MAK-8 MAK-12 System

Report
High Power Terminals & Connectors
MAK8 & MAK12
MAK Terminal & Connector Overview, 20-Feb-2009
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Power Terminals Application Range
MAK Terminal & Connector Overview, 20-Feb-2009
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Product Line-Up
MAK8 Crimp
MAK Terminal & Connector Overview, 20-Feb-2009
MAK8 Sonic Weld
3
MAK12 Sonic Weld
Product Line-Up
Female Terminal
Male Terminal
MAK8 Crimp
Product currently not available
MAK8 Sonic Weld
Product currently not available
Can be installed short term
MAK12 Crimp
None, product not planned
MAK12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009
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None, product not planned
Product Outline
Terminal
Comment
2.5 – 16.0mm²
MAK8 Crimp
Sn and Ag plating
For Cu wire only
For sealed & unsealed applications
Max. 25.0mm² (Cu wire)
MAK8 Sonic Weld
Max. 27.0mm² (Al wire)
Sn and Ag plating
For Cu and Ag wire
For sealed & unsealed applications
Max. 35.0mm² (Cu wire)
MAK12 Sonic Weld
Max. 42.0mm² (Al wire)
Sn and Ag plating
For Cu and Ag wire
For sealed & unsealed applications
MAK Terminal & Connector Overview, 20-Feb-2009
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Available Connectors MAK8 Crimp
MAK8, 2-way
connector to EPS
MAK8, 1-way
(19060)
direct connection to
PowerFuse
(13679)
MAK8 + MAK48, 4-way
direct connection to
cooling fan
MAK8, 2-way
(18943)
direct connection to
PowerFuse
(13676)
MAK8, 3-way
power feed into engine
junction box
(19028)
MAK8, 6-way
power feed and fuse
connection into junction
box
MAK8, 1-way
direct connection to
PowerFuse
(13478)
(18610)
MAK Terminal & Connector Overview, 20-Feb-2009
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Available Connectors MAK8 Crimp
MAK8, 2-way
connector to EPS
MAK8, 1-way
(19060)
direct connection to
PowerFuse
(13679)
MAK8 + MAK48, 4-way
direct connection to
cooling fan
MAK8, 2-way
(18943)
direct connection to
PowerFuse
(13676)
MAK8, 3-way
power feed into engine
junction box
(19028)
MAK8, 6-way
power feed and fuse
connection into junction
box
MAK8, 1-way
direct connection to
PowerFuse
(13478)
(18610)
MAK Terminal & Connector Overview, 20-Feb-2009
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Available Connectors MAK12 Sonic Weld
MAK12, 1-way
MAK12, 1-way, 90°
'clip-in‘ connector for
sealed fusebox
power supply into central
junction box
(17956)
(13693)
MAK12, 1-way
MAK12/MAS12, 1-way
direct connection to
PowerFuse
inline connection for EPS
(17161/17164)
(17959)
MAK12, 2-way
MAK12/MAS12, 1-way
inline to PTC heater
direct connection to EPS
(standard AK interface)
(17968/17973)
(17999)
MAK12 + MAK28, 5-way,
90°
MAK12 + MAK28, 4-way
inline connection for 1kW
cooling fan
direct connection on
capacitor
(17969/17988)
(17265)
MAK Terminal & Connector Overview, 20-Feb-2009
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Available Connectors MAK12 Sonic Weld
MAK12, 1-way
MAK12, 1-way, 90°
'clip-in‘ connector for
sealed fusebox
power supply into central
junction box
(17956)
(13693)
MAK12, 1-way
MAK12/MAS12, 1-way
direct connection to
PowerFuse
inline connection for EPS
(17161/17164)
(17959)
MAK12, 2-way
MAK12/MAS12, 1-way,
90° and straight
direct connection to EPS
(standard AK interface)
inline to PTC heater
(17999)
(17968/17973)
MAK12 + MAK28, 5-way,
90° & straight
MAK12 + MAK28, 4-way
inline connection for 1kW
cooling fan
direct connection on
capacitor
(17969/17988)
(17265)
MAK Terminal & Connector Overview, 20-Feb-2009
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MAK12 Application Example
 Power supply to central junction box
 replaced eyelet terminal with direction connection
 elimination of bolt and nut  weight saving
 elimination of screwing operation  process
improvement
 elimination of screwing operation  deletion of
power tools from assembly line
 optimised wire routing  package space
improvement
MAK Terminal & Connector Overview, 20-Feb-2009
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MAK8 Application Example
51 pieces
19 pieces
1*
Housing
1*
Housing
1*
Busbar
1*
Busbar/Powerfuse
16*
Bolts
2*
Bolts
17*
Nuts
2*
Nuts
8*
Fuses
1*
Eyelets
8*
Eyelets
7*
Terminals
8*
Screwing operation
5*
Connectors
2*
Screwing operation
5*
Mating operation
at vehicle plant
at harness plant
9*
Screwing operation
at vehicle plant
Example: Pre-Fuse box for passenger vehicle, mounted direct on battery (in production)
MAK Terminal & Connector Overview, 20-Feb-2009
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Terminal Electrical Performance
Derating Curves - LEAR MAK Power Terminals
250
Current / A
200
150
100
50
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
Temperature / °C
MAK8 Crimp 16mm²
MAK8 Sonic Weld 25mm²
all parts with Ag surface finish and maximum applicable wire size
* MAK8 Sonic Weld, preliminary derating, from prototype parts
MAK Terminal & Connector Overview, 20-Feb-2009
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MAK12 Sonic Weld 35mm²
150
Terminal Performance Summary
Lear Power Terminals, Performance Summary
MAK8 Crimp
MAK8 Sonic Weld
MAK12 Sonic Weld
Applicable Wire Size
2.5 - 16.0mm²
2.5 - 25.0mm²
6.0 - 35.0mm²
Contact Resistance
< 1mOhm
< 1mOhm
< 1mOhm
Maximum Rating
120A @ 80°C, 16mm², Ag finish
130A @ 80°C, 25mm², Ag finish
190A @ 80°C, 35mm², Ag finish
Derating
100A @ 80°C, 16mm², Ag finish
110A @ 80°C, 25mm², Ag finish
160A @ 80°C, 35mm², Ag finish
-40°C … +130°C, Sn finish
-40°C … +130°C, Sn finish
-40°C … +130°C, Sn finish
-40°C … +150°C, Ag finish
-40°C … +150°C, Ag finish
-40°C … +150°C, Ag finish
< 25N on first insertion
< 25N on first insertion
< 40N on first insertion
< 20N on second insertion
< 20N on second insertion
< 35N on second insertion
10 for Sn finish
10 for Sn finish
10 for Sn finish
50 for Ag finish
50 for Ag finish
50 for Ag finish
> 120N
> 120N
> 120N
Operating Temperature
Terminal Mating Effort
Mating Cycles
Terminal Retention to Housing
derating preliminary, taken from prototype parts
 Outstanding electrical performance and mechanical robustness
 Sonic weld version offers additional harness routing flexibility
MAK Terminal & Connector Overview, 20-Feb-2009
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Terminal Drawings: MAK8 Crimp
MAK Terminal & Connector Overview, 20-Feb-2009
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Terminal Drawings: MAK8 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009
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Terminal Drawings: MAK12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009
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Terminal Drawings: MAS12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009
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