The connection functions contained in vehicles are becoming increasingly rich, and new automotive technologies are advancing rapidly. Soon, the space inside the vehicle will be insufficient. Robust and durable micro connectors can meet the huge demands for performance and space in demanding vehicle applications.

Author: Kirk Ulery, Business Development Manager of Molex

     Whether it is new energy sources other than gasoline or fully autonomous vehicles, the automotive industry is experiencing an era of surging new technologies and new functions. Nowadays, electronic devices usually account for more than half of the value of a vehicle. Each new function added requires a new module called the Electronic Control Unit (ECU). The latest cars use 100 to 150 such ECUs, and each ECU has its own dedicated connections and circuits. These modules, along with the increasing number of sensors, motors and other components, have brought about a huge demand for connection solutions.
    Vehicle manufacturers are facing a severe challenge: the space inside vehicles is getting smaller and smaller, unable to accommodate these constantly expanding systems. Connecting hundreds of components requires a lot of wiring, which means that cable harnesses have now become one of the most complex structures in vehicle manufacturing, and the next generation of cars will offer even more functions. As vehicles continue to evolve and develop, their functions will become more powerful, and thus the demand for compact high-performance connectors that can withstand harsh conditions will also increase.

Solve increasingly complex problems
     The brand-new technologies being introduced in the automotive industry will define the next generation of automobiles. Manufacturers are keen on leveraging the latest 5G wireless communication technology to enhance security and user experience. Vehicles will become part of a dynamic network, capable of sharing information with other road users and even traffic control infrastructure, making travel safer and more efficient. This kind of "vehicle-to-everything" (V2X) communication requires vehicles to be equipped with more sensors, control devices and computing capabilities.
    This will be even more important for the development of autonomous driving or "self-driving" vehicles that have received widespread attention and anticipation. Advanced driver assistance systems (ADAS) have provided drivers with complex road safety solutions. Whether a vehicle can interact with other road users will depend on whether the system can collect, analyze information about the surrounding environment and take action with the lowest possible delay.
    However, the vehicle environment poses challenges to safety-critical systems. Even a momentary connection interruption caused by vibration can lead to the loss of a large amount of important information. Designers need a series of micro-connector solutions that can not only withstand vibration but also provide data transmission rates several times higher than those of today's automotive systems.
 
Support the new automotive architecture
     Each car has approximately one mile of wires and hundreds of connectors. The number of copper cables directly affects the performance of the vehicle, especially when all sectors encourage people to adopt smaller and more efficient means of transportation. The weight of a large amount of copper cables will consume the vehicle's endurance and performance. To solve this problem, the concept of zonal architecture has been proposed.
    The partitioned architecture is a method for building vehicle electronics. Unlike the domain architecture, the partition architecture provides a more effective solution; Domain architecture groups systems by function, while partition architecture divides the functions within a vehicle into several areas based on their locations. Each area is responsible for managing the equipment installed in a specific part of the vehicle and connecting it to the nearby zone controller or gateway. Because the partition gateway is relatively close to the devices it controls, the cable length required to connect these devices is relatively short. This makes it even more necessary to have reliable micro connectors to connect these shorter cables.
    Each partition gateway is connected to the central computing cluster of the vehicle center. The communication between the partition gateway and the central computer is similar to that of a computer network. Therefore, communication between various zones can be carried out through small high-speed network cables, thereby significantly reducing the number and size of wiring harnesses inside the vehicle.
    The zoning structure also creates brand-new ways for managing power distribution and high-speed communication. The traditional voltage of a vehicle power supply is 12V, but when a voltage as high as 48V is adopted, the current will decrease accordingly while providing the same energy to the device, thus allowing designers to use smaller-sized wires and smaller connectors. For example, when providing the same amount of electrical energy as a 12V system, a 48V system can use 10 AWG wires instead of 4 AWG wires. Just the wiring alone can reduce the weight by up to 85%. In the entire automotive wiring harness, reducing weight has a significant effect on improving efficiency.

The micro connector integrates all components
     The partitioned architecture has brought changes to vehicle manufacturing, thereby affecting the design of connectors. The connection between the device and the partition gateway requires a new generation of hybrid or combined connectors, which can simultaneously carry power and high-speed signals. For example, Molex's stAK50h connector system has a hybrid contact function, allowing designers to combine signal, data and power functions in each connector and reduce the required space. The stacked housing of this connector system simplifies the design and installation of the wiring harness and complies with USCAR-2 and global automotive OEM standards, thereby simplifying the application.
    Not all connectors will be exposed to external conditions, so a brand-new solution of "inside the box" is still needed. Connectors used for central computing clusters need to provide high density and low side height, while also being able to provide a large number of circuits. The existing wier-to-board solutions can provide the required connectivity, but their performance is not stable enough to withstand the continuous shock and vibration in vehicle applications.
Molex's DuraClik wire-to-board connectors offer stable connection and high PCB retention in applications that require strong vibration resistance. The DuraClik series has undergone extensive testing and complies with the LV214 and ES91500-03 regulations for the vehicle markets in Europe, China and the United States.
    Micro connectors are the key to achieving functional expansion. Molex's ConnTAK50 system features a small package and offers both single-row and double-row connector systems, making it easier to design new functions. The ConnTAK50 terminal adopts a two-piece crossbeam design, which offers stronger vibration resistance while providing outstanding electrical performance. The ConnTAK50 system is used in up to 22 circuits, with each contact having a rated current of up to 6 amperes. Its compact package saves space and is not inferior to the Molex Mini50 connector.

Molex: Offering future-oriented solutions
     The zoning structure is the greatest change in the field of vehicle design in decades. Vehicles with a zoned structure will reduce wiring requirements, thereby reducing weight, lowering costs, and improving performance at the same time. However, the continuous increase in the functions of the next generation of vehicles will put forward higher requirements for space. Designers will need methods to connect power and high-speed data in harsh automotive environments, while also providing the high reliability that consumers expect.
    Molex's innovative micro-connection solutions provide robust and reliable performance for the harsh conditions of the automotive environment. They are small in size and light in weight, making positive contributions to improving the efficiency of the automotive industry.