FEATURE CABLES & CONNECTORS
CABLES & CONNECTORS FEATURE TITLE
FEATURE
CONNECTING THE POINTS between performance and safety
More than 25 million automotive push-fit connector products are supplied each year by John Guest, helping vehicle manufacturers achieve demands for efficiency, reliability, low emissions, robustness and increased comfort. Gary Hall, divisional director for John Guest UK’s special products, discusses how the connector found its place in the automotive sector and why it is crucial to future innovations
W
hile there is increasing demand in the automotive manufacturing
and design sector to reduce production and assembly time, there must be no compromise when it comes to performance and safety. To help, advanced components such as the push-fit connector are being used. Typically used in fuel, brake vacuum, air suspension and low-pressure power steering systems, the push-fit connector has evolved from a basic solution to a product capable of meeting the ever- changing technical requirements of the automotive industry - including crash robustness, emissions reduction, space restriction, cost efficiency and reliability.
WHY PUSH-FIT? The Ford Motor Company was the first to adopt the JG connector after facing a last minute dilemma at the launch of a new model back in 1983. The company approached John Guest and within days a dedicated push-fit connector was designed, developed, manufactured and supplied. This fast response led to JG fuel connectors becoming standard across Ford’s European car platforms as well as common platforms in North America. Using the push-fit technology,
manufacturers could achieve a rapid and
validated combination of chassis fuel system components, resulting in reduced assembly times and system complexity. The quality of such a connector also meant that fuel bundles no longer relied on rubber hose and band clamp connection which required operator access for assembly tools. Car manufacturers were quick to seize on the opportunities the push-fit connectors offered and system architecture began to be simplified, leading to vehicle weight and size reduction. Differing from other tube mounted connectors, the innovation of the push-fit connector in cartridge and assembly kit formats has enabled the rapid connection technology to be incorporated into a multitude of system components. Previously restricted to tube mounting, the connector can now be easily incorporated into major system components such as fuel delivery modules, carbon canisters, injector fuel rails, intake manifolds, vacuum pumps, urea dosing tanks, axle/bell housing breathers, etc. Of additional benefit, this method
of assembling can provide a number of benefits such as enhanced crash resistance, safeguarding core components, sealing integrity, and reduced tooling and
/ DESIGNSOLUTIONS
machining complexities. The repeatable connection ability can also benefit after-sales servicing.
A VERSATILE CONNECTOR More recently, the push-fit connector is being used in models that strive to reduce emissions output and create a generally greener footprint, without compromising performance or safety. Both the connector and cartridge solutions are currently being used and evaluated for fuel cell vehicles. In particular, cartridges are beneficial for the development phase, being used in prototype manifolds and coolant arrays for test and evaluation purposes prior to design freeze and costly tooling commitment. The versatility of such a connector
means that many of the world’s renowned vehicle manufacturers are taking full advantage of this small but essential piece of technology. Thanks to components such as the push-fit connector, today’s vehicles are now more readily able to include, as standard, options previously only enjoyed on top end models – such as power steering, air conditioning and pre-heating.
John Guest
www.johnguest.com
DESIGN SOLUTIONS | NOVEMBER 2015 19
Typically used in fuel, brake vacuum, air suspension and low-pressure power steering systems, the push-fit connector has evolved from a basic solution to a product capable of meeting the ever-changing technical requirements of the automotive industry
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