Automotive
Vehicle electronics depend on ever-smaller connectors
By Rolf Horn, applications engineer at DigiKey A
uto manufacturers continually add or improve features and functions to their vehicles, many of which are dependent on electronic control units
(ECUs). However, space is limited, prompting a continual drive for miniaturized and more efficient connectors to handle power flow and communications to ensure functioning electronics and electrical systems. Today’s door mirrors are a prime example: It’s not unusual for these devices to incorporate motors, blind spot monitoring indicators, turn signal lights, heating elements, ground illuminators, keyless entry system antennas, and even ultrasonic wave generators to blow off water droplets. That’s a lot of electronics—all of which must be waterproof and highly resistant to vibrations—contained in a relatively compact housing.
The auto industry is in the throes of a massive transformation, fuelled by continuing computerization of features and functions, and massive investments by governments and industry aimed at accelerating a transition away from internal combustion engines. Vehicles are increasingly-mobile computer systems that automakers envision paving the way to new revenue- generating connected-car services. Advanced driver assistance systems (ADAS), autonomous driving, predictive maintenance, and shared ownership models are also contributing to the shift in emphasis toward software-driven vehicles. These forces will also impact component suppliers who must adapt amid a highly disruptive transition as automakers fine- tune their strategies to match consumer expectations and demands, which can quickly shift. Several auto manufacturers have accelerated or decelerated their plans to shift to electric vehicles (EVs), for example, and supply chain management remains a persistent issue that can
22 July/August 2024
Figure 1: The MX80B02PZ1A 2-pin in-line connector housing (Source: JAE Electronics)
Figure 2: The MX80A02SZ1B 2-position socket connector. (Source: JAE Electronics)
complicate supplier relationships. One certainty to plan for is the continuing demand for the miniaturization of components as auto manufacturers seek to add more electronics capabilities within an overall vehicle footprint that varies little year to year.
Component suppliers must design smaller products, and they must also plan on increasing the performance of those products as manufacturers seek to take advantage of more ECUs crowding limited space. Connectors—which are often a final thought when designers plan new products— are becoming more critical in the design process as manufacturers look for smaller modules and routing cables.
Going big by getting small and more reliable
Cables and connectors essentially provide the central nervous system and must become more innovative and compact to support the expanding role of computers and sensors. In some cases, traditional connectors in today’s vehicles may be larger in size than
Components in Electronics
the modules that depend on them. They must become smaller, more reliable, and enable more flexible configurations in tight and crowded spaces, making them increasingly difficult to service.
The miniaturization of connectors has often been accomplished at the cost of performance, which is unacceptable to manufacturers operating within stringent testing criteria and seeking competitive advantages. The door mirrors cited earlier illustrate
the need for more sophisticated capabilities that raise the technical requirements for connectors. Automotive customers and component suppliers are demanding connectors that save space, carry high currents, improve workability, and resist water and high vibration.
Engineers at JAE Electronics, a global top 10 interconnect supplier, took on the challenge by designing a waterproof automotive connector that provides the performance, design, and flexibility needed
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