Consumers expect a more connected experience everywhere they go, including their cars, and automakers are racing to design more features into less space. As a result, 50% of a new car’s cost will come from electronic components.
Most of today’s new cars offer customizable digital dashboards, multiple screens for driver and passenger infotainment options, touch controls for seats and lighting, and advanced safety features to protect the driver and passengers.
All these features require their own wiring systems, which are encased in an electronic control unit (ECU) attached to the wiring harness. And now automakers and component manufacturers are racing to miniaturize everything to fit more content into the same amount of space.
The challenges of integrating more electronics into vehicles
This increased amount of wiring adds weight to a car. In fact, wiring is now the third-heaviest component in the car, behind only the engine and the chassis, and it’s the third-most expensive part to produce.
These challenges grow when considering overall energy efficiency into the design. A feature-heavy harness adds drag and reduces gas mileage for cars with internal combustion engines. The added weight also contributes to the production of more carbon-laden emissions. In EVs, every new feature has the potential to drain power from the battery and decreases driving range.
The growing demand for miniaturized electronics
To fit all the new electronics into vehicles while lightening the load, manufacturers and their suppliers need to shrink modules and components to the maximum extent possible, all while enabling 100 million lines of software code to be transmitted quickly and reliably throughout the car.
Electronics producers have been working closely with manufacturers and Tier 1 suppliers to cut down on both space and weight. As an example, Molex has reduced the size of wiring harness terminals carrying heavy currents from the standard 1.5 mm2 to just 0.13 mm2. Lower-current terminals have been reduced from 0.64 mm2 to 0.5 mm2.
While these numbers may appear small, they add up to a big difference. In fact, compared to traditional systems, Molex miniaturized connector systems can create 50% more board space on devices within the vehicle. This frees room for the OEM to incorporate more advanced semiconductors on the board to support expanded functionality while helping harness manufacturers reduce weight.
Finding rugged connectors for harsh environments
Automakers must also ensure the reliability of sensitive electronic equipment in harsh interior and exterior environments. Within the chassis, temperatures of over 100 degrees combined with strong, frequent vibrations can loosen connections. There’s also condensation from moisture that seeps in from the outside, while incoming dirt and grime erode the casings — which is more prevalent in trucks and tractors. Water may also be introduced during manufacturing, and assembly errors can cause contacts to back out during operation.
The more software and hardware connections a vehicle contains, the greater the chance for problems. And as driver assistance systems move closer to autonomy, the stakes are growing higher. Preventing accidents—and potentially saving lives—requires enormous amounts of data to be reliably transferred in near-real time.
Solutions for space constraints and rugged environments
Recent innovations in electronics are helping manufacturers solve these complex problems. For example, Molex has developed miniaturized connectors, such as the Mini50connectors, for power steering, cameras, sensors, braking systems, exterior lighting and mirrors. Designers can also conserve space by arranging wires with stackable connection systems, such as Molex’s Stac64 connectors, grouping components for unsealed applications in flexible configurations.
Rugged applications can be subject to shock, vibration or rough handling that can dislodge terminals and cause signal interference. Secure mating and PCB retention is required for high-vibration applications. Molex’s MXP 120 connectors offer miniaturized solutions with superior electrical contact reliability and solutions that maintain performance in high-heat applications such as lighting systems, with ambient temperatures ranging from -40ºC to +125°C.
A trusted supplier of rugged and reliable miniaturized connectors
With years of expertise across the spectrum of connectors, Arrow and Molex provide a unique partnership offering solutions from the design phase through testing and delivery. Explore Molex’s solutions on Arrow.com to learn more about how your automotive connection systems can meet cost and space requirements while providing reliable transmission and durability in the toughest conditions.