and single packed Power-Junior-Timer recaptacle is: 2-964346-1 No drawing available at this time. http://catalog.tycoelectronics.com/TE/bin/TE.Connect?C=11557&P=49173,49176,10250,83080,113538,49193,138778,218&M=PROP&LG=1&I=13&G=G&N=1&IDS=325885
The 0.5-1.0 sq.mm, 1.4-2.31mm isolation, non sealed, selective gold plated + tin plated and single packed Power-Junior-Timer recaptacle is: 927779-9 or 927779-8(spring gold plated too) http://ecommas.tycoelectronics.com/commerce/DocumentDelivery/DDEController?Action=showdoc&DocId=Customer+Drawing%7F1355046%7FA6%7Fpdf%7FGerman%7FGER_CD_1355046_A6.pdf
The 0.5-1.0 sq.mm, 1.4-2.7mm isolation, sealed, selective gold plated and single packed Power-Junior-Timer recaptacle is: 2-964285-1 No drawing available at this time. http://catalog.tycoelectronics.com/TE/bin/TE.Connect?C=11557&P=49173,49176,10250,22643,113514,138778,218&M=PROP&LG=1&I=13&G=G&N=1&IDS=325892
The 0.5-1.0sq.mm, 1.4-2.1mm isolation, non-sealed, gold plated, single packed Micro-TimerII receptacle is: 964264-3
Thanx for the hunt! Don't worry, we'll need recepticles for other JPT housings.
Junior-power-timer:
2-964346-1 1.5-2.5sq.mm
927779-9 0.5-1.0sq.mm
927779-8 0.5-1.0sq.mm
2-964285-1 0.5-1.0sq.mm sealed
MicroII-timer:
964264-3
All the parts are available (on mass-order) for the SAAB42 connector solution. A bit pricey (almost as pricey as the SAAB70, which is not exactly cheap itself) and one part is 12 weeks (another is MOQ=1000), but otherwise OK (higher initial order value than the EC18 + EC36 were together).
Should I order the part now, that ships in 12 weeks?
Can someone look up the related tyco receptacle and round rubber seal part numbers so we can get quote ASAP ? The MPT receptacles too, not the tape but the standalone ones that have superior crimpability.
SAAB70: 60 microtimer + 10 junior power timer pins This is about 103 mm and is a wonderful connector for ECM-to-wire applications. Some of the microtimer pins would be bundled in pairs, because the 10 junior pins is a bit too few. 6 of them is on the left side, 4 is on the right.
- 1-968879-1 MOQ 66 pieces
- 1-963484-1 MOQ 55 pieces
For the higher current connection the same connector as currently or other higher density connectors should be evaluated.
The US car manf have started to get together to make and define connectors.
From
http://ewcap.uscarteams.org/ConnectorCatalog.htm
EWCAP standard pins have the following recommended maximum current carrying capacity. Maximum current load may be more or less depending on the specific application and materials used. Use the methods described in SAE/USCAR-2 Specification For Automotive Electrical Connection Systems to determine the specific current carrying capability of the terminal and connection system.
Pin Size Current Capacity
0.64mm 5 Amps
1.5mm 15 Amps
2.8mm 25 Amps
6.35mm 40 Amps
Wire to Wire Connectors
Molex carries a new type of connector
They are called the[ MX150 & MX150L]
Molex describes them as:
''MX150™ and MX150L™ Sealed Connector Systems
Pre-assembled housings and seals provide a rugged connector system with guaranteed superior performance under submersed water conditions.''
Another site of interest is the Molex connectors.
Its a long link.. But sorry about that.
more bits down at the bottom
This page shows the selection matrix for the sealed connectors.
This page shows AMP/TYCO std Molex style connector with weatherproofing a tiny bit
[ Universal wxproof connectors]
Here we have some information on Delphi connectors.
this is thier main site
Summary:
PCB to Wire
- Tyco as always has a selection but they are a PITA to deal with
- [SAAB mixed timer connectors] connector -- works very well on old BOSCH units. Note that there is a 36+6 smaller version. Jörgen mumbled something about the HV connections: it seems he assumes all ignition driver outputs must be on JPT (not MPT) pins (the smaller connector has only 6 JPT, the bigger 10), but is this surely true?
- Mixed Timer, Works but not quite as good as SAAB connector.
- ITT/Cannon has a solution for the plain rect sealed connector 28 pin as near as I could tell
- [ FCI] may have a solution, some connectors are [sealed] like [FCI 200PL329L0008 32pin] similar to EC36 or [this 55way IP67 male]
- Delphi definately has a solution, but it is unknown if its big enough for our application
- Could do flying lead to
- Molex has some nice Wire to Wire connectors these compete with the GM weather connectors
- GM weather connectors are avail
Other Options
Cannon plug type connectors
[SOURIAU TRIM TRIO Circular Connectors] look reasonable for the price.
At the top end, [Deutsch] AutoSport connectors are light, durable, and withstand vibration extremely well. Details can be found on the website, but PDF downloads wants a login (no problems registering online though) They are apparently derived from a design for the Eurofighter. Motec uses it on their 880 ECU, and Pectel has them on it's top-of-the-line [T10S ECU]. Easiest way to get AS connectors in low quantities seems to be [Servo] in the UK. Nice company to deal with, but they aren't cheap parts - around 40 Euro in low quanties (with contacts and insertion tools). MOQ is 1 and available next day, unless something really special needs to be produced. A couple of brochures can be found [here]. The tech manual was too large to upload to filethingie.
Amphenol seems to have a line of very similar connectors. Their [FAST] connectors look quite good, but no idea on pricing. Probably somewhere between Mouser and Deutsch?
These circular connectors aren't available in a right-angle PCB mount footprint - only vertical mount. Some other industrial connectors have this same design. It raises the question of weather we need a right-angle connector at all... We can probably get a thinner case profile, better sealing, and more robust connectors by mounting vertically. High voltage/current outputs can have their own low density plug if needed, while regular or sensor IO can be on a higher density plug. The downside is different mounting requirements, and possibly difficult routing on high-density connectors.
I think these circular connectors are perfect as band-aid when more outputs are needed with better than DSUB.. sealing. For main connector we only have EC36, SAAB42 and SAAB70. It is already a nightmare to stock and pay for the connectors, let's not add more connectors unless absolutely necessary (like EGT, maybe knock). Since the SAAB70 is just a tiny bit more expensive than the SAAB42 (and more available), I'd even consider a wider design with easier layout.