CN113859141B - Automobile door harness connector and design method thereof - Google Patents
Automobile door harness connector and design method thereof Download PDFInfo
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- CN113859141B CN113859141B CN202111048801.1A CN202111048801A CN113859141B CN 113859141 B CN113859141 B CN 113859141B CN 202111048801 A CN202111048801 A CN 202111048801A CN 113859141 B CN113859141 B CN 113859141B
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- 238000013461 design Methods 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000009826 distribution Methods 0.000 claims abstract description 9
- 238000012938 design process Methods 0.000 claims abstract description 5
- 238000004519 manufacturing process Methods 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 19
- 238000004458 analytical method Methods 0.000 claims description 15
- 230000003014 reinforcing effect Effects 0.000 claims description 12
- 239000002184 metal Substances 0.000 claims description 10
- 238000011156 evaluation Methods 0.000 claims description 9
- 230000007613 environmental effect Effects 0.000 claims description 8
- 230000017525 heat dissipation Effects 0.000 claims description 8
- 238000003780 insertion Methods 0.000 claims description 8
- 230000037431 insertion Effects 0.000 claims description 8
- 230000002093 peripheral effect Effects 0.000 claims description 8
- 238000007789 sealing Methods 0.000 claims description 7
- 230000003993 interaction Effects 0.000 claims description 6
- 230000002265 prevention Effects 0.000 claims description 4
- 238000012795 verification Methods 0.000 claims description 4
- 238000010146 3D printing Methods 0.000 claims description 3
- 238000002788 crimping Methods 0.000 claims description 3
- 239000007769 metal material Substances 0.000 claims description 3
- 230000008569 process Effects 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 2
- 238000004364 calculation method Methods 0.000 claims 1
- 230000009286 beneficial effect Effects 0.000 abstract description 3
- 239000003365 glass fiber Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000010009 beating Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
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- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
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- 238000004513 sizing Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/0207—Wire harnesses
- B60R16/0215—Protecting, fastening and routing means therefor
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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Abstract
The invention relates to automobile line connection, in particular to an automobile door harness connector and a design method thereof. The invention provides a new design method aiming at the connector, optimizes the steps in the design process, further definitely defines the design points, is beneficial to improving the design efficiency and meets the requirements of production and clients as soon as possible. The automobile door harness connector is designed by adopting the method and comprises a male end body and a female end body; the male end body is provided with a female end terminal hole area and a movable block, the movable block is provided with a plurality of adjustable female end terminal holes, and the male end body is provided with a fixed structure below the plane of the male end body connector; the female terminal body is provided with a male terminal hole area matched with the female terminal hole area and the movable block. The automobile door harness connector has the advantages of multiple hole sites, high strength, easy assembly and more reasonable distribution.
Description
Technical Field
The invention relates to automobile line connection, in particular to an automobile door harness connector and a design method thereof.
Background
At present, the hole site of the automobile door butt-joint connector cannot meet the requirements of design application, the situation that the connector is likely to break during the clamping and assembly of the connector or the function of an electric appliance is unreliable is generally realized by adopting a cantilever structure, and many manufacturers develop door connectors to adopt a copying method and inherit the defect of a copy at the same time.
CN112703643a discloses a modular door connector comprising: a female connector and a male connector; the female connector comprises a plurality of female standard sub-cavities, wherein the space sizes of the plurality of female standard sub-cavities are equal, a fixed baffle is arranged between two adjacent female standard sub-cavities in the plurality of female standard sub-cavities, and the plurality of female standard sub-cavities are used for installing female standard functional modules; the male connector comprises a plurality of male standard sub-cavities, the space size of each male standard sub-cavity is equal to that of each female standard sub-cavity, a fixed baffle is arranged between two adjacent male standard sub-cavities in the male standard sub-cavities, and the male standard sub-cavities are used for installing male standard functional modules. A method of installing a modular door connector is also provided that includes selecting a modular door connector and a standard functional module of the modular door connector based on a vehicle configuration, and then performing a modular mating and installation.
Patent CN 208368877U discloses a butt-joint connector for automobile door, including binding post unit and be used for with the binding post unit is fixed in the connector fixed unit of automobile body, the binding post unit includes public end body and butt-joint female end on public end body, and the key lies in, still be equipped with connector sub-terminal and the cassette of fixed this connector sub-terminal on the public end body. The automobile door butt-joint connector is additionally provided with the connector sub-terminals and the clamping seat for fixing the connector sub-terminals, so that the butt-joint connector is conveniently expanded and increased, the door butt-joint connector does not need to be redesigned, and the development cost is reduced while peripheral parts are not influenced.
This is also an attempt to solve the problem.
Disclosure of Invention
The invention aims to solve the technical problems that the hole sites of the butt-joint connectors of the automobile door at present cannot meet the requirements of design and application, and the situation that the connectors are likely to break during clamping and assembly or the functions of electric appliances are unreliable is generally realized by adopting a cantilever structure.
The technical scheme of the invention is that the automobile door harness connector comprises a male end body and a female end body; the male end body is provided with a female end terminal hole area and a movable block, the movable block is provided with a plurality of adjustable female end terminal holes, and the male end body is provided with a fixed structure below the plane of the male end body connector; the female terminal body is provided with a male terminal hole area matched with the female terminal hole area and the movable block.
Specifically, female end terminal hole district is equipped with 2 rows of female end small terminal holes, is equipped with 3 rows of female end signal terminal holes in the middle of the 2 rows of female end small terminal holes.
Wherein, the movable block is provided with 1 to 3 female end FAKRA (coaxial connector) holes and 3 to 5 female end big end holes.
Specifically, the female end body is further provided with a lever, and the peripheral surface of the male end body is provided with a guide groove matched with the lever above the connector plane.
And the female end body is also provided with a limiting hole for limiting the lever.
Further, the male end body is further provided with a buckle above the plane of the male end body connector.
Preferably, the buckle comprises a left buckle and a right buckle.
Preferably, cantilever reinforcing rib structures are arranged on the left buckle and the right buckle.
Further, the fixing structure comprises a primary locking structure, a secondary locking (TPA) structure, a TPA fixing structure, a needle tilting prevention structure (PLR), a PLR fixing structure and a sealing structure.
Specifically, the door butt connector is made of PA66 or/and PBT. PA66 is preferred in high temperature environments and PBT is preferred in high humidity environments. The connector auxiliary material duty ratio can be adjusted according to the subsequent requirements.
Preferably, GF20 or GF30 may be added to the material, which may increase strength.
The invention further provides a design method of the automobile door harness connector, which comprises the following steps:
s1, analyzing the functional requirements of the electrical appliance: the basic functions and the extended functions which the connector needs to contain are clarified, wherein the basic functions comprise a door and window motor, a door lock motor, a handle, atmosphere and the like, a rearview mirror, a panoramic camera or/and a high-low sound speaker; the expansion function comprises a face recognition camera, an automatic driving camera or/and a rearview mirror camera, and the initially required terminal types are obtained through function analysis;
s2, standard matching design: aiming at the size, the function, the hole site number, the terminal structure, the material, the fixing structure, the strength of the fixing structure and the basic mechanical and basic electrical properties of the connector, a reference value can be obtained through standard comparison, the reference value is used as an evaluation reference in the subsequent design process, and the equivalent design is not lower than the reference value;
s3, designing functional requirements: the corresponding number and specification of functional hole sites are obtained by combining a function definition list, corresponding current, wire diameters, a fixed structure mode, an assembly mode and environmental requirements, the material requirements to be used are also considered, and the expandability of the functions required by the connector is also considered;
s4, size design: the method comprises the steps of determining the sizes of a door butt connector boundary, a connector periphery and a connector inner frame; the method also comprises the steps of determining the assembly space size of the male-female connector and the female-female connector, and the space size and the assembly mode of the matched assembly of the male-female connector and the metal plate;
s5, hole site design: the method comprises terminal selection, hole site structure design and terminal distribution;
s6, connector temperature field analysis is carried out through CAE analysis: rated current is conducted at the ambient temperature of each terminal, the temperature rise and the heat dissipation condition of the terminals are analyzed, and meanwhile, the heat dissipation capacity of the sheath can be improved by changing the material structure;
s7, analyzing a matched size link of the male end and the female end: through the position size of the sheath of the male terminal, the position size of the female terminal in the sheath, the position size of the male and female terminals matched with each other and the matched size chain of the connector, the normal insertion of the female terminal in the tolerance range of the male terminal is ensured, the centering performance of a hole site size link is ensured, and meanwhile, the consistency of a designed size link can be verified through the insertion force of the terminal;
s8, structural design of peripheral buckles: the matching of the buckle and the metal plate, the win-win amount and the structure (simple support beam and cantilever beam) can be optimized according to the standard reference value;
s9, performing sheath stress analysis: analyzing various stresses in the assembly process, and obtaining a functional relation Y (intensity) =f (reinforcing rib parameter) +f (thickness parameter) +f (length parameter) +f (other parameters) +f (interaction parameter) of the thickness, the length, the other parameters and the interaction relation of each parameter of the cantilever reinforcing rib structures of the left buckle and the right buckle through CAE analysis;
s10, sample manufacturing and verification: evaluating the size and the structural appearance through 3D printing or a soft module, providing an evaluation latitude, then evaluating, and verifying basic performance, electrical performance and environmental resistance which meet design requirements; the evaluation dimensions include size, appearance, assemblability, strength, cost, volume, and distribution.
Specifically, in step S1, the initially required terminal types are a signal terminal, a small current terminal, a large current terminal, and a high frequency signal terminal.
Further, in step S3, the extended function is made into a movable block, and the composition inside the movable block is adjustable and can be adjusted according to the expandability of the function.
Specifically, in step S4, the dimensions include a space dimension, a sheet metal material, a thickness, and a gap.
Preferably, in step S4, the average value of the gap at each side of the metal plate of the connector is between 0.2mm and 0.4 mm.
Specifically, in step S4, the size of the inner frame of the connector calculates the accumulated area according to the number of the terminal hole spaces of each type; the computing company is as follows: ts=ts1+ts2+ts3+tsx; ts1= (n 1S 1), ts2= (n 2S 2) ts3= (n 3S 3) … … tsx=nx S x; TS: the total area of the terminal holes; TS1: total area of class 1 terminal holes; total area … … TSx of TS2:2 class terminal holes: total area of x class terminal holes; n is the number of similar terminals; the area of the inner frame of the connector is larger than 1.5 times of the total area of TS terminal holes; the size can be adjusted according to the subsequent hole site arrangement, the temperature field and the structural strength simulation condition.
Specifically, in step S4, the step assembly mode may be a clamping or lever pushing and pulling.
In step S5, the terminal is selected to be the minimum size meeting the requirement according to the function list, the size of the terminal, the terminal crimping section parameter, the FAKRA number, the large current number and the small current number.
Specifically, in step S5, the hole site structure is designed to design the fixing structure of the terminal according to the minimum hole site size, and the fixing structure includes a primary locking structure, a secondary locking TPA structure, a TPA fixing structure, a needle-skew preventing structure PLR, a PLR fixing structure, and a sealing structure.
Specifically, in step S9, the sheath stress analysis includes the assembly force of the sheath, the assembly force of the terminal, the assembly force of the lever, the locking force of the lever limiting structure, and the force of the buckle loading into the metal plate.
In step S5, the terminal distribution principle is that the long-time power terminal and the short-time power terminal are separated, and the high-current terminal is placed at two ends or at the outermost side, so as to facilitate heat dissipation.
At present, the main stream materials of PA66 and PBT are preferably PA66 in a high-temperature environment and PBT in a high-humidity environment. The connector auxiliary material duty ratio can be adjusted according to the subsequent requirements. For example: insufficient PA66+ GF20 strength may increase the glass fiber content to increase the strength PA66+ GF30.
The invention has the beneficial effects that: the invention provides a new design method aiming at the connector, optimizes the steps in the design process, further definitely defines the design points, is beneficial to improving the design efficiency and meets the requirements of production and clients as soon as possible. The connector which has the advantages of multiple hole sites, high strength, easy assembly and more reasonable distribution is designed and obtained by adopting the method; stable in structure, the simple operation just is favorable to expanding the function.
Drawings
Rear mechanism of male connector of fig. 1
Side structure of male connector of fig. 2
Fig. 3 female end connector rear structure
Fig. 4 right end clip of male connector
Fig. 5 internal structure of male connector
Method for designing butt connector of door of fig. 6
The marks in the figure: the connector comprises a 1-connector periphery, a 2-movable block, a 3-female FAKRA hole, a 4-female big-end hole, a 5-female small-end hole, a 6-female signal terminal hole, a 7-connector inner frame, an 8-guide groove, a 9-right buckle, a 10-connector plane, a fixing structure of 11-TPA, a fixing structure of 12-PLR, a 13-left buckle, a 14-lever, a 15-male small-end hole, a 16-male signal terminal hole, a 17-limit hole, a 18-male big-end hole, a 19-male FAKRA hole, a 20-FAKRA connector, a 21-buckle, a 22-connector boundary, a 23-female terminal hole region, a 24-male terminal hole region, a 25-pin-distortion preventing structure, a 26-secondary locking structure, a 27-sealing structure, a 28-primary locking structure and a 29-buckle cantilever reinforcing rib structure.
Detailed Description
Example design of the door abutment of the invention
The specific flow is shown in fig. 1, and comprises the following steps:
and (3) analyzing the functional requirements of the electrical appliance: the functions that the connector needs to contain, the basic functions, are clarified: door and window motor, door lock motor, handle, atmosphere etc. extension functions such as rear-view mirror, panoramic camera, high bass speaker: face recognition camera, automatic driving camera, rearview mirror camera and the like, and a required signal terminal, a small current terminal, a large current terminal and 4 terminals of a high-frequency signal terminal can be preliminarily obtained through functional analysis
And (3) target matching design: the size, the function, the hole site number, the terminal structure, the material, the fixed structure, the strength of the fixed structure, the basic mechanics and the basic electric performance of the connector can obtain a reference value through the standard comparison, the reference value is used as an evaluation reference in the subsequent design process, and the equivalent design is not lower than the reference value.
Functional requirement design: the corresponding number of functional hole sites and specifications are obtained by combining a function definition list, corresponding current, wire diameters, a fixed structure mode, an assembly mode and environmental requirements (vibration, temperature and water resistance requirements), and the required material requirements are met.
The dimensions of the door butt connector boundary 22, namely the space dimension, sheet metal material, thickness and tolerance of the door connector, ensure the fitting of the connector plane 10 and select different materials according to different requirements according to the use position, and the current main stream materials PA66 and PBT are preferably PA66 in a high-temperature environment and PBT in a high-humidity environment. The connector auxiliary material duty ratio can be adjusted according to the subsequent requirements. For example: insufficient PA66+ GF20 strength may increase the glass fiber content to increase the strength PA66+ GF30.
And (3) determining an assembly mode: the direct clamping connection, or the lever 14 (shown in fig. 3), the knob type, the maximum assembly space and the minimum assembly space are analyzed, whether the lever is matched with the guide groove 8 (shown in fig. 2) when the lever structure is arranged is determined to be inserted in a correct position when the operation space is checked later.
Sizing the connector periphery 1: the peripheral dimension design of the connector (the maximum gap average value of each side of the sheet metal is between 0.2mm and 0.4 mm) ensures the assembly smoothness.
Connector inner frame 7 dimensions: calculating an accumulated area ts=ts1+ts2+ts3+tsx according to the number of each type of terminal hole spaces; ts1= (n 1S 1), ts2= (n 2S 2) ts3= (n 3S 3) … … tsx=nx S x; TS: the total area of the terminal holes; TS1: total area of class 1 terminal holes; total area … … TSx of TS2:2 class terminal holes: total area of x class terminal holes; n is the number of terminals of the same type. The area of the inner frame 7 of the connector is required to be larger than 1.5 times of the total area of TS terminal holes, and the optimal size is adjusted according to the subsequent hole site arrangement and the temperature field and structural strength simulation conditions.
Terminal selection design: and calculating the minimum size meeting the requirement according to the function list, the size of the terminal and the terminal crimping section parameters, namely the FAKRA number, the large current number and the small current number.
Hole site design: the fixing structure of the terminal designed according to the minimum hole site size includes a primary locking structure 28, a secondary locking (TPA) structure 26, a fixing structure 11 of TPA, a pin-skew prevention structure (PLR) 25, a fixing structure 12 of PLR, and a sealing structure 27.
Distribution of terminals: the principle is that the long-time power utilization terminal and the short-time power utilization terminal are separated, and the high-current terminal is arranged at two ends or at the outermost side, so that heat dissipation is facilitated.
The temperature field of the connector is simulated and analyzed through CAE, rated current is conducted on the environment temperature of each terminal, the temperature rise and the heat dissipation condition of the terminals are analyzed, and meanwhile, the heat dissipation capacity of the sheath can be improved by changing the material structure.
And (3) carrying out link analysis on the matched size of the male end and the female end: the normal insertion of the female terminal within the tolerance range of the male terminal (as shown in fig. 1) is ensured by the position dimension of the sheath of the male terminal, the position dimension of the female terminal in the sheath, the position dimension of the male and female terminals already mated, and the mating dimension chain of the connector. Male end FAKRA hole 19, female end FAKRA hole 3, male end big terminal hole 18, male end little terminal hole 15, male end signal terminal hole 16, female end big terminal hole 4, female end little terminal hole 5, female end signal terminal hole 6, ensure the centering performance of hole site size link, accessible terminal insertion force simultaneously verifies the uniformity of design size link.
The structure of the peripheral buckle 21: the cooperation of left buckle 13, right buckle 9 and panel beating, win-win amount, structure (simple beam, cantilever beam) can be based on the optimization to mark reference value.
The sheath stress analysis, the sheath assembling force, the terminal assembling force, the lever 14 assembling force, the lever limiting hole 17 locking force, the buckle loading sheet metal force (the buckle optimal design, strength and root stress), the various stresses in the assembling process are analyzed, the cantilever reinforcing rib structure 29, thickness and length functional relation of the left buckle and the right buckle can be obtained through CAE analysis, and the interaction relation of the reinforcing rib parameter, the buckle degree parameter, the buckle length parameter, other parameters and each parameter can be obtained through the functional relation of Y (strength) =f (reinforcing rib parameter) +f (thickness parameter) +f (length parameter) +f (interaction parameter).
Sample preparation, namely evaluating the size and the structural appearance through 3D printing or a soft module, providing an evaluation latitude, then evaluating, and verifying basic performance, electrical performance and environmental resistance, which meet design requirements; the evaluation dimensions include size, appearance, assemblability, strength, cost, volume, and distribution.
And (3) test verification: basic performance, electrical performance, environmental resistance, and overall performance. The basic performance includes appearance/size, terminal bending strength, terminal retention, board end pin retention, connector binding force, connector separation force, unlocking force, buckle insertion force/release force, buckle fixing structure mechanism strength, tightness and connector error proofing structure; the electrical performance comprises contact resistance, microcurrent contact resistance, electrifying temperature rise, insulation resistance, high voltage resistance and leakage current; the environmental resistance includes repeated insertion cycle, vibration/mechanical impact, heat resistance, cold and hot impact, temperature/humidity cycle and water resistance.
As shown in fig. 1 to 3, the designed automobile door butt joint part comprises a male end body and a female end body; the male end body is provided with a female end terminal hole area 23 and a movable block 2, the movable block 2 is provided with a plurality of adjustable female end terminal holes, and the male end body is provided with a fixed structure below the male end body connector plane 10; the female terminal body is provided with a male terminal hole area 24 matched with the female terminal hole area and the movable block. The female terminal hole area is provided with 2 rows of female small terminal holes 5, and 3 rows of female signal terminal holes 6 are arranged in the middle of the 2 rows of female small terminal holes. The movable block 2 is provided with 1 to 3 female end FAKRA holes 3 and 3 to 5 female end big end holes 4.
As a preferred embodiment, the female end body is further provided with a lever 14, and the peripheral surface of the male end body is provided with a guide groove 8 above the connector plane 10, which is matched with the lever. And the female end body is also provided with a limiting hole 17 for limiting the lever. The male body is also provided with a buckle above the male body connector plane 10. The clasp comprises a left clasp 13 and a right clasp 9. Preferably, the left buckle 13 and the right buckle 9 are further provided with cantilever reinforcing rib structures 29. Preferably, the securing structure comprises a primary locking structure 28, a secondary locking TPA structure 26, a TPA securing structure 11, a needle-skew prevention structure PLR 25, a securing structure 12 for PLR, and a sealing structure 27. In a preferred embodiment, the door butt connector is made of PA66 or/and PBT. PA66 is preferred in high temperature environments and PBT is preferred in high humidity environments. The connector auxiliary material duty ratio can be adjusted according to the subsequent requirements. Preferably, GF20 or GF30 may be added to the material, which may increase strength.
Claims (8)
1. The design method of the automobile door harness connector is characterized by comprising a male end body and a female end body, wherein the male end body is provided with a female end terminal hole area (23) and a movable block (2), the movable block (2) is provided with a plurality of adjustable female end terminal holes, and the male end body is provided with a fixed structure below a plane (10) of the male end body connector; the female end body is provided with a male end terminal hole area (24) matched with the female end terminal hole area and the movable block;
the female end body is also provided with a lever (14), and the peripheral surface of the male end body is provided with a guide groove (8) matched with the lever above the connector plane (10);
the female end body is also provided with a limiting hole (17) for limiting the lever;
the male end body is also provided with a buckle above the male end body connector plane (10);
the buckle comprises a left buckle (13) and a right buckle (9);
the left buckle (13) and the right buckle (9) are also provided with cantilever reinforcing rib structures (29);
the fixing structure comprises a primary locking structure (28), a secondary locking TPA structure (26), a TPA fixing structure (11), a needle tilting prevention structure PLR (25), a PLR fixing structure (12) and a sealing structure (27);
the design method of the automobile door harness connector comprises the following steps:
s1, analyzing the functional requirements of the electrical appliance: determining basic functions and extended functions which need to be contained in the connector, wherein the basic functions comprise a door and window motor, a door lock motor, a handle, an atmosphere lamp, a rearview mirror, a panoramic camera or/and a high-low sound speaker; the expansion function comprises a face recognition camera, an automatic driving camera or/and a rearview mirror camera, and the initially required terminal types are obtained through function analysis;
s2, standard matching design: the method comprises the steps of obtaining a reference value by aiming at the size, the function, the hole site number, the terminal structure, the material, the fixing structure, the strength of the fixing structure and the basic mechanical and basic electrical properties of the connector through benchmarking, wherein the reference value is used as an evaluation reference in the subsequent design process, and the equivalent design is not lower than the reference value;
s3, designing functional requirements: the corresponding number and specification of functional hole sites are obtained by combining a function definition list, corresponding current, wire diameters, a fixed structure mode, an assembly mode and environmental requirements, the material requirements to be used are also considered, and the expandability of the functions required by the connector is also considered; the expansion function is made into a movable block, the composition in the movable block is adjustable, and the movable block is adjusted according to the expansibility of the function;
s4, size design: the method comprises the steps of determining the sizes of a door butt connector boundary, a connector periphery and a connector inner frame; the assembly structure also comprises the assembly space size of the male-female connector and the female-female connector, the space size of the matched assembly of the male-female connector and the metal plate and the assembly mode; the size of the inner frame of the connector is calculated according to the space and the number of each type of terminal hole, and the accumulated area is calculated; the calculation formula is as follows: ts=ts1+ts2+ts3+tsx; t1=n1×s1, t2=n2×s2, t3=n3×s3 … … tsx=nx×sx; TS: the total area of the terminal holes; TS1: total area of class 1 terminal holes; total area … … TSx of TS2:2 class terminal holes: total area of x class terminal holes; n is the number of similar terminals; the area of the inner frame of the connector is larger than 1.5 times of the total area of TS terminal holes; the size is adjusted according to the subsequent hole site arrangement, the temperature field and the structural strength simulation condition;
s5, hole site design: the method comprises terminal selection, hole site structure design and terminal distribution;
s6, connector temperature field analysis is carried out through CAE analysis: rated current is conducted at the ambient temperature of each terminal, the temperature rise and the heat dissipation condition of the terminals are analyzed, and meanwhile, the heat dissipation capacity of the sheath is improved by changing the material structure;
s7, analyzing a matched size link of the male end and the female end: through the position size of the sheath of the male terminal, the position size of the female terminal in the sheath, the position size of the male-female terminal in the mutual matching, and the matching size chain of the connector, the normal insertion of the female terminal in the tolerance range of the male terminal is ensured, the centering performance of a hole site size link is ensured, and meanwhile, the consistency of a designed size link is verified through the insertion force of the terminal;
s8, structural design of peripheral buckles: the matching, interference and structure of the buckle and the metal plate are optimized according to the standard reference value, and the structure comprises a simply supported beam and a cantilever beam;
s9, performing sheath stress analysis: analyzing various stresses in the assembly process, obtaining a functional relation Y (intensity) =f (reinforcing rib parameter) +f (thickness parameter) +f (length parameter) +f (other parameters) +f (interaction parameter) of the thickness, length and intensity of the cantilever reinforcing rib structure (29) of the left buckle and the right buckle through CAE analysis, and obtaining interaction relations of the reinforcing rib parameter, the buckle thickness parameter, the buckle length parameter, the other parameters and each parameter through the functional relation;
s10, sample manufacturing and verification: evaluating the size and the structural appearance through 3D printing or a soft module, providing an evaluation dimension, and then evaluating to meet the verification of basic performance, electrical performance and environmental resistance of the design requirements; the evaluation dimensions include size, appearance, assemblability, strength, cost, volume, and distribution.
2. The method for designing an automotive door harness connector according to claim 1, wherein the female terminal hole area is provided with 2 rows of female terminal holes (5), and 3 rows of female terminal signal terminal holes (6) are provided in the middle of the 2 rows of female terminal holes.
3. The method for designing an automotive door harness connector according to claim 1 or 2, characterized in that the movable block (2) is provided with 1 to 3 female-end FAKRA holes (3) and 3 to 5 female-end large-end holes (4).
4. The method for designing an automotive door harness connector according to claim 1, wherein the automotive door harness connector is made of PA66 or/and PBT;
the material can also be added with GF20 or GF30.
5. The method of designing an automotive door harness connector according to claim 1, wherein in step S1, the preliminarily required terminal types are a signal terminal, a low-current terminal, a high-current terminal, and a high-frequency signal terminal.
6. The method of designing an automotive door harness connector according to claim 1, wherein in step S4, the dimensions include a space dimension, a sheet metal material, a gap, and a tolerance;
the average value of the gap at each side of the metal plate of the connector is between 0.2mm and 0.4 mm;
the assembly mode of the steps adopts clamping or lever pushing and pulling.
7. The method for designing an automotive door harness connector according to claim 1, wherein in step S5, terminal selection is to calculate minimum dimensions meeting requirements according to a function list, dimensions of terminals, terminal crimping section parameters, FAKRA number, large current number, and small current number;
in step S5, the hole site structural design, according to the minimum hole site size, designs the structural design fixing structure of the terminal, including a primary locking structure (28), a secondary locking TPA structure (26), a TPA fixing structure (11), a needle-skew preventing structure (25), a PLR fixing structure (12) and a sealing structure (27).
8. The method of designing an automotive door harness connector according to claim 1, wherein in step S9, the jacket stress analysis is performed including the fitting force of the jacket, the fitting force of the terminal, the fitting force of the lever, the locking force of the lever stopper structure, and the force of the snap fitting into the metal plate.
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