Four Key Points to Consider When Selecting Automotive Connectors

With the development of transportation technology, the connector industry is moving toward a new generation of miniaturization, lightweighting, and multi-functionalization.

Many automotive connectors have been on the market for decades. Traditional connectors are widely used in modern automobiles, light trucks, motorcycles, and other vehicles. Transportation technology has changed dramatically. To meet consumer demand for safer, smarter, and more eco-friendly vehicles, significant advances are being made in transportation technology. These developments often require designers and OEM manufacturers to seek new interconnection solutions. New developments in vehicle propulsion systems are a key driving force behind this task. Examples include the following factors:

In addition, the growing popularity of electronics in automobiles, especially passenger cars and light trucks, means there are far more electrical connections than ever before. Even entry-level vehicles now have 30 to 50 electronic control units (ECUs), while a luxury vehicle can have as many as 150 ECUs. Meanwhile, a high-tech vehicle may contain up to 65 central processing units (CPUs), which demand another level of technical performance from connectors.

When high-voltage interconnection systems are used, electrical designs must also account for clearance and creepage distances. Since connections for high-voltage applications are typically larger than traditional 12V interfaces, this can create additional design challenges. More importantly, all connections must fit within the same limited space, creating spatial challenges due to the larger overall cable and connector volumes in electric vehicle systems.

Identifying the latest generation of vehicle interconnection solutions requires consideration of the following points.

As OEMs integrate higher levels of functionality into vehicles, the number of interconnection units continues to rise, along with increasing power requirements. However, design space remains largely limited and fixed. Miniaturization has been a major industry trend for many years, and compact connectors offer one solution. Therefore, when evaluating interconnection systems, seek an optimal balance between compact size and power handling capability.

Choosing more compact connectors has often meant compromising functionality. Today, however, connector suppliers offer an expanded range of highly reliable miniature connectors that meet global OEM specifications for temperature resistance, vibration resistance, and sealing performance. These interconnection systems also feature secondary locking, clip retainers, latch protection, and other options.

A connector system with a wide wire size range provides OEMs with greater flexibility across entire vehicle application systems. Connectors can remain unchanged even with different current requirements, with only the wire size needing adjustment. A single, reusable connector system simplifies and speeds up design and manufacturing, while also delivering a more cost-effective solution for OEMs. A wire size range that can support and maintain the specified ingress protection (IP) rating of the connector is particularly valuable.

Flexibility in a connector system enables greater functionality, higher integration, and more opportunities to improve electrical design and overall vehicle experience. Ultimately, the greater flexibility a connector system provides, the more OEM manufacturers can save on space, weight, time, and cost.