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Useful information about on-board power connectors

  • What was the vehicle on-board power connector?

  • Which on-board power connectors are available from Conrad?

  • FAQ – Frequently Asked Questions about automotive on-board power connectors

What was the vehicle on-board power connector?

Car on-board voltage plug connector

With car-on-board voltage connectors, different consumers are connected to the on-board voltage supply of a car. Basically, a distinction must be made between connectors that are used in existing plug-in devices and those that can be installed later in the car. The materials used are chosen in such a way that they can withstand the often higher thermal loads caused by engine or exhaust heat or solar radiation as well as the mechanical challenges caused by vibration or shock.

There are two types of automotive on-board power connectors:
 

  • Car socket according to DIN ISO 4165 with 12 mm diameter: It is attributed to a safer contact behavior due to its design. There are adapters from these automotive on-board voltage connectors to the following SAE standard.
  • Car socket according to SAE J563 with approx. 21 mm diameter, the so-called cigarette lighter. Two types have established themselves here: Size A in mainly American cars and size B in European cars The plug diameter of B is about 0.4 millimeters larger than that of A.

With space-saving electronic solutions in the housings of the on-board power connectors, their use is possible in on-board networks with different voltages (for example 12 or 24 V with automatic detection or switchable).

There are many special designs, such as plug-in housings for plugging into the beverage holder, equipped with LEDs for car battery status and with separate fuse in the plug. Here too, there are symbol prints (cigarette), so that when you buy used non-smoking cars, you can replace a dummy plug in the cigarette lighter with a functioning plug. 

The car on-board voltage connectors are connected to the on-board voltage supply for subsequent installation by means of flat plugs, screws or soldering.

Data sheets from the manufacturers are available for download on the respective product page for some on-board power connectors. These are particularly relevant with regard to the installation dimensions as well as the current carrying capacity and the temperature range at the place of use in vehicles.

Which on-board power connectors are available from Conrad?

The car on-board voltage connectors can be selected according to:

  • Maximum load capacity from 0.5 to 20 Ampere. The special feature is zero ampere, including protective caps.
  • Different connections: 
    • 6.3 mm flat plug connector: These are usually plug connectors to be installed subsequently for installation or assembly
    • Stripped or open end cable
    • Solder contacts for fixed subsequent installation or replacement of defective connectors
    • Standard plug: Connection with connectors according to DIN ISO 4165
    • Ring cable lugs for screwing with the on-board voltage source
    • Screw connections as terminals or contacts inside the plug
    • Universal safety plugs: These are equipped with adapter pieces, so that their use is possible with both standards.
    • USB connection with the option of supplying devices with a USB connection from the cigarette lighter. This includes a USB universal adapter that fits two Apple and two mini USB ports.
    • Cigarette lighter socket: These are mostly extensions or multiple distributors or universal connectors, which also have USB outputs. Versions with battery terminals are also available.
    • Cigarette lighter plugs are also available as extension and distribution cables, sometimes combined with USB outputs.
  • New products and offers, partly with low-emission production RoHS
  • Store availability
  • Trademarks

FAQ – Frequently Asked Questions about automotive on-board power connectors

What safety instructions must be observed for vehicle on-board power connectors?

  • When handling or retrofitting automotive on-board voltage connectors, please note that work on the on-board power supply of the vehicle may only be carried out by trained specialists. The relevant occupational safety regulations of the motor vehicle industry must be observed.
  • If you disconnect the on-board power supply from the car battery, components in the vehicle that must be activated for recommissioning with codes (for example, car radios) may be affected. Have this information ready before you begin work.
  • Always observe correct polarity of the connections.
  • The improper execution of electrical connections in vehicles can cause considerable risks.
  • Only connect and disconnect car plug connections from the power supply, because due to the high currents, dangerous electric arcs can occur when disconnecting.
  • If required, use suitable tools to avoid damaging any of the elements, housings, insulations and vehicle components used.
  • When using automotive on-board voltage connectors, pay attention to the nominal voltage ranges, nominal current and, if necessary, temperature resistance.
  • Most automotive connectors are not intended for outdoor use.
  • Oil, chemical substances and corrosion gas can affect any connector in its function.
  • Fix temporarily used cables so that there is no tensile force on them. Also use the strain relief clamps that may be present directly at the connectors.
  • Car on-board power connectors that are no longer usable are specially designed for disposal of electrical waste for public collection points. They must not be disposed of with household waste.

How do defective on-board power connectors become apparent?

  • Corrosion can cause increased contact resistance, which was associated with heating. This can damage insulation or housing. Connected components can be impaired in their function, for example by reduced light yield of lamps or too low power of small compressors.
  • Lack of spring force of terminals for temporary use on car batteries.
  • Insulation elements can become unusable due to exposure to high temperatures. Determine the causes of the temperature rise and correct them before replacing the car connectors.
  • The spring force of cigarette lighter plugs can decrease over time, so that the electrical connections also become unreliable.
  • Strong bending or clamping of cables of the on-board power connectors, for example in car doors and windows, can greatly reduce the current carrying capacity of the entire connection, was usually noticeable by heating the plug, the socket or the cable itself.
 
 
This text is machine translated. Useful information about on-board power connectors What was the vehicle on-board power connector? Which on-board power connectors are available from Conrad? FAQ – Frequently Asked Questions about aut...