Architecture design and small wire diameter of automotive electronic neural system
It is a fitting term to use "complex" to describe today's cars. Safety, handling, driving and entertainment are just some of the subsystems that rely on electronic / electrical architecture. Today's drivers expect their vehicles to operate with infinite precision and without interruption. But the interior of the electronic nervous system that controls the entire car is so complicated. Today, most cars use more than a mile of wires, a dozen controller modules, and several serial data networks to meet the functions that are currently needed on the market.
The necessity of "architectural design"
As cars gradually have more and more electronic control systems such as navigation systems, satellite broadcasting, airbags, temperature control, 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 manufacture the entire system to meet their needs.
"Architecture design" is the process of defining the vehicle's electronic and electrical systems in the early stage of the vehicle design process. Like a master architect building a house or a tall building, automotive electronics / electrical engineers create virtual models of electronic / electrical architectures with extensive experience and proprietary design tools. Through computer testing and simulation tools, the design ideas are verified to ensure that they can meet customer requirements in terms of cost, weight, and layout.
The attention to detail and meticulousness in the early stages of design ensure that a complete electronic / electrical architecture system can be created for the customer. Compared with the previous design, Delphi engineers found that the redesign can reduce the overall weight of the vehicle by up to 20%, the cost can be reduced by up to 30%, and effectively improve the performance of the vehicle. In addition, the electronic / electrical architecture provided by Delphi has also greatly improved the reliability of vehicle operation, ease of assembly and compatibility.
The elaborate design of the electronic / electrical architecture involves all areas of the vehicle, including the harsh driving environment and high-density layout. The electronic / electrical architecture fulfills the automotive manufacturer ’s product philosophy and also meets the vehicle owner ’s expectations for performance and functionality. The electronic / electrical architecture also helps to improve the layout space, enabling electronic / electrical components to be placed in narrower or more accessible places. In some cases, it can even omit some special components completely, which greatly reduces the cost.
In order to reduce the cost of products by 1 ~ 3%, spare parts suppliers have made unremitting efforts to continuously improve efficiency. However, if the entire car is developed as an organic system, then the cost savings in the entire system will be more. There will only 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 open standards for electronic / electrical architecture. Members include automotive manufacturers, electronic component suppliers, semiconductor suppliers and tool suppliers). The first stage of development. The goal of AUTOSAR is to standardize the design of software to achieve interchangeability between components made by different manufacturers, while also enabling easy transfer of functions between different hardware. The BMW Group has applied AUTOSAR in the fourth quarter of last year to the new BMW 7 Series of production vehicles. Automakers are aiming to achieve higher flexibility, lower costs, and develop new directions for automotive electronic systems. The head of the R & D department of the BMW Group's electronic / electrical and driving environment system also clarified the future development goal: BMW will fully apply the AUTOSAR system in all vehicles produced.
Energy-saving and environmentally friendly small wire diameter conductor
From consumer electronics to automotive systems, technological advancements are moving toward miniaturization to achieve smaller and lighter goals. From the perspective of car manufacturers, weight reduction is the key to improving fuel efficiency and reducing CO2 emission standards, and thus meeting current and future government regulations. Electrical components are becoming more and more compact, and some companies now plan to use 0.13mm2 cross-sectional area wires. 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 inseparable. For most product innovations to become a reality and generate tangible benefits, it is often necessary to develop unique processes. The same applies to the application of small-diameter wires 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 the usual manual wiring and plugging of connector terminals: this process not only depends on the operator being able to correctly identify the wire with the naked eye, but the operator must also be able to see the correct hole position into the connector. However, if you start to use a wire with a cross section of only 0.13mm2 or less (its diameter is approximately equivalent to the thickness of the nail), the human eye cannot distinguish the code, size, and color of the wire, and it is also difficult to distinguish the holes connecting the system terminals. The thinner the wire, the smaller the terminal, of course. In addition, the rigidity of the wire cannot guarantee that the terminals are properly inserted. Delphi ’s ultra-thin-wall halogen-free wire can ensure the specified rigidity of the minimum 0.13mm2 wire manual insertion operation, and the automated manufacturing process can improve the reliability of terminal insertion.
The trend of automated assembly and miniaturization will help to promote the development of next-generation weight loss technology, increase the flexibility of production scale and improve the quality of off-line. For example, according to some application case studies, after adopting Delphi's honeycomb chip integration (waferizaTIon), automation and miniaturization technology, the traditional wiring harness can be used without any parallel connection, reducing the amount of copper wire by 50%, and can also reduce 40% The weight of the wire harness, and the outer diameter of the wire harness has also been reduced by 20%. It is for this reason that Delphi will develop new processes at the Technology Center in Champion, Ohio, and Wuppertal, Germany, to ensure that the manufacturing process can meet small wire diameters in terms of flexibility and functionality. Application requirements. By designing unique process and equipment by yourself, and combining the capabilities of equipment suppliers, we can ensure the efficiency of the process and the capabilities of equipment, such as small cutting machines and automation supporting technologies. Delphi is developing new non-crimp terminal technology and small wire diameter.
These are practical solutions to practical challenges. Delphi ’s product technology and manufacturing processes are transforming these concepts into practical products, achieving tremendous benefits in layout and weight reduction, and thus helping automakers meet the needs of global consumers and the environmental standards set by governments.
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