Feature: Interconnects
Traditional bus systems like CAN and FlexiBus are becoming increasingly inadequate for this data-intensive environment, paving the way for the adoption of Automotive Ethernet, which offers a streamlined, two-wire solution, capable of handling advanced data requirements
Sensor connectivity Typically these sensor applications come with integrated connectors. For instance, upon examining the interior of a radar sensor housing, you would find six to eight pins, all of which are press- fit and insert-moulded. Tier-1 suppliers receive these radar sensors with pre- integrated terminals, allowing them to easily press-fit their PCB hardware onto the sensor, seal the housing and complete the assembly. As the automotive industry shifts to
more advanced sensors, the integration of Automotive Ethernet within these setups becomes essential. The Automotive Ethernet structure now has a couple of terminals that are press- fit because there are still low-speed signals within the radar housing. These are next to a solder-based Ethernet connector, which means a soldering process must be added into the radar housing assembly – which is not ideal. Opting for additional soldering not only prolongs the assembly time but also generates unwanted fumes and calls for additional cleaning, complicating the manufacturing process.
The adoption for press-fit pins By having access to press-fit interconnects, automotive customers are presented with a far simpler and faster assembly process, with a much lower risk of errors occurring. Moreover, press-fit solutions align seamlessly with existing Tier 1 assembly lines, requiring no modifications to current manufacturing practices.
26 April 2024
www.electronicsworld.co.uk As solder use is eliminated, there are
no problems caused by variations in the amount of solder paste applied (and the capacitance associated with this). In addition, the shortness and lower capacitance of press-fit pins, compared to through-board solder pins, means resonance is reduced. For both of these reasons, greater signal integrity can be achieved. Additionally, a press-fit strategy
supports manufacturing operations to be conducted in a socially responsible way, with minimal impact on the environment, in comparison to
soldering processes that create solder fumes during assembly.
More factors are involved Another critical factor to consider is the tighter manufacturing tolerances required for high-speed interconnects. Accuracy in the design and manufacturing of the signal and ground terminals, plastic housing and shielding are paramount, as even minor deviations in shape can significantly affect their electrical performance. This precision becomes increasingly important in high-speed data transmission, where the tiniest deviances impact functionality. Comparing high-speed solder-based
connectors to their press-fit counterparts illustrates this point. Press-fit connectors are designed with precision, featuring pins of exact shape and length that adhere to strict manufacturing tolerances, ensuring minimal variability. When these pins are matched with a PCB of a corresponding hole size, the result is a highly consistent and reliable connection with little room for error. In contrast, solder-based connections
Figure 1: ENNOVI-NET Automotive Ethernet connector technology with press-fit solution incorporated into a radar housing
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