UNITED STATES COUNCIL FOR AUTOMOTIVE RESEARCH LLC
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Press Release: USCAR'S EWCAP HELPS TO COMMONIZE 1.2 MM TERMINAL SYSTEMS GLOBALLY
SOUTHFIELD, Mich., Jan. 4, 2011 – Anyone who travels abroad quickly learns that electrical ‘plug-in’ configurations can vary greatly from one country to the next. Similarly, it would come as no surprise to learn that, until recently, the automotive 1.2 mm electrical terminal system commonly used in European vehicles was different from the 0.64 and 1.5 mm systems in use by U.S. automakers in North America. Now, however, thanks in large part to the work of USCAR’s Electrical Wiring Components Application Partnership (EWCAP), a collaboration of Chrysler Group LLC, Ford Motor Company and General Motors Company, both continents have ‘connected’ and are adopting the 1.2 mm system as a global standard. Originally, the 1.2 mm terminal system was not considered for use by U.S. automakers because adding a third system when two others were in place appeared to add complexity without benefit. However, as global platforms began to take hold in the 1990s, U.S. manufacturers began to pursue options to commonize electrical components with their European counterparts. With EWCAP’s help, all three U.S. Automakers recognized an advantage to adopting the 1.2 mm terminal system for global use in order to achieve improved economies of scale. “There are differences between European and North American assembly and performance requirements, dimensional tolerances and design systems,” said Jim Roberts, EWCAP technical specialist, who worked with USCAR/EWCAP colleague, Harry Zaverzence, and the EWCAP team to help the automakers and component suppliers understand and resolve the differences. “We benchmarked 1.2 mm terminal and connector designs and created drawings that could be used to produce components that meet North American requirements and function with other global components,” Roberts said. In addition, when one USCAR OEM identified the need for additional index options that would increase the application possibilities for the parts, EWCAP created index features, without affecting the original design, to keep the system truly global. “The USCAR/EWCAP drawings have been updated and we are in the process of providing the additional index design information to the European community through the international and German standards organizations, ISO and VDA,” Roberts said. To date, EWCAP has added 14 (seven long- and seven short-shroud) footprint drawings to its component catalog and the 1.2 mm terminal has been added to its terminal drawings. In addition, parts are being incorporated into designs for sealed applications by Chrysler, Ford and General Motors. Although the USCAR/EWCAP activity has been focused on a sealed 1.2 mm system packaged on 4 mm centerlines, typically used as device connectors in the engine compartment and underbody, EWCAP expects to expand the 1.2 mm family as device and wire harness designs dictate, keeping its European counterparts informed of its activities. EWCAP’s work on globalization of the 1.2 mm system was recognized last year with a USCAR Team Award, which was presented to the group at USCAR’s annual Recognition Event. About USCAR Founded in 1992, USCAR is the collaborative automotive technology organization for Chrysler Group LLC, Ford Motor Company and General Motors Company. The goal of USCAR is to further strengthen the technology base of the domestic auto industry through cooperative research and development. For more information, visit USCAR’s Web site at www.uscar.org 1/4/11 ###
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