Rev 1 Flex Beam Technology (FBT) - Amazon Web Services · Flex Beam Technology (FBT) Selected for...

Flex Beam Technology (FBT)Selected for the Distribution Channel

Products presentationRev 1

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2

Table of contents

Connection Systems

For additional product information and engineering drawings, please visit our website at www.delphi.com/connectors.

What is Flex Beam Technology? 3

Benefits of Flex Beam Technology 4

Typical Applications & Performance Advantages 5

Application Guidelines & Patent Information 6

Flex Beam 150 unsealed 7-8

Flex Beam 090 II unsealed 9

Flex Beam 280 unsealed 10-11

Flex Beam 150 280 unsealed 12

Flex Beam 150 sealed 13-14

Flex Beam 280 sealed 15

Flex Beam 150 280 sealed 16


3

What is Flex Beam Technology?

Connection Systems



Flex Beam Technology (FBT) is a product / process system that consists of:• The integration of the primary lock feature (PLR) into the design of the connector• A holder design that ensures that the terminal is properly seated, eliminating the need for a separate secondary lock (TPA)FBT is a technology that can be applied to existing compatible connection systems and developed into new systems.FBT uses a rigid ramp, in place of a flexible lock arm, to provide the terminal primary lock.A flexible, integrated Primary Lock Reinforcement beam pushes the terminal against the rigid lock, thus ensuring maximum contact and retention.In conventional systems the PLR pushes the lock into the terminals. In Flex Beam the IPLR pushes the terminals into the lock.Flex Beam Technology provides robust wiring harness manufacturing provisions.Mating terminal lead-in is molded into the connector.The cavity / holder design relationship assures that a terminal has been seated:• The FBT design accommodates variation in the plastic component, holder, and process (Checks for the terminal, not just plastic like other

systems)• The ring out pin port in the connector locates the holder ring out pin, reducing variationTerminal position is assured without a secondary piece.ALRO (at line ring out) holder utilizes a stabilizer pin/bar. The stabilizer ensures the terminal is in contact with the ring out pin throughout the ringout process.

Integrated Primary Lock Reinforcement

Rigid Lock

4

Benefits of Flex Beam Technology

Connection Systems



• Simplified Harness Assembly• Reduced complexity during wiring harness build process

• No opportunity for closed PLR/SLC/Secondary Locks uponreceipt

• Reduced holder complexity• No need for presence check devices for extra

pieces• No added actions for the operator

• Plug the terminal and the operation is complete• No secondary locks to install or nosepieces to close

• Improved Quality and Enhanced Reliability• Reduced number of failure modes

• With conventional systems, terminal lock failure is theresult of 1) buckling of the primary lock and 2) the metalterminal shearing through the plastic lock arm

• With Flex Beam, buckling is eliminated because theprimary lock is rigid. Shear is controlled by a coined edgeon the terminal that directs it through the heaviest part ofthe rigid terminal lock

• With Flex Beam the terminal is either seated or it isn’t• The terminal seats from a different plane than the ring-out

pin enters the cavity• A long ring-out pin can’t “seek out” an unseated

terminal

• Terminal Retention• Even though there is only one piece of plastic, terminal retention in

a Flex Beam cavity is comparable to conventional two piececonnections

• Mass Reduction• Due to its efficient design, connectors with Delphi’s Flex Beam

Technology have lower mass than comparable connectors fromother suppliers

• The Delphi Flex Beam replacement offers a 28% mass reductionover the competition

• Service Provisions• Simplified and more robust procedure

• No extra parts to move to pre-stage (PLR / SLC) or removecompletely (TPA)

• Loose pieces can be lost or damaged or not evenreassembled

• Value Stream Reduced• Replace two-piece connector design with one-piece design• Eliminate secondary lock (TPA)• Eliminate connector assembly operation• Eliminate installation of secondary lock in wiring final assembly

� Terminal position assurance without additional plastic pieces� Improved terminal retention vs. a conventional two piece assembly� Improvement in harness first time quality vs. a conventional two piece

assembly� Up to 10%

� Mass reduction vs. a conventional two piece assembly� Up to 28%

� Warranty improvement on terminal unseat vs. a conventional two piece assembly

� 0 IPTV (Incidents per thousand vehicles)� Simple and easy servicing

� No secondary pieces to remove/damage� Uses industry standard repair tools

5

Typical Applications & Performance Advantages

Connection Systems



The Delphi FBT series of connection systems is designed for general vehicle power and signalapplications. The series consists of sealed and unsealed connections, including USCAR standardfootprints.

• Meets ISO (International Organization for Standardization) and USCAR electrical, mechanical, and environmental• performance criteria• Package size suited to fit tight space requirements of today's vehicles• Enables the transportation market to increase plant efficiencies and eliminate labor related to secondary plastic pieces• The system includes:

• Tangless terminals with stamped serrations and compatible with ISO or SAE blades• Connector lock with features for optional Connector Position Assurance• Low engage force for improved reliability and ergonomics

6

Application Guidelines & Patent Information

Connection Systems



Delphi has been awarded several U.S. patents for its FBT:

� 5,980,318, Connector with a flexible beam for holding a terminal down and in position� 7,048,584, Electrical connector� 7,179,136, Electrical connector� 7,252,553, Ring out system providing terminal position assurance� 7,252,559, Two piece electrical terminal� Additional patents are pending

7

Flex Beam 150 unsealed

Connection Systems


Flex Beam FemaleDPN

Flex Beam Female Description

GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN

13699622 2-way Unsealed 150 GT FBT Connector Black U 2

13668003 2-way Unsealed 150 GT FBT Connector Black 15332129 U 2 15332130

13586106 2-way Unsealed USCAR 150 GT FBT Connector Black 150-U-002-1-A01 U 2

13586107 2-way Unsealed USCAR 150 GT FBT Connector Gray 150-U-002-1-B01 U 2

13586108 2-way Unsealed USCAR 150 GT FBT Connector Brown 150-U-002-1-C01 U 2

13586109 2-way Unsealed USCAR 150 GT FBT Connector Green 150-U-002-1-D01 U 2





13586120 4-way Unsealed USCAR 150 GT FBT Connector Rust 150-U-004-2-C01 U 4




13592279 6-way Unsealed USCAR 150 GT FBT Connector Orange 150-U-006-2-A01 U 6









13668279 10-way Unsealed 150 GT FBT Connector Black15332153

15459918U 10 15332158




8


Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN










15332177U 16 13516907





13666136 16-way Unsealed 150 GT FBT OBD II / ALDL Connector Black U 16

13526678 150 Unsealed GT FBT Terminal 0.8 gap Sn 0.75 - 1.0 mm2






9

Flex Beam 090 II unsealed

Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN

13597206 2-way Unsealed 090 II FBT Connector Natural

13627263 4-way Unsealed 090 II FBT Connector Natural

13592499 090 II Unsealed FBT Terminal Sn 0.35 - 0.5 mm2

13592500 090 II Unsealed FBT Terminal Sn 0.75-1.25 mm2

13592501 090 II Unsealed FBT Terminal Sn 2.0 mm2


10


Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN


13609693 3-way Unsealed USCAR 280 GT FBT Connector Natural 280-U-003-2-A01 U 3

13609694 3-way Unsealed USCAR 280 GT FBT Connector Black 280-U-003-2-B01 U 3

13609695 3-way Unsealed USCAR 280 GT FBT Connector Gray 280-U-003-2-C01 U 3


13578732 3-way Unsealed 280 GT FBT Connector Gray U 3


13797473 4-way Unsealed USCAR 280 GT FBT Connector Black 15466671 280-U-004-1-A01 U 4

13665410 5-way Unsealed 280 GT FBT Connector Black 15326893 U 515326897

15326894





15459914U 8

15326928

15459916





13544533 8-way Unsealed USCAR 280 GT FBT Connector Orange 280-U-008-2-E01 U 8




13523064U 12 15326942





11


Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN







12

Flex Beam 150 280 unsealed

Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN

13578693 10-way Unsealed 150 280 GT FBT Connector Black U 10

13677808 12-way Unsealed 150 280 GT FBT Connector Black 15336205 U 12 15336209


13839171 18-way Unsealed 150 280 GT FBT Connector Dark Gray 15304690 U 18 15336467


13839172 22-way Unsealed 150 280 GT FBT Connector Gray 15317325 U 22 15317322

13839173 22-way Unsealed 150 280 GT FBT Connector Dark Gray 15326063 U 22 15326064

13839174 30-way Unsealed 150 280 GT FBT Connector 15304908 U 30 15326762

13839175 30-way Unsealed 150 280 GT FBT Connector 15326416 U 30 15317735

13717758 40-way Unsealed 150 280 GT FBT Connector Black15448129

15448130U 40

13717762

13717764 (Door)

13717759 40-way Unsealed 150 280 GT FBT Connector Gray 15401211 U 40 13717763


13

Flex Beam 150 sealed

Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN

13705951 2-way Sealed 150 GT FBT Connector Black13510085

15326801S 2 15326806

13592515 2-way Sealed 150 GT FBT Connector Black 150-S-002-1-A10 S 2

13592516 2-way Sealed 150 GT FBT Connector Gray 150-S-002-1-C10 S 2

13627749 2-way Sealed GT FBT 150 Connector Black S 2

13627750 2-way Sealed USCAR 150 GT FBT Connector Black 150-S-002-1-A01 S 2

13627751 2-way Sealed USCAR 150 GT FBT Connector Black S 2

13513272 2-way Sealed 150 GT FBT Connector Black S 2

13605112 2-way Sealed 150 GT FBT Connector Natural S 2

15489798 2-way Sealed 150 GT FBT Connector Dark Gray S 2

15489799 2-way Sealed 150 GT FBT Connector Gray S 2

15492200 2-way Sealed 150 GT FBT Connector Natural S 2

13547918 2-way Sealed 150 GT FBT Connector Rust S 2

13610965 2-way Sealed 150 GT FBT Connector Rust S 2

13605563 2-way Sealed 150 GT FBT Connector Base 3 Black 150-S-003-1-A03 S 2

13590275 2-way Sealed 150 GT FBT Connector Base 3 Black 150-S-003-1-A03 S 2

13590276 2-way Sealed 150 GT FBT Connector Base 3 Green 150-S-003-1-D03 S 2

13590270 3-way Sealed 150 GT FBT Connector Black 150-S-003-1-A03 S 3


15326822S 5 15326827


15397577S 6 15326833

13733083 6-way Sealed 150 GT FBT Connector Black with CPA 15326830 S 6 15326833

13706922 6-way Sealed 150 GT FBT Connector BASE 8 Black 15465945 S 6 15326840

13706547 8-way Sealed 150 GT FBT Connector Black 15326835 S 8 15326840



14


Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN




15326849S 12 15326854



15479300S 16 15326868

13522325 150 Sealed GT FBT Terminal Sn 0.35 - 0.5 mm2



15


Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN


15326642S 5 15326647


15326635S 6 15326640


13538370S 8 15326655





16

Flex Beam 150 280 sealed

Connection Systems


Flex Beam FemaleDPN


GT Equivalent

Female

DPN

USCAR

FootprintSealed I/O

Mating GT Male

Delphi PN

13706562 24-way Sealed 150 280 GT FBT Connector Gray 15366099 S 24 13706569

13706561 24-way Sealed 150 280 GT FBT Connector Black 15488829 S 24 13706568


17

Notes

Connection Systems


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www.delphi.com/connectors

Delphi Connection Systems reserves the right to improve, enhance and modify the design specifications and construction ofDelphi products without prior notification. For additional product and engineering information visit our website at www.delphi.com/connectors18 Rev Jul 2015

Asia Pacific Regional Operations60 Yuanguo RoadAnting, Jiading DistrictShanghai, 201814 ChinaTel: (86) 21. 5956.3300Fax: (86) 21. 6957.3797

Europe Regional OperationsCustomer Technology CenterDelphiplatz 142119 Wuppertal, GermanyTel: (49) 202.291.0Fax: (49) 202.291.2777

North America Customer Center5725 Delphi DriveTroy, Michigan 48098-2815USATel: (1) 248.813.2000Fax: (1) 248.813.2673

South America Regional OperationsDelphi Automotive Systems do Brasil Ltda.Rod. dos Tamoios, Km 21,8Jambeiro, São Paulo 12290-000 BrazilTel: (55) 12.3978.2005Fax: (55) 12.3978.2077

Contact Information

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