Automotive Electronic Connectors

The implementation of electric vehicles requires close cooperation between component manufacturers and original equipment manufacturers. Keeping pace with electric vehicles, self-driving cars have become the second biggest challenge. In different driving assistance systems, data need to be collected and processed by a large number of sensors, and the actuators are controlled accordingly. Only a reliable and secure network or connection can achieve good interaction between multiple systems. The connector system must not only be as compact as possible, but also have strong vibration resistance, sealing, temperature resistance, large current carrying capacity and easy operation in harsh and usually close to the engine environment. To achieve this, there are many connector solutions optimized for the automotive industry. Ultimately, the realization of electric vehicles and automation requires unprecedented connectivity in the vehicle, which requires high-performance, space-saving, and reliable connector solutions. Applications range from highly sensitive front and rear camera solutions to sophisticated headlight systems with dynamic cornering lights and airbags that can be precisely adjusted to the weight of the passenger. Connectors similar to Koshiri are used in the electronically controlled steering system and headlamp range adjustment system. Space-saving cable connectors can also be found in the reversing camera and park assist sensors. In many cases, the corresponding connector not only has certification such as ISOTS16949 or meets Koshiri specifications, but also provides sufficient design margin to handle larger currents or voltages at small pitches. The MiniBridge (1.27 mm pitch), MaxiBridge (2.54 mm) and MicroBridge (1.27 mm) cable connectors also meet the applicable LV214 specifications. Electrical, climatic, mechanical, and corrosive stresses were determined in 29 tests. The battery management system and the corresponding power electronic equipment (inverter) play an important role in electric vehicles. The BMS ensures safe charging and discharging of the battery and monitors the battery cells. It is generally not installed directly in the high voltage battery, but connected through a decoupled bus system (such as CAN). Basically, the contact resistance at the charge input must be as low as possible. As such, this is why the connector needs to have a minimum contact resistance that remains substantially constant even as the temperature rises. This can be accomplished by proper contact design. Increasing market penetration of LED technology is another growth driver for automotive lighting systems. Especially in the headlights, there is a clear tendency to turn to LEDs. The corresponding connector system, tested according to the vehicle standard, must ensure that the components function properly in all weather and road conditions. Interlocking performance is good and SMD welding point is firm, which can resist severe vibration. Even high temperatures in the narrow space of the headlight (150 ° C) should not cause any problems. A flexible and small form factor wire-to-board solution and a high degree of plug reliability are key here. Confined space LED systems are typically wired or modularly connected to a printed circuit board. Properly assembled Mini Bridge cable connectors accommodate both ribbon and single cables for a particularly simple, flexible and cost-effective installation. Mini Bridge connectors are also available with white insulation for this type of compact lighting task. Connectors with colorless insulation to avoid shadowing effects in lighting applications, such as led light bars, use transparent diffusing lenses to ensure uniform light distribution. The automotive industry has a very high demand on the reliability of the connector process. The male connector must not be broken, especially when the male and female connectors are inserted askew. The Koshiri version of the Mini Bridge connector ensures that this requirement is met during the mating process. Its 4-pin version, measuring only 10mm X 10mm X 3mm, is able to achieve a high current-carrying capacity over a wide temperature range of -55 ° C to + 125 ° C with the right cable, thanks to the use of a special contact material. Right angle, right angle male connectors, female connectors with right angle and straight cable outlets for a wide range of applications. The male connector has SMT terminals for economical machining, while the female connector uses insulation displacement contact (IDC) technology. It also provides a female connector with reliable interlocking capability to accommodate extremely high vibration and shock loads. Originally designed specifically for automotive applications, ERNI has always been able to meet the needs of customers in the automotive industry when developing MicroBridge cable connectors. Initially, wire-to-board connectors were developed to meet stringent automotive test specifications VW75174 and USCAR-2. Koshiri security, optional electronic CPA (Connector Position Assurance) and color and mechanical coding of any number of pins ensure safe, secure and correct connections. For Micro Bridge, the tongue of the female connector and the groove on the male connector allow the connector housing to be pre-aligned to ensure an accurate connection process. The plug of the male connector will not be damaged by the wrong skew insertion. The electrical CPA is able to test the safe contact between the female and male connectors even during coordination. To achieve this, the male connector employs a shortened test pin without signal and power functions. The functional characteristics of high fit integrity and reliable contact described above help to reduce possible failures in production and in the field. The Micro Bridge is solid, even at a tiny 1.27mm pitch. This means that the connector is capable of withstanding the harsh environment caused by vibration or shock loads (as described in VW75174) and high temperatures within the vehicle. This point is determined by the locking mechanism on both sides and the heat resistance. In cooperation, the two housing locking mechanisms provide interlocking audible and tactile feedback. No tools are required to release the locking device. The male connector's welding fixture absorbs mechanical stresses and resists shock and vibration loads. Its high temperature resistance of up to 150 ° C allows the connector to be used in harsh temperature conditions, such as LEDs near the headlights. The rated current for each contact point is 9.0 A at 20 ° C (2-pin format). The Micro Bridge can be used as a single-row male connector in straight and beveled SMT versions. Male connectors are packaged on tape and reel for automatic assembly. Single row female connectors can be used as insulation displacement contacts (IDC). Their export cables are now 90 ° and meet internationally recognized standards. Dual designed insulation displacement terminals ensure contact reliability. In addition, the overall strain eliminates insulation displacement stress due to cable movement. The SMC series with a dual safety separation of 1.27 mm is also recommended for use in the automotive industry where space is critical. For example, the SMC connector series is also available in a 50-pin version with Secure Lock functionality. The Secure Lock version provides a highly reliable electrical contact after a long history of dual beam female contacts. The wire-to-board solution (connector system with IDC female and SMT male connectors) has been modified and optimized accordingly in order to achieve a safe mechanical connection of the two components. This means that even the most demanding applications, such as inverters for electric/hybrid vehicles, can be addressed. The reliability of the lock state (as under vibration and shock loading) is as important as the accuracy of the insertion process. The special construction of the female IDC and male SMT connectors requires a certain amount of force in order to connect the wire to the board. In this way, the user will receive a clear confirmation (audible, tactile) that the connection is safely established. With additional guide rails and a widened locking lever, it is almost impossible to break contact during mating. Use a cost-effective unlocking tool to release the connection.

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