Impact of 42 Volts on Connection Systems

Prepared by : John Yurtin Staff Product Specialist

August 5, 2003
August 5, 2003 1
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Agenda

14/42 V Electrical System

Proposed Voltage Specification Vehicle Power Requirements Shock Hazard Protection Electrical Architectures

What 42 Volt means to Standard Connections

42V Impact on Electrical Contacts
Non-arcing Connectors Sliding contacts in Sensors Arcing Contacts Switches Relays

High Power 42 Volt Connections

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Automotive Electrical System History (cont)

Vehicle Power Requirements

Generator Peak Power of Average Passenger Vehicle (watts) w/Propulsion (HV, FC, EV)
40 kW
15 kW

100,000
Growth Rates: 1920-40 6%/yr 1940-70 2%/yr 1970-90 6%/yr Projected 1990-2030: excl. Proplsn 5%/yr w/Propulsion 8%/yr 1.8 kW

10,000

Watts

excl. Propulsion

1,000

100

1930

1920

1940

1950

1960

1970

1980

1990

2000

2010

2020

Year
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2030

Changing Trend In Automotive Electrical Systems

1 - 2 kW

>90 kW

Conventional Internal Combustion Engine and Electrical System

3 - 5 kW 45 kW - 90 kW

Fuel Cell or All Electric

Starting Motor Alternator Battery Engine Driven Motor/Generator

Internal Combustion Engine High Power Electrical System

5 - 45 kW Internal Combustion Engine

Large Battery or Fuel Cell Hybrid Electric Propulsion Motors Inverter/Converter

Small Internal Combustion

I.C. Engine Dominant

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Battery Dominant or Fuel Cell

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WHY 42 VOLTS?
HIGH POWER ELECTRICAL SYSTEMS HYDRO-CARBON REFORMER SYSTEMS

ELECTRIC VALVE SYSTEMS

ELECTRIC HVAC SYSTEMS

ELECTRIC TURBO SYSTEMS

FUEL CELL SYSTEMS

MOBILE AC POWER SYSTEMS

IMPROVED FUEL ECONOMY

ELECTRIC SUSPENSION SYSTEMS

ELECTRIC STEERING SYSTEMS

ELECTRIC BRAKING SYSTEMS Packard Electric Systems

August 5, 2003

WHY 42 VOLTS?
Proposed New Electrical Loads
Subsystem 36V Starter AC Mobile Power EPS (Electric Power Steering) QuadraSteer Hybrid Cooling Fan Electric A/C Compressor/Ht.Pump PTC Rapid Heat Electric Water Pump (Htr Core) Electric 42V Blower Motor Active Roll Control Brake-by-wire Heated Windshield AVERAGE PEAK POWER (W) POWER (W) 4000 3150 4725 20 900 20 900 200 200 2000 4000 1750 4000 200 200 194 310 24 500 8058 820 2500 22555
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Total:
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Impact of 42V Electrical System

V42 = 3V14 P42 = P14 P42 = I 42 * V42 = I 14 * V14 3 * I42 = I14 I42 = 1/3 I14 By reducing the cable cross-section to 1/3 of original: R14 = 1/3 R42 P14loss = V14I14 P42loss = V42I42 P14loss = (I14R14) I14 P42loss = (I42R42) I42 P14loss = (I14 )2 R14 P42loss = (I42 )2 R42 P42loss = (1/3 I14)2 3R14 P42loss = 1/9 (I14 ) 2* 3R14 P42loss = 1/3 (I14 ) 2* R14 = 1/3 P14loss Therefore, the cable power loss @ 42 V is 1/3 the cable power loss @ 14V.
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14-Volt Electrical System

12 V Lead Acid Battery

14 V Starter/ Generator

12 V Starter

14 V Loads

August 5, 2003

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14/42-Volt Electrical System

36V Battery

42V Liquid Cooled Generator

42V LOADS 14V LOADS

* Includes 42 V Starter

42/14V DC-DC Converter

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14/42-Volt Electrical System

42 V 36 V AGM Lead Acid or 42 V Lithium Polymer Battery 14 V

Dual-Output Generator

14 V Loads

42 V Loads

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High Current and High Voltage

42 Volt systems do not necessarily mean High Current
A 42 Volt system may have small low current connections (e.g. 150 GT). In fact the higher voltage will allow for smaller connectors and wiring for the same current requirements. This is one of the advantages of 42 V systems. 42 Volt systems will provide the support for high current devices and options as well. This is the other advantage of 42V systems. In these cases, high current connectors may be used ( e.g. Power-Pack).

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Proposed Voltage Specification

Voltage Requirements @ 14V
0
9V

11V

14.3V 16V 20V

minimum minimum voltage operating at start voltage

PowerNet Voltage (Alt/Regulator)

max. static overvoltage

max. dynamic overvoltage (load dump)

Voltage Requirements @ 42V

0 21V 30V 42V 52V 58V

minimum minimum voltage operating at start voltage

PowerNet Voltage (Alt/Regulator)

max. static overvoltage

max. dynamic overvoltage (load dump)

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Safety: Shock Hazard Protection

Historically, the SAE industry standard for Low Tension is a nominal system voltage of 50V dc or less in vehicle electrical system. Discussions are underway to revise the upper limit to 60V dc.
IEC 479 defines safe contact limit of 60V dc (1998) The limiting factor for direct voltages is a shock-hazard protection limit of 60V.at low temperatures the charging voltage of the battery (a 48V string) can attain 60V. Determining a safe dc voltage limit is a complex task affected by multiple variables including time, voltage, skin impedance, internal body impedance, environment, current path and an individuals susceptibility to electrical current. Discussions are continuing to establish industry standards on both voltage limits and safe practices.

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42V Impact On Electrical Contacts

NON-ARCING CONTACTS
CONNECTORS SLIDING CONTACTS IN SENSORS

ARCING CONTACTS
SWITCHES RELAYS

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Direction For Non-Arcing Contacts

New Higher Current 42V Connections (100 Amps +)

Battery DC-DC converter Starter/generator

Downsized Harness Connections

Minimal downsizing for initial 14/42V systems Significant downsizing with full 42V system - many terminals will carry under 5 Amps

Change in connector product mix

Smaller conductor size makes IDC and flex circuit connections more attractive

Changes not expected for low voltage sensors

5V bus for sensor and signal circuits expected to remain on 42V vehicles

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Challenges For Separable Connectors

Hot

Plug/Disconnect

Corrosion

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Hot Terminal Disconnect

14 Volt 22 Amps

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14 Volt Corrosion
14 Volt 22 Amps 3 Drops of Salt Water

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Hot Terminal Disconnect

42 Volt 21 Amps

August 5, 2003

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Hot Terminal Disconnect

42Volt 7 Amps

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42Volt Corrosion
42 Volt 31 Amps 3 Drops of Salt Water

August 5, 2003

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Challenges For Separable Connectors Hot-Plugging

Hot

Plugging

14V Fuses, relays, and harness connections are often disconnected while circuit is active small arcs can be produced Hot plugging of 42V circuits can produce arcs with enough power to melt terminals

Arc extinguishing lengths are much longer with 42V

August 5, 2003

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Predicted arc extinction length

80 V 70 UArc 60 50 40 30 20 10 0
THS 2000

42 V, 21 A
1,0 mm

42 V, 7 A

0,8 mm 0,5 mm 0,3 mm

14 V, 21 A

0,1 mm

U
m

I
1 2 3 7 8 A

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42 Volt Hot Plugging

Hot Plugging can degrade the performance of terminals at current levels far below their maximum rated current

25A-rated terminal after 8A hot plug

It will take a combination of new hardware designs and system designs to minimize the effects of 42V hot plugging

August 5, 2003

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42 Volt Corrosion

42V corrosion expected to be 3 times faster than 14V corrosion, based on Faradays Law New corrosion-related degradation mechanisms are possible with 42V systems

Ground + 42V

Corrosion after 2 min. @ 42V in 5% Saltwater

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42V Corrosion

Connection

degradation mechanisms from corrosion

Removed plating and substrate metal leads to high resistance connections Build-up of corrosion products can lead to short circuits Leakage current to sensor circuits - can give false signals
August 5, 2003 26
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42 Volt Corrosion
Some

existing 14V connection systems may need modified for use at 42V
Increased terminal spacing Longer creep path distance between conductors Less use of hygroscopic connector materials Increased usage of environmentally sealed connectors

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42V Effect On Terminal Contact Finishes

No

changes to contact finishes expected

Fritting of degraded contacts usually occurs below 14V. 42V contacts still have the potential to reach unacceptably high resistance levels if a suitable contact finish is not used

For the same Joule heating as existing 14V connectors, 42V connections with 1/3 of the current can have 9 times more resistance

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42V Arcing Contacts - Switches

Most 14V switches not designed to operate at 42V 42V switches may not be practical due to cost and size Low current switches combined with relays expected to be more attractive Optimum switching solutions not yet identified

August 5, 2003

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42V Arcing Contacts - Relays

About 30 relays in todays luxury cars

14V relays not designed to withstand 42V

Product performance requirements for 42V relays not yet defined

Increased size for 42V due to larger contact gaps and arc extinguishing methods Solid State relays not a direct replacement for EM relays polarity sensitive system cost impact Sealing may be more critical
August 5, 2003 30
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Summary
Higher

voltage automotive electrical systems are here and will be on the increase change to 42V will have a significant effect on automotive electrical systems
component designs and system solutions will be required

The

New

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High Power 42 V Connections

Prepared by : John Yurtin Staff Product Specialist

August 5 , 2003
August 5, 2003 32
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1500 Series Terminal

Electrical 150 amps max. continuous (room temp.) 55C max. temperature rise at rated current -40C to 155C operating temperature 0.5 mv/Amp max. voltage drop after conditioning crimp to crimp 0.5 m max. resistance total after conditioning crimp to crimp 35mm cable max. and 13mm cable min. Mechanical Hand engage/disengage(no tool and <80 N) Terminal engage force : 45 N max. Terminal insertion force : 30 N max. Terminal retention force : 150 N min. w/o TPA, 200 N min. w/TPA Connection un-mating force : 160 N min. w/o CPA, 200 N min. w/CPA

August 5, 2003

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2000 Series Terminal

Electrical
200 amps max. continuous (room temp.) 55C max. temperature rise at rated current -40C to 155C operating temperature 0.5 mv/Amp max. voltage drop after conditioning crimp to crimp 0.5 m max. resistance total after conditioning crimp to crimp 50 mm cable max. and 13mm cable min.

Mechanical
Hand engage/disengage(no tool and <80 N) Terminal engage force : 45 N max. Terminal insertion force : 40 N max. Terminal retention force : 200 N min. w/o TPA, 230 N min. w/TPA Connection un-mating force : 450 N min. w/CPA

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1500 and 2000 Series Terminals

2000 Series

10 vane Insert

8 vane Insert

1500 Series

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2000 Series Inline Unsealed Connection

In-line with 1 full insert

August 5, 2003

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2 Way Power-Pack Connection

Current production plans for the 2000 Series connection system

Ford Think 2 2 way sealed right angle connection Start of production 6/02 2004 vehicle program 2 way sealed right angle connection

12 vane insert

2 way connection
August 5, 2003

HC 2000
200A terminal
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2 Way Power-Pack Connection

August 5, 2003

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1500 Series In-Line Connection

Connector seal
Same design approach as 2 way under test

Cable seal
Same design approach as 2 way under test

Female terminal
- Uses 8 vaned, silver plated BeCu insert

14.5mm wide blade

Conforms to design developed for SAE/USCAR 42v standard battery

TPA/Seal Retainer
Same for male and female connector
August 5, 2003

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2000 Series In-Line Connection

TPA Individual Cable Seals

Mechanical Assist

Female Terminal Assembly Cable Seal Male Connector Male In-line Terminal Female Connector

August 5, 2003

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Summary

High Power Connection system Engaged and Disengaged by Hand Sealed and Unsealed Designs Silver Plated Terminals for Higher Temperature Environments Hermaphrodite Terminal Inline and Header Mating Designed to meet SAE/USCAR Class 3 Requirements

August 5, 2003

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42 V Battery

Connection System

Prepared by : John Yurtin Staff Product Specialist

August 5, 2003
August 5, 2003 42
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42V Battery Interface

August 5, 2003

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42V Battery Interface

The system incorporates a 1.80 mm by 14.5 mm plated, high conductivity blade The system is insert molded Side mounted connection (horizontal) Low height profile for side mounted configuration Mating terminal design provides 90 wire dress Recessed terminals prevent shorts between terminals and from positive to ground Narrow shroud opening prevents attachment of standard jumper cables The system is designed to be sealed (sealing code 2) Targeted continuous current is 150 Amps with 55C temp. rise

August 5, 2003

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24V Battery Connection System

Application Sealed, 2 way 42V Battery Connection Features Make last / break first 280 sense terminal to prevent system arcing High current blade is 14.5 mm wide and 80% conductivity material min. High current female terminal is two piece design utilizing hertzian insert Individually sealed connector cavities Mechanical assist to control mate/unmate speed Flame retardant materials TPA & PLR for terminal retention Capabilities Meets SAE J2622 design standard Stage of Development Design concept complete Prototype availability : Header available, female connector asm. available 9/03. Contact Jim Daugherty (01)330-373-3735 fax-4147 (james.daugherty@delphi.com)
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Connection System- Closed Position

High Current Female Terminal with Hertzian Insert

August 5, 2003
Date of status: June 16, 2003

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