Potential

Failure Mode and Effects Analysis

FMEA Number: MIT 1
___System (Design FMEA) Page 1 of 3
___Subsystem
_X_Component: Connector System Design Responsibility: Workgroup Prepared by: M.Andrew
Model Year/Vehicle(s): / 42 VOLT SYS Key Date: October 2000 FMEA Date (Orig.): 2000.02.16 (Rev.): 2010.02.16
Core Team: Refer to workgroup list

Item C Potential O D A c t i o n R e s u l t s
Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility
Failure Effect(s) of e a Mechanism(s) c Design t P. Action(s) & Target Actions S O D R.
Mode Failure v s Failure u Controls e N. Completion Date Taken e c e P.
Function s r c v c t N.

- handles rated Excessive voltage Overheating 8 decreased normal force end-of-line check test
electrical current drop Reduced voltage to loads
with maximum voltage partially backed-out
drop of (50mV), for connector
up to xxx sec. over
and ambient partially backed-out
temperature range of terminal
-40C to 80C.
loss of asparities(terminal
Voltage drop spec. interface)
referenced to
end-of-conditioning Environmental conditions
status, including
material properties
Meet stds.for
underhood
environment
(corrosion system not open circuit 7 excessive mating force
resistance) electrically
Must withstand connected broken connector latch
SAEJ537 spec.for
vibration inadequate connector latch
Must satisfy thermal
cycling spec. terminal not open circuit 7 terminal partially seated
connected
damaged terminal

improper terminal
orientation

excessive mating force

maintains mechanical doesn't support open, short, or intermittent inadequate material

integrity cable load circuit, or overheating selection(housing or
terminal)

inadequate strain relief

unmated connectors Open circuit partially backed-out

overheating connector
Reduced voltage to loads
partially backed-out
terminal

Printed on: 2000.03.01 12:47:35

Filename: Produced by FMEAplus for Windows v4.1 Registered to: FMEAplus User
C:\SYS\FMEA41\DATA\MIT3R.FME
 Potential
Failure Mode and Effects Analysis
FMEA Number: MIT 1
___System (Design FMEA) Page 2 of 3
___Subsystem
_X_Component: Connector System Design Responsibility: Workgroup Prepared by: M.Andrew
Model Year/Vehicle(s): / 42 VOLT SYS Key Date: October 2000 FMEA Date (Orig.): 2000.02.16 (Rev.): 2010.02.16
Core Team: Refer to workgroup list

Item C Potential O D A c t i o n R e s u l t s
Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility
Failure Effect(s) of e a Mechanism(s) c Design t P. Action(s) & Target Actions S O D R.
Mode Failure v s Failure u Controls e N. Completion Date Taken e c e P.
Function s r c v c t N.

loss of asparities(terminal
interface)

Prevents accidental Short from positive Excessive current draw Design Dependent - to be
shorting of positive to negative or to Overheating identified for each design.
terminal to ground ground

mate/unmate Increased voltage Overheating loss of asparities(terminal

connections - under drop Excessive voltage drop to interface)
load (less than 10 load
amps for a minimum decreased normal forc
of 50 cycles)
reduced mechanical open, short or intermittent broken connector latch
retention force circuit
inadequate connector latch

unmate force is Can't disconnect battery Cold welds at the interface

excessive Permanent damage to the
system Corrosion

Mechanical latch failure

Mechanical distortion of
separable interface

Prevent reverse Reverse connections Damage to vehicle electrical Inadequate polarization or

connections are made system. indexing
Damage to connection

Prevent 12 volt to Wrong connections Damage to vehicle electrical Inadequate indexing

36 volt connections are made system.
Damage to connection Allows for alligator style
Battery damage jumper cable attachment

Prevent connection Wrong connections Damage to battery Inadequate indexing

to different battery are made
chemistry
technology(indexing
required at positive
only)

Printed on: 2000.03.01 12:47:36

Filename: Produced by FMEAplus for Windows v4.1 Registered to: FMEAplus User
C:\SYS\FMEA41\DATA\MIT3R.FME
 Potential
Failure Mode and Effects Analysis
FMEA Number: MIT 1
___System (Design FMEA) Page 3 of 3
___Subsystem
_X_Component: Connector System Design Responsibility: Workgroup Prepared by: M.Andrew
Model Year/Vehicle(s): / 42 VOLT SYS Key Date: October 2000 FMEA Date (Orig.): 2000.02.16 (Rev.): 2010.02.16
Core Team: Refer to workgroup list

Item C Potential O D A c t i o n R e s u l t s
Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility
Failure Effect(s) of e a Mechanism(s) c Design t P. Action(s) & Target Actions S O D R.
Mode Failure v s Failure u Controls e N. Completion Date Taken e c e P.
Function s r c v c t N.

Prevent customers Alligator style Damage to the vehicle Allows for alligator style
access with standard jumper cables can electrical system jumper cable attachmen
jumper cables on the be attached Damage to battery
connection system Damage to connector

Disconnect under XX Damage to Oveheating excessive arcing - impact

electical load connection system warping will be design dependent
excessive spark
permanent damage to the
connection system

75 N maximum mating requires more than Cannot mate connection Out of spec on mating
force requirement 75 N to mate open circuit alignment assurance
Partially mated
Ergonomic concerns damaged terminals

improper terminal
orientation

damaged housing

Contamination

75 N maximum requires more than excessive unmating force damaged terminals

unmating 75 N unmating force
force(minimum improper terminal
locking strength of orientation
110 N) USCAR 5.4.2.4
damaged housing

Contamination/corrosion

Less than 110 N Terminal latch disengages Inadequate terminal

locking strength before the connector unmates retention feature

Improper material

maintain stable cable out of damaged battery cable Inadequate mechanical

cable routing desired position positioning feature
orientation

Printed on: 2000.03.01 12:47:36

Filename: Produced by FMEAplus for Windows v4.1 Registered to: FMEAplus User
C:\SYS\FMEA41\DATA\MIT3R.FME