Correlation of Assembly Speed to Electrical Connector Mating Force

Paper #:
  • 2017-01-1642

Published:
  • 2017-03-28
Author(s):
Affiliated:
Abstract:
Each of the 300 (or more) electrical connectors in a vehicle is assembled by hand. Since there is a risk of a repetitive stress injury resulting from any of these connectors, significant work has been done to determine what test needs to be performed to determine whether a connector is ergonomically safe for the person performing the assembly operation. This prior work has determined the maximum force that can be safely applied to mate a connector... what is not known is whether the mate force of a connector is influenced by the assembly speed on connector. This has significant practical interest since the preferred lab-based test speed is 50mm/min., which is ten times slower than the typical assembly speed in a vehicle assembly plant. There have been some calls for a change in the current testing method to use speeds that match typical assembly speeds. But implementing high-speed testing is difficult for several technical reasons so there is a need to understand whether test speed actually matters. Research done recently has evaluated how mate force changes with assembly speed and gives practical recommendations on how testing methods should be constructed to assure they are representative of the operations done in the plants. Analysis is given for several different designs of both sealed and unsealed connectors and good correlation has been shown. Therefore, the test protocol needed can be agreed on for optimal and assembly-safe designs. Results showed that high speed testing is not needed and if implemented, it would lessen the accuracy of the testing since the standard deviation of the measurements increases significantly at higher speeds.
Also in:
  • SAE International Journal of Engines - V126-3EJ
  • SAE International Journal of Engines - V126-3
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