GroupstandardVW80106

Issue2021-11

Class.No.:8ME20

Descriptors:connector,device-mountedconnector,plugconnection

PlugConnectiononandinElectricalandElectronicComponentsinVehicles

Requirements

Previousissues

VW80106:1994-01,2000-02,2000-08,2008-06,2014-01

Changes

ThefollowingchangeshavebeenmadetoVW80106:2014-01:

a)Completelyrestructured

b)Requirementsandcriteriaforusingsilversurfacesadded

Contents

Page

1

Scope

2

2

Abbreviations

2

3

Definitionconnector

ofdevice-mounted

2

3.1

Description

2

3.2

Device-mountedcontactspin

3

3.3

Connector

shroud

3

3.4

Properties

3

3.4.1

Plugging

andoperatingforces

3

3.4.2

Keying

4

3.4.3

Polarization

4

3.4.4

Number

ofpins

4

3.4.5

Pluggingsafety(scoop-proofing)

4

3.4.6

Clearancecreepage

anddistance

4

4

Requirementsconnectors

fordevice-mounted

4

4.1

Generalrequirements

4

4.2

Device-mountedcontactspin

5

4.2.1

General

5

4.2.2

Materialcontacts

ofdevice-mountedpin

5

4.2.3

Contact

surfaces

5

4.3

Connector

shroud

6

4.3.1

General

6

Alwaysusethelatestversionofthisstandard.

Thiselectronicallygeneratedstandardisauthenticandvalidwithoutsignature.Acommaisusedasthedecimalsign.TheEnglishtranslationisbelievedtobeaccurate.Incaseofdiscrepancies,theGermanversioncontrols.

Page1of8

Allrightsreserved.NopartofthisdocumentmaybeprovidedtothirdpartiesorreproducedwithoutthepriorconsentofoneoftheVolkswagenGroup’sStandardsdepartments.|internal

?VolkswagenAktiengesellschaft

VWNORM-2020-10

Page2

VW80106:2021-11

4.3.2

Socket

housing/shroudguidance

6

4.3.3

Polarizing

andkeying

7

4.3.4

Touch

protectionandinsulation

7

4.3.5

Clearancecreepage

anddistance

7

4.3.6

Pressureequalization

7

5

Applicable

documents

7

1Scope

Thisstandardspecifiestherequirementsforelectricalandelectroniccomponentsthatareneces-sarytoproducetheelectricconnectiontothevehicleelectricalsystembymanualplugging.

2Abbreviations

HFHighfrequency

PCBPrintedcircuitboard

TGTestgroup

3Definitionofdevice-mountedconnector

3.1Description

Electricalandelectroniccomponentsareelectricallyconnectedtothevehicleelectricalsystembypluggingcontactsockethousingsontodevice-mountedconnectorssecuredtothecomponents(

figure1

).

Legend

1Sealingsurface(onlyforsealeddevice-mountedconnectors)

2Connectorshroud

3Snap-fithook

4Componenthousing

Figure1一Device-mountedconnector

Page3VW80106:2021-11

Legend

5Polarization(example)

6Keying(example)

7Pincontact

Figure2–Matingfaceofadevice-mountedconnector(example)

Device-mountedconnectorsaredefinedduringpinhousingdevelopmentanddocumentedwithpertinentdrawingsbythepurchaser.

3.2Device-mountedpincontacts

Contactdimensionsandplatingmustbedefinedaccordingtorequirementsandeconomicfeasibili-ty.Thefollowing,inparticular,areselectioncriteriaforrequiredcontactsurfaces:

–Magnitudeandnecessarystabilityoftheelectricresistance

–Thermalload

–Dynamicload

Thefollowingappliesingeneral:

–Designofdevice-mountedpincontactsaspertabulardrawingTAB.029.601.A

1)

–Holdingforcesofdevice-mountedpincontacts:RequirementsasperTAB.029.601.A

1)

andver-ificationasperVolkswagenstandard

VWTG

75174,31

–Contact-size-dependentlimitsofvolumeresistancesasper

VW?Resistancelim-

75174,

its“section

However,specialapplications(e.g.,high-frequencyconnectors)mustbeconsideredseparately.Requirementsasper

section4.2

3.3Connectorshroud

Sufficientlengthandappropriatepluggingplaygivestheconnectorshroudtherequiredpluggingsafety(

section3.4.5

).Thedevice-mountedconnectoriskeyed(

section3.4.2

)andpolarized

(

section3.4.3

)bytherespectivedesignoftheconnectorshroud.

3.4Properties

3.4.1Pluggingandoperatingforces

Pluggingforceinpluggingdirectionoroperatingforceofthepluggingandpullingaidcorrespondtotheforcesrequiredtomanuallyestablishtheplugconnections.

1)Thedrawingmustbeobtainedviathepurchaser.

Page4

VW80106:2021-11

Theoperatingforceovercomesinparticular:

–Contactpluggingforces

–Compressiveforceoftheshroudsealingsurface(forsealedshrouds)

–Frictionduetorelativemotionofmovablepartsduringthepluggingprocess

–Compressionsurfacestoeliminatetheconnectorplayunderdynamicloads

Requirementsasper

section4.1

3.4.2Keying

Keyingsensuredefinedpairingsofvariousconnectorshroudsandsockethousings.

Mechanicalkeyingmethodsmustbeused.

Requirementsasper

section4.3.3

3.4.3Polarization

Polarizationensuresthatthesockethousingcanbeinsertedintheconnectorshroudonlyinonedefinedorientation.

Thisdesignprevents180°rotationsoftheconnectorandthusreversepolarity.

3.4.4Numberofpins

Thenumberofpinsisthetheoreticallypossiblequantityofthedevice-mountedpincontactsperdevice-mountedconnector.

3.4.5Pluggingsafety(scoop-proofing)

Safetyoftheplugconnection,inparticularofdevice-mountedpincontacts,againstmechanicaldamageduringthepluggingprocess

Requirementsandverificationasper

VWTG

75174,9

3.4.6Clearanceandcreepagedistance

Clearanceisdefinedastheshortestdistanceinairbetweentwoconductiveparts.Creepagedis-tanceisdefinedastheshortestdistancealongthesurfaceofaninsulatingmaterialbetweentwoconductiveparts.

Requirementsasper

section4.3.5

4Requirementsfordevice-mountedconnectors

4.1Generalrequirements

Thedevice-mountedconnectorisalwayslocatedontheelectrical/electroniccomponent.Thecon-tractormustverifythesuitabilityfortheintendedapplicationduringthecomponentdevelopment.Fornewlydevelopedcomponents,thedevice-mountedconnectorsmustbeagreeduponwiththepurchaser.

Page5VW80106:2021-11

Thedevice-mountedconnectormustbenotedindrawingsasfollows:

–Device-mountedconnectorasper?drawingnumber“,withspecificationofnumberofpins(

section3.4.4

)andkeying(

section3.4.2

)

–Device-mountedpincontactspartnumber,asperTAB.029.601.A

2)

,withspecificationofsemi-finishedproduct,hardness,andyieldpoint

Pinhousingandconnectorshroud/connectorhousingmustbesufficientlyrobusttoabsorbtheop-eratingforces.Theforcesmustbeabsorbedbythecontacthousing.

Requirementsandtestingoftheoperatingforcesasper

VW75174

Thedevice-mountedpincontacts(

section3.2

)mustbearrangedinrows(oneormorerows).

PluggingforcesmustnotbeabsorbedbyaPCB(e.g.,solderjoints,press-inzones)viatheelectri-calconnectionofthedevice-mountedconnector;

VW80808-1

mustbeused.

4.2

4.2.1

Device-mountedpincontacts

General

Thedevice-mountedpincontactisdefinedwithrespecttonominalsizeandsurfacebyspecifyingthestandard-partnumberasperTAB.029.601.A

2)

.

Theconnectorsizeisdimensionedasper

VW75212

.

RequirementsasperTAB.029.601.A

2)

,verificationasper

VWTG

75174,31

4.2.2Materialofdevice-mountedpincontacts

Dependingontheusecaseandtheassociatedambienttemperatureandcurrentheating,thenec-essaryconductivityclassL1,L3,L5,orL6asperTAB.029.601.A

2)

mustbeselected.Itmustbe

ensuredandverifiedinthereleaseteststhattheuppertemperaturelimitofthecontactsystemisnotexceeded.Thecriteriaforthisarethederatingresultsofthewholesysteminthespecificappli-cation,basedon

VW75174

.ThewholesystemconsistsofthePCB,thefasteningsolutionforthedevice-mountedpincontactandPCB(soldering,press-fit),andtheconductanceofthedevice-

mountedpincontactaswellasthecontactsocketwithcrimpandconnectingcable,inconsidera-tionofthemutualheatingofdevice-mountedpincontactsinmulti-pinhousings.Thelimitingfactoristheusetemperatureortemperaturelimitofthespecifiedsystemparts.

4.2.3

Contactsurfaces

General

Thedevice-mountedpincontactsareusuallymanufacturedfrompre-platedsemi-finishedprod-ucts.Thespecifiedsurfacecoatingthicknessesmustbeverifiedforthecontactarea.Reducedcoatingthicknessesintheareaoftheformedpincontacttipsarepermissible.

Thecontactsocketandthepincontactsmustpreferablyhavethesamecontactsurfaces.Mixedcontactsusuallyhavethepropertiesofthelessnoblecoatingandmustthereforebeavoided.

Mixedcontactsoftinandgoldarenotpermissible.

Inthecaseofothermixedcontacts,theirsafetymustbeverifiedfortheindividualusecaseasperthecriteriaofelectricalresistancestabilityandelectrochemicalcorrosion.

2)Thedrawingmustbeobtainedviathepurchaser.

Page6

VW80106:2021-11

Surfacesofcontactelementsmustbedesignedasperthefollowingspecifications,unlessdefinedotherwiseinthereleasedrawings.

Tin

Thefollowingcoatingthicknessesmustbeadheredto:

Sn1Galvanictincoating,matteorreflowed:1,0μm–3,0μmoftinover

1,0μm–2,2μmofnickel

Sn2Hot-diptincoating:1,0μm–3,0μmoftin

Ingalvanicallydepositedtincoatings,measurestopreventwhiskerformationarerequired,e.g.,re-floworundercoatingwithnickel.

Silver

Thefollowingcoatingthicknessesmustbeadheredto:

Ag1Fortemperaturelimits<150°Candseverities1and2(

VWTG17

75174,)

1,5μm–5,0μmofsilver,optionallyover1,0μm–3,0μmofnickelor

0,1μm–0,5μmofcopper

Ag2Fortemperaturelimits≥150°Candseverities3and4(

VWTG17

75174,)

3,0μm–6,0μmofsilver,over1,0μm–3,0μmofnickel

Thecoatingadhesionmustbeverifiedusinglong-termtemperatureagingfor10000hatthetemperaturelimit.

Ag+Fortemperaturelimits>170°C

Thecontactsurfaceisspecifiedinthepertinentreleasedrawingforthecontactelement.

Ifsilverisused,itmustbepassivatedfortarnishprotectionandforpluggingforcereduction.

Gold

Thefollowingcoatingthicknessmustbeadheredto:

–0,8μm–2,0μmofhardgold(AuCo)over0,8μm–2,2μmofnickel

4.3Connectorshroud

4.3.1General

Theplugconnectionmusthaveacatchforthesockethousing(vehicleelectricalsystemside).

Itmustbepossibletoconnectadevice-mountedconnectorwiththematchingcontactsockethous-inginapluggingprocess.

Thewalloftheconnectorshroudmustberesistanttodeformationandevenremainsounderthespecifiedmechanicalandthermalloads.

Contactpin(s)andprotectiveshroudmustbedesignedasonemechanicalcomponent.Theedgesandthesealingareamustbefreeofburrs.Sealingsurfacesmustbefreeofpartinglines.

4.3.2Sockethousing/shroudguidance

Designmeasures(e.g.,spacingmaterial,heightofprotectiveshroud)mustpreventthecontactsfrombeingbentduetocontact(evenwithmatingcoupling)(scoop-proofing).

Page7VW80106:2021-11

Theplayintheguidanceoftheplugconnectionmustbesufficientlysmallaccordingtothedynamicrequirements.

4.3.3Polarizingandkeying

Polarizingandkeyingmustbeimplementedmechanicallyusingasuitableshapeoftheoutercon-tour.

Keyingviathearrangementofthepincontactsisnotpermissible.

Aclearvisualassociationofthesockethousingwiththematchingdevice-mountedconnectorisre-quiredfortrouble-freeassemblyprocesses.Thiscanbeachievedinparticularusingcolorcoding,whichmustbeagreeduponwiththepurchaser.

Requirementsandtestsasper

VWTG7

75174,

4.3.4Touchprotectionandinsulation

Forhigh-voltageplugconnections(≥60V),ahigh-voltageinterlock(HVIL)andIPXXB(inunplug-gedcondition)oranenhancedtouchprotectionIPXXB+mustbeused.

Thedesignofthehigh-voltageplugconnectionwithIPXXB+mustbeagreeduponwiththepur-chaser.

Verificationasper

TG51A/TG51B

VW80332,

4.3.5Clearanceandcreepagedistance

Thedesignmustadhereto

DINEN

60664-1.Thisappliestoplugconnectionsthatareoperatedwithavoltage≥60V.

Requirementsandverificationasper

VW80332

4.3.6Pressureequalization

Sealedplugconnectionsencloseairvolumesjustlikeelectroniccontrolunits.