Abstract
Vehicle manufacturers are focusing on development of electric / hybrid vehicles for clean air environment. While on other hand, conventional fuels will require meeting Euro VI emission norms and in India called as Bharat Stage VI in all major metropolitan cities by 2020. This is going to push up developments in SCR (Selective Catalytic Reduction) technologies that use urea as diesel exhaust fluid (DEF) to reduce noxious exhaust gases. Both electric vehicles (EV) and SCR technologies are thus imposing the challenge on quick connector manufacturers to provide appropriate fastener solutions to validate the product that will meet the demands of OE industry. Presently most of vehicles on the road use quick connectors for wide applications in automotive for fuel lines, cooling system, air conditioning, exhaust, power steering and brake fluid areas to secure line connections for the safe transfer of fluids. The benefits that accrue thru use of quick connectors include – improved quality of the joints, improved assembly ergonomics (reducing assembly effort), improved productivity (reducing assembly cycle time), easy to disconnect and connect again during maintenance, possible integration of functions (valve, regulator, sensor), etc. When the industry needs to shift to EV and SCR technologies, then selection of materials, injection molding process parameters, on-process quality control and validation of finished product will play vital role in design and product development for QC. In EC, the connectors will require to offer proper protection and deliver AC power to the vehicle’s onboard charger meeting SAE J1772. The power density and lifelong performance maintaining climatic control are main desired requirements. The major challenges for SCR technology development are – DEF freezes at -11°C, requirement of electrically heated plastic urea tube systems, loss of power irrespective of plastic tubes are good insulator, etc. Some other materials and process challenges for both SCR include – low viscosity of urea fluid which has tendency to creep out at every possible voids and tearing of the heated rods. Variety of design approaches are available which will require evaluations such as – unheated SCR systems, coolant heated SCR systems, electrically heated systems. The methodology in validation of product is emphasized in the technical paper.