Using "complexity" to describe today's cars is a more appropriate word. Security, control, drive and entertainment are just some of the subsystems that rely on electronic/electrical architecture. Today's drivers want their cars to operate infinitely and without interruption. But the interior of the electronic nervous system that controls the entire car is so complex. Today, most cars use more than a mile of wire, more than a dozen controller modules, and several serial data networks to meet the functions that are currently available on the market.
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The necessity of "architectural design"
As cars increasingly have more and more electronic control systems such as navigation systems, satellite broadcasts, airbags, temperature controls and electric doors, the development of electronic/electrical architecture has also played a pivotal role in the automotive transportation industry. Today's OEMs are more than ever eager to have a supplier who can analyze, design and build their entire system to meet their needs.
"Architectural design" is the process of defining the electronic and electrical systems of a vehicle in the early stages of the vehicle design process. Like architects building a house or a tall building, automotive electronics/electrical engineers create virtual models of electronic/electrical architecture with a wealth of experience and proprietary design tools. Through computer testing and simulation tools, the design ideas are verified to ensure that they meet the customer's requirements in terms of cost, weight and layout.
Attention to detail in the early stages of design and meticulous attention to ensure a complete electronic / electrical architecture system for customers. Compared to past designs, Delphi engineers found that redesign can reduce the overall weight of the vehicle by up to 20%, cost up to 30%, and improve vehicle performance. In addition, Delphi's electronic/electrical architecture has been greatly improved in terms of vehicle reliability, ease of assembly and compatibility.
The careful design of the electronic/electrical architecture involves all areas of the vehicle, including harsh driving conditions and high density arrangements. The electronic/electrical architecture fulfills the automotive manufacturer's product philosophy and also meets the owner's expectations for performance and functionality. The electronic/electrical architecture also helps to improve the layout space so that electronic/electrical components can be placed in tighter or more accessible locations. In some cases, it can even completely eliminate some special parts, which greatly reduces the cost.
In order to reduce the cost of products by 1 to 3%, component suppliers have made unremitting efforts to continuously improve efficiency. However, if the entire car is developed as an organic system, the cost savings will be greater throughout the system. There will be more and more content to be developed in the future. Automotive Open System Architecture (AUTOSAR - AUTOSAR International Alliance was established in 2003 to establish an open standard for electronic/electrical architecture. Members including automotive manufacturers, electronic component suppliers, semiconductor suppliers and tool suppliers) have just completed The first phase of development. The goal of AUTOSAR is to standardize the design of software to achieve interchangeability between components manufactured by different manufacturers, while also enabling easy transfer of functions between different hardware. In the fourth quarter of last year, the BMW Group has applied AUTOSAR to the new BMW 7 Series for production cars. Automakers aim to achieve greater flexibility, lower costs, and new directions for automotive electronics systems. The head of the BMW Group's Electronics/Electrical and Driving Environment Systems R&D department also defined the future development goals: BMW will fully apply the AUTOSAR system to all vehicles produced.
Energy-saving and environmentally friendly small wire diameter wire
From consumer electronics to automotive systems, advances in technology are moving toward miniaturization to achieve smaller, lighter goals. In the eyes of automakers, weight reduction is key to improving fuel efficiency and lowering CO2 emissions standards to meet current and future government regulations. Electrical components are becoming smaller and smaller, and some companies now plan to use wires with a cross-section of 0.13 mm2. The result of continuous improvement is to make electronic/electrical systems smaller, lighter, and more reliable.
The connection between the product and the process is inextricably linked. In order for most product innovations to become reality and generate tangible benefits, it is often necessary to develop unique processes. The same applies to the use of small wire diameters in automotive electrical/electronic systems. It is important to be able to reliably produce and process thinner wires, but the wire harness assembly process must also be improved to ensure consistent and reliable application of these wires.
This is a challenge for conventional manual wiring and connector terminal insertion: this process depends not only on the operator's ability to correctly identify the wire, but also the operator must be able to see the correct hole in the push-in connector. However, if you start to use a wire with a cross section of only 0.13 mm2 or less (the diameter of which is approximately equivalent to the thickness of the nail), the human eye cannot distinguish the coding, size and color of the wire. It is also difficult to distinguish the hole position of the system terminal. The thinner the wire, the smaller the terminal will of course be. In addition, the rigidity of the wire does not guarantee the insertion of the terminals. Delphi's ultra-thin wall halogen-free conductors guarantee a specified stiffness of a minimum of 0.13mm2 wire for manual insertion, while automated manufacturing processes improve the reliability of terminal insertion.
Automated assembly and miniaturization trends will help advance the next generation of weight reduction technology, increase production scale flexibility and improve a downline quality. For example, according to some application examples, after using Delphi's honeycomb wafer integration, automation and miniaturization technology, traditional wire harnesses can be used without any parallel connections, reducing copper wire usage by 50% and reducing by 40%. The harness weight and the outer diameter of the harness are also reduced by 20%. It is for this reason that Delphi will develop new processes at the Technology Center in Champion, Ohio, and the Technology Center in Wuppertal, Germany, to ensure that the manufacturing process meets small wire diameters in terms of flexibility and functionality. Application requirements. By designing unique processes and equipment, combined with the capabilities of the equipment supplier, we ensure the efficiency of the process and the capabilities of the equipment, such as small cutting machines and automation technology. Delphi is developing new dieless terminal technology and small wire diameters.
These are practical solutions to practical challenges. Delphi's product technology and manufacturing processes are transforming these concepts into practical products that deliver significant benefits in placement and weight reduction, helping automakers meet the needs of global consumers and environmental standards set by governments.
With Push-in connection technology, you can connect conductors easily – both directly and without tools, insert forces reduced by 50%. it is suitable for various applications. Insert rigid conductors or conductors with ferrules from 0.25mm² into the conductor shaft.The contact spring opens automatically and provides the required pressure force against the current bar.
When installing smaller conductors from 0.14mm², use a standard screwdriver to push the orange button and actuate the contact spring.
Push-in Connection have test and passed various certificates. For example, Vibration resistance in accordance with railway standard DINEN50155,shock and corrosion resistance in accordance with current shipbuilding registers.
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