Molex MX150 connector, widely applied in the automotive wiring harnesses thanks to its water resistance, IP67-rated and high vibration resistance. Its sealed structure has a leak rate <0.01 ml/min when the connector was 1 meter water soaked for 30 minutes (0.1 ml/min is allowed by industry standard IP67). It will pass the USCAR-2 vibration test (frequency 10-2000 Hz, acceleration 50 m/s 2). Contact resistance variation is less than 0.5 mΩ (2 mΩ for a traditional connector). For instance, once Tesla Model 3’s high-voltage battery harness uses MX150, the failure rate of the harness decreases from 9 cases per thousand vehicles to 0.7 cases, and the cost of bicycle maintenance is lowered by 85 percent within the warranty period (saving 42.5 million yuan for every 500,000 vehicles yearly).
Another significant benefit is adaptability to extreme temperatures. MX150 keeps contact resistance deviation ≤1.5% (5% for comparable products) under the temperature -40°C to 125°C, and insertion and withdrawal force still remains 95% of the original value after temperature cycle test (-40°C⇄125°C, 1000 times). It uses the MX150 in the car harness for a German car company. This way, the total connector life can be extended to 15 years from 5 years. Number of insertions increases from 200 to 500. This results in reduction of total harness weight by 12% that is from 8.7kg to 7.6kg. Thus, energy consumption by the vehicle reduces by 0.8%.
Electrical performance and safety meet demanding requirements. The MX150 has a terminal coating thickness of 0.8μm (industry standard 0.3μm), a temperature rise of only 7°C at 85A current load (15°C for conventional connectors), and a 53% reduction in power loss. After MX150 is accepted by the BMS (battery management system) of Toyota hybrid cars, the contact resistance of the high-voltage circuit is reduced from 1.2mΩ to 0.8mΩ, the transmission efficiency of energy is increased by 1.2%, and the carbon emissions per year are reduced by 1.3 tons/vehicle. It is qualified with UL 1977 (3000V AC) for leakage current <0.5μA and meets the ISO 20653 road vehicle waterproofing requirement.
Cost performance and supply chain efficiency are necessary. The price of MX150 is 0.35 (common connector 0.18), but the installation time is 40% less (blind insertion design tolerance ±0.1mm, misinsertion rate from 1.5% to 0.1%), and the efficiency of the production line is 22% higher. Since GM implemented the MX150 in its Mexico factory, the assembly time of a single model harness was decreased from 120 minutes to 74 minutes, with a savings of $8.6 million in labor costs annually. In addition, its modular design accommodates AWG28−8 wire diameters (9,912,000 / month).
Compliance and certification benefits accelerate time to market. MX150 reached VDA 6.3 (Automotive Process Audit) and LV 214-2 (Automotive Connector standard) on the first try, reducing the certification process from the usual 18 months to 10 months. Through the adoption of MX150, Volkswagen’s ID.4 project has reduced the verification of the wiring harness system by 30%, brought the vehicle to market time 14 weeks ahead, captured 3.2% of the European electric vehicle market, and raised revenue by 750 million euros within its first year.
Severe environmental validation case: Saudi Arabian desert road test, using daytime temperature 58°C and dust density >5 g/m³. The MX150 connector completed the testing after 100,000 km with IP67 protection guarantee, contact resistance variation <0.3 mω, and failure rate 0.2% with 4.7% for the competitors’ products. Every 1% improvement in the failure rate can save a car maker US$ 1.2 million in warranty annually.
Due to water resistance, heat resistance, vibration resistance, and electrical efficiency problems according to the overall optimization requirement to become the cornerstone of car wiring harnesses in response to the challenges of electrification, light weight, and intelligence, molex mx150 is developed to enhance reliability, prompt automobile companies to save costs and enhance efficiency and recreate industrial standards.