With the increasing degree of electronics in automobiles, automobile architecture is undergoing a profound change. TE Connectivity (TE) takes a deep dive into the connectivity challenges and solutions for next-generation automotive electronics/electrical (E/E) architectures.
Transformation of intelligent architecture
Modern consumers’ demand for cars has shifted from mere transportation to a personalized, customizable driving experience. This shift has driven the explosive growth of electronic components and functions within the automotive industry, such as sensors, actuators, and electronic control units (ECUs).
However, the current vehicle E/E architecture has reached the limits of its scalability. Therefore, the automotive industry is exploring a new approach to transform vehicles from highly distributed E/E architectures to more centralized “domain” or “regional” architectures.
The role of connectivity in centralized E/E architecture
Connector systems have always played a key role in automotive E/E architecture design, supporting highly complex and reliable connections between sensors, ECUs, and actuators. As the number of electronic devices in vehicles continues to increase, the design and manufacturing of connectors are also facing more and more challenges. In the new E/E architecture, connectivity will play a more important role in meeting growing functional requirements and ensuring system reliability and security.
Hybrid connectivity solutions
As the number of ECUs decreases and the number of sensors and actuators increases, the wiring topology evolves from multiple individual point-to-point connections to a smaller number of connections. This means that ECUs need to accommodate connections to multiple sensors and actuators, creating the need for hybrid connector interfaces. Hybrid connectors can accommodate both signal and power connections, providing automakers with an effective solution to increasingly complex connectivity needs.
In addition, as features such as autonomous driving and advanced driver assistance systems (ADAS) continue to develop, the demand for data connectivity is also increasing. Hybrid connectors also need to support data connection methods such as coaxial and differential connections to meet the connection needs of equipment such as high-definition cameras, sensors, and ECU networks.
Connector design challenges and requirements
In the design of hybrid connectors, there are several critical design requirements. First, as power density increases, more advanced thermal simulation technology is needed to ensure the thermal performance of connectors. Second, because the connector contains both data communications and power connections, electromagnetic interference (EMI) simulation and emulation are required to ensure optimal spacing and design configurations between signals and power.
Additionally, within a header or male connector counterpart, the number of pins is higher, requiring additional protective measures to prevent damage to the pins during mating. This includes the use of features such as pin guard plates, kosher safety standards, and guide ribs to ensure mating accuracy and reliability.
Preparation for automated wire harness assembly
As ADAS functionality and automation levels increase, networks will play an increasingly important role. However, current vehicle E/E architecture consists of a complex and heavy network of cables and devices that require time-consuming manual production steps to produce and assemble. Therefore, it is highly desirable to minimize manual work during the wire harness assembly process to eliminate or minimize potential sources of error.
To achieve this, TE has developed a range of solutions based on standardized connector components specifically designed to support machine processing and automated assembly processes. In addition, TE works with machine tool manufacturers to simulate the housing assembly process to verify feasibility and ensure the accuracy and reliability of the insertion process. These efforts will provide automakers with an effective solution to cope with increasingly complex connectivity needs and increasing production efficiency requirements.
Outlook
The transition to simpler, more integrated E/E architectures provides automakers with an opportunity to reduce the size and complexity of physical networks while standardizing the interfaces between each module. Additionally, the increasing digitization of E/E architecture will enable complete system simulation, allowing engineers to account for thousands of functional system requirements at an early stage and avoid critical design rules being overlooked. This will provide automakers with a more efficient and reliable design and development process.
In this process, hybrid connector design will become a key enabler. Hybrid connector designs, supported by thermal and EMC simulation and optimized for wire harness automation, will be able to meet growing connectivity demands and ensure system reliability and safety. To achieve this goal, TE has developed a series of standardized connector components that supports signal and power connections, and is developing more connector components for different types of data connections. This will provide car manufacturers with a flexible and scalable solution to meet future challenges and needs.
Post time: Apr-10-2024