MD GROUP HANDLING INSTRUCTION

MD GROUPHANDLING INSTRUCTION

For assembled Multi-Core-Cables for the data transmission in the automotive sector

Contents

1. List of Abbreviations 2 2. Range of Application 2 3. General Requirements 2 3.1 Interface 3 3.2 Order and cleanliness 3 3.3 Delivery and storage 3 3.4 Simplifiedinstallationbyheating 3 3.5 Handling 3 4. MechanicalandThermalLoads 4 4.1 Tensileload 4 4.2 Bending load 4 4.2.1 Staticinstallationinthevehicle 4 4.2.2 Dynamicinstallationinthevehicle 4 4.2.3 Definitionofthebendingradius 5 4.2.4 Use of MQS stranded wires 5 4.3 Load due to torsion 5 4.4 Combined load (bending-torsional load) 6 4.5 Thermalload 6 5. Add-onPartsandTaping 6 5.1 Add-on parts 6 5.2 TapingofMulti-Core-Cables 6 5.3 Torsion-freeprocessinginthecaseofmultiplesystems 7 5.4 Attachingfixingelements(e.g.cableties,holders) 7 5.5 Spliceconnections 7 6. Mating of Assembled Cables 8 6.1 Matingprocessoftheassembledcable 8 6.2 Disconnectingtheconnectors/cable 9 6.3 Matingcycles 9 7. PositioningoftheCableExit 9 8. Tests 10 8.1 Errortest 10 8.2 Not allowed electrical tests 11 8.2.1 Use of not allowed testing equipment 11 9. ProtectionNote 1210. AdditionalNotes 12

Handling Instruction Multi-Core-Cables PUBLIC Page 1C3065510200271

1. List of AbbreviationsMCC Multi-Core-CableHSD HighSpeed DataAssembled cables Cables consisting of goods on reels and connector(s) Coding Unambiguousdistinctionofthecoding housingsintermsofgeometryandcolorInterface specification Definitionofanelectricalsupplyterminalon thebasisofthegeometryandthe mechanicalandelectricalpropertiesOEM Original Equipment ManufacturerDMU / PMU Digital Mock Up/PhysicalMock UpCustomer Requesterororderingpartyoftheassem- bledcables(OEM,Tier1,othercustomers)

2. Range of ApplicationThis instruction describes the intended installation and the intended handling ofassembledMulti-Core-Cables of theMDGroup. The data and values indicated inthis handling instruction refer to the technical specifications of the individualcomponents and to the experiences in the automotive field of application. The(mechanical,electrical, thermalandenvironmental) requirementsarebindingfortheintendeduseandforthehandlingoftheproducts.

3. General RequirementsWhenhandlingassembledcablesand their components, allmechanical influencesthat are not causedby thematingprocess itself have to be avoided. It has to bealwaysconsideredthatstrongdeformations(e.g.bytheloadofheavyobjectsorbystepping on the cables and their add-on parts) are not allowed and have to beavoidedduringhandling. Ingeneral, tensile loadsarenotallowed. It isnotallowedto throw assembled cables (e.g. into the vehicle body). The placement of theassembled cables in the vehicle has to be adapted by the customer in the KSKdesign according to the installation situation in the vehicle (e.g. static/dynamic,engine compartment/passenger compartment, tensile loads, ...). Continuous loads(e.g. tensile loads) during operation are not covered by the manufacturerspecifications (see respective data sheets) and have to be coordinated with thecomponentmanufacturer ifnecessary (seechapter4).Onlysubstances/media (e.g.lubricants) that are released according to the manufacturer’s standard and OEMspecification and that are qualified in combination with the assembled cables areallowedtobeusedinordertofacilitatetheprocessing.Inordertominimizetheloadson theassembledcables,anoptimumdesignand installationof thecableharness(DMU/PMU)istobestrivedfor.Inordertoensurethisrequirement,thewidevarietyofconnectors(e.g.cableexitdirections)istobeusedandlowloadsareexplicitlytobe considered. Additionally, the MD document “Application Instruction” (C30301)hastobeconsidered.


3.1 Interface

OnlycomponentsthatarequalifiedandreleasedaccordingtotherespectiveOEMinterfacespecificationareallowedtobeused.Thematingcompatibilityhastobeensuredbytheindividualmanufacturers.

3.2 Order and cleanliness

When handling assembled Multi-Core-Cables, any type of dirt has to beavoided and order and cleanliness are required at any time.

3.3 Delivery and storage

Thedelivery, receiptandstorageofassembledcables,seealsotheStorageAdviceMDELEKTRONIK–finishedproducts (C11569),mustnot takeplaceoutdoorswithoutanyprotection.Undersuchconditions,theprotectionofthematingareasagainstdirtorhumidityisnotensured.Additionally,UVirradiationand increased temperature can result in an unintentional aging.

3.4 Simplified installation by heating

Thecablesmustnotbepreconditionedabove+60°C(140°F)forthepurposeofsimplifiedcableharnessinstallationbecausethiscanresultinanunintentio-nalaging/damageofthecables.Inconsequence,thiscanadverselyaffecttheirfunction and lifetime.

3.5 Handling

Inordertoavoidinjuriesduringmating,disconnectingandinstallingcables,itisrecommended to wear protective gloves.

Thishandlinginstructionmakesnoclaimtobecomplete.Subjecttoerrorsandchanges.Solelysuchhandlingand/orapplicationsbeingdefinedasallowedinthisdocumentarereleased.Anyotherhandlingand/orapplicationsis/areexplicitlydeemedtobenotreleasedandis/arethesoleresponsibilityofthecustomer.


4. Mechanical and Thermal Loads

Regarding the mechanical load, Multi-Core-Cables are subject to special criteria.Duringprocessing andoperation, tensile forces on the cable or the connector arenot allowed.Tensileforcesbetweenthecableandconnectorthatwillresultinthemalfunctionoftheassemblycanbecausedby:- acablelengththatistooshort- acablefixationthatisundertension- an insufficientfixationand thereforedamagedue toself-weight, vibrationor strokes.

Themanufacturerspecificationsrefertothepurequalificationtestsaccordingtotherequiredspecifications for thecomponents.These testsareonlyasnapshotof themoment of qualification. In case the requirements do not meet those of thequalification,atestaccordingtotheseconditionsismandatory.Incaseofadeviationfrom these requirements, a qualification according to the divergent conditions ismandatory.

4.1 Tensile load

During the installationof assembledcables, it has tobeensured that thebendingradiionallassembledcablesarecompliedwith.Thisappliestoallvariants.

4.2 Bending load

Forastatic installationof thecables, i.e. installationwithoutmovement, thevaluescanbefoundinthemanufacturerspecificationsundertheitem“Bendingradius”(e.g.under“Single”orat“Singlebending”).

4.2.1 Static installation in the vehicle

Fortheinstallationwithdynamicallyrecurringbending(flexibleapplication)ofthecable(e.g.indoors,exteriormirrorsortailgates),thevaluescanbefoundinthemanufacturerspecificationsundertheitem“Bendingradius”(e.g.under“Multiple”orat“Repeatedbending”).Loadsthatexceedthespecificationsoftheindividualcomponents(connectors)havetobevalidatedonacase-by-casebasisortheymustbeindependentlytestedandreleasedbytheOEMorthecableharnesssupplier.

4.2.2 Dynamic installation in the vehicle


4.2.3 Definition of the bending radius

Figure4-1Correctbending Figure4-2Incorrectbending

4.2.4 Use of MQS stranded wires

Ifadditionalstrandedwiresareusedwithdynamicapplications,theadditionofthestrandedwirelengthaccordingtothebendingradiushastobeconsidered.Otherwise,theriskofdamagingthepoints13arises.Furthermore,thelengthoftheadditionalstrandedwireshastobeselectedaccordinglysothatanaxialloadonthecablesisavoided.Whentaping,theloopoftheadditionalstrandedwireshastobeinsuchashapethatitcannotcomeintocontactwiththeouterconductor(seepicturebelow).

Since in case ofMulti-Core-Cables the rotation of the connector in the cable axis(seepicturesofexamplesbelow)cannotbeavoideddue to thepitch lengthof thecores,itmayhappenthattheassembledcablehastobetwisteduptoanangleof180°.Ingeneral, it isrecommendedtoverifythisonacase-by-casebasisbecausethissignificantlydependsonthecableandcontact(seedatasheet).Regardingthetaping,ithastobeconsideredthataminimumfreecablelengthmustbecompliedwith(seepoint5.2).

4.3 Load due to torsion

Figure4-3

Figure4-4


Combined loads that occur due to special applications (e.g. retracting the mirror,panorama display, retractable display, tailgate) have to beminimized by the cableharnessdesign.Sincecombined loadsexceed the specified loads, it is necessarytoprovethefulfillmentoftheapplication-relatedrequirementsofthecustomer.

4.4 Combined load (bending-torsional load)

5. Add-on Parts and Taping

The individual components of an assembled cable have different thermalspecifications. The total load limit dependson theweakest part of the assembledcable,thusspecifyingtheareaofapplication.Thetemperaturerangescanbefoundinthecomponentdatasheets.

4.5 Thermal load

When taping an assembled cable, it has to be ensured that nomechanical loadsinfluencethecable/cables.Thenon-tapedminimum lengthbetween the endof the connector and the endofthe taping that is specified below must be complied with in any case. (Separatemanufacturerspecificationshavetobeconsidered.)

5.2 Taping of Multi-Core-Cables

Theimproperassemblingofadd-onpartscanresultinchangedproperties,damageand/oradditionalloads.TheMDGroupdoesnotassumewarrantyforsubsequentlyassembled add-on parts and affixed tapings. Additionally, the bending radii (seechapter 4.2.3) for thecontinuingcables (e.g. fixingelements) have tobecompliedwith.

5.1 Add-on parts

Table5-1


Figure5-2Severalcableswithinonetaping

(Theexampleshows2HSDcables;thisalsoappliestocombinationswithothercabletypes)

Figure5-1Tapedsinglecable(example:HSD)

The manner of taping and the location where the cable is fixed have a directinfluence on the torsion of every single cable within the multiple system. Norotational load is allowed to occur during taping. The minimum clamping length(distance between the mated housing on the cable side and the cable fixation)ensuresthatatwist(torsion)ofthecablestowardseachotherisavoided.Incaseofmultiple systems, the minimum distance (see Table 5-1 in item 5.2) withouttaping/fixationhastobecompliedwith.

5.3 Torsion-free processing in the case of multiple systems

Thecablefixationmustbedesignedinsuchawaythatitdoesnotrequireadditionalphysicaleffortwhenmating.Squeezing/damaging thecableby thefixingelementsis not allowed. Fixing with cable ties is only allowed on taped surfaces.ForfixinginlineconnectionsonlyfixingelementsoftheMDGroupareallowed.

5.4 Attaching fixing elements (e.g. cable ties, holders)

Spliceconnectionsmustnotbeexposedtomechanical loadsneitherduringfurtherassemblingnorduringtheinstallationinthevehicle.

5.5 Splice connections

Handling Instruction Multi-Core-Cables PUBLIC Page7C3065510200271

6. Mating of Assembled Cables

Asabasicprinciple, it has tobeensured that theassembledcable is heldduringmatingontheconnectorhousingorcontact (ifpartiallyassembled),butnotonthecableitself.Theconnectorhastobeinsertedinthecorrectdirectionintothecorrectslot (coding) until it locks clearly audibly.

6.1 Mating process of assembled cables

Figure6-1Incorrecthandling

Figure6-2Holdingontheconnectorhousing Holdingontheconnectorcontact

Correcthandling

During the mating process, the housings must not tilt. Tilting may result in bentcontacts.Maleandfemalehousingsmustbeconnectedwithoutany largephysicaleffort.Itismandatorytocomplywiththecomponentmanufacturer’srequirements.

Figure6-3Incorrectmating Bent inner contacts


Figure6-4Correctmating

Inordertodisconnecttheconnectors,itisnecessarytofollowthesesteps:Firstpushthehousingstogethertomaketheconnectionfreeofforces(withoutload).Thenpushthelockinglatchwiththefingersothatthelockingelementopens.Finally,pulloffthetwoconnectorsinaxialdirection.Thetwoconnectorsareonlyallowedtobeheldatthehousings.Tools(suchasscrewdrivers,knivesorsimilar)mustnotbeusedforpushingthelockinglatch.

Correctly mated

6.2 Disconnecting the connectors/cable

6.3 Mating cycles

Thequantityofthemaximumpermissiblematingcyclesisdefinedbythecomponentmanufacturer(datasheet)andmustnotbeexceeded.

7. Positioning of the Cable Exit

ForMulti-Core-Cables,therearesolelyfixedexitdirections(left,right,upanddown)whichhavetobetakenintoconsiderationforcableharnessdesign.

Figure7-1Exitright Exitleft Exitup Exitdown

(SeeFigure7-1Positionlateralprotrusiononthehousing)


8. TestsIt isnotallowedtomatethecablesdeliveredandtestedbytheMDGrouppriortothe installation in the vehicle. If the OEM requires the mating in the course of a100%functional test, thespecialOEMspecificationshave tobeobserved. In thiscase,theMDGroupdoesnotassumewarrantyforanycomplaintsaftertheperformedtest.

Insomeinstances,theautomotivemanufacturershavespecificationsfortestsintheevent of errors. If a test is necessary, solely test devices and test adapters beingsuitable for theconnector, both releasedbyMDELEKTRONIKGmbH,are allowedtobeused.Only instructedpersonsareallowed toperform theerroranalysis.Thetestdevicesaredesignedexclusively for thediagnosisof suspiciouscables in thereworkzoneonthecustomer´spremises.Sortingbymeansofshort-circuittestersisprohibited.

ThesetestdevicescanbepurchasedfromMDELEKTRONIKGmbHuponrequest.Thefollowingtestdevicesareavailable:

- MDshort-circuittesterforHSD/HSDe(Multi-Core-Cables)

8.1 Error test

Figure8-1Correcttestingequipment


Itisnotallowedinanycasetousecontactsfortheelectricaltestofassembledcables.Reason:Usingcontactscandamagetheconnector.

ThefollowingpicturesshowexamplesfortestsofHSD/HSDeconnectorsthatarenotallowed:

8.2 Not allowed electrical tests

8.2.1 Use of not allowed testing equipment

Figure8-2Example:HSDConnector Example:HSDeConnector

Figure8-3Example:HSDConnector Example:HSDeConnector


9. Protection Note

10. Additional NotesSubjecttoerrorsandchanges.Theoriginalversionofthishandling instructionwascreatedinGerman.Additionally,otherlanguageversionscanbemadeavailable.Ifthecontentsoftwolanguageversionsdifferfromeachother,solelytheoriginalversionapplies.

If protectable information is transmitted in this handling instruction or the relateddrawing,MDELEKTRONIKGmbHreservesall rights forapatentand/orprotectiverightapplication.Eachpowerofdisposition, includingtherightofreproductionanddisclosure,isthesolepropertyofMDELEKTRONIKGmbH.


LEGAL NOTICE

Company address:MDELEKTRONIKGmbHNeutraublinger Straße 484478WaldkraiburgGermany

t.:+498638/604–0f.:+498638/604–169

e.:[email protected]

Web:https://www.md-elektronik.de

Executive BoardRobert HofmannCtiborŽižkaRalfEckert

VAT numberDE129263719

Court of RegisterTraunsteinHRB1514

©Copyright2017,MDELEKTRONIKGmbH.Allrightsreserved.

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MD GROUP HANDLING INSTRUCTION