Interconnection


Interconnects for the transportation market

18 March 2015 Interconnection

The pace at which the electrical and electronic architecture of vehicles is being innovated is one of the major challenges facing the automotive industry. An increasing number of these systems enriches modern vehicles and makes them more attractive. At the same time, reliability is one of the automotive industry’s core strengths.

To meet this industry’s demands for intelligent, efficient and high-performing products and solutions that are proven in harsh environments, TE Connectivity has a division dedicated to developing interconnection and passive component technologies.

Terminals and connectors

TE Connectivity has been working on concepts for smaller terminals and connectors, based on its MQS contact family, since 2007. Initially, the NanoMQS terminal was developed and tooled to test electrical performance, and the first housings are now available for serial applications.

These products enable a reduction in printed circuit board (PCB) size for electronic components, smaller wires down to 0,13 mm2 and a reduced total connector package. These features combine to conserve energy and resources while reducing weight and, ultimately, CO2 emissions as well.

NanoMQS supports modular integration, with both primary and secondary locks positioned inline. This enables the connector system to be hybridised with the MQS terminal, PQ, MPQ and MQS 1.5. This unique product offers reductions of up to 50% terminal weight and up to 55% housing weight and package reduction, compared to conventional solutions.

In addition, the headers can be designed for press fitting, through-hole and SMD, with board termination technology to complement a wide range of product options.

Wire crimp termination

TE Connectivity has developed a crimping solution to the challenges of terminating stranded aluminium wires in vehicle applications. The LITEALUM crimp, its surface topography, and geometry have been specially tailored to the material properties of aluminium conductors.

Among other things, the durable electrical connection is not based on the residual stress in the crimp barrel. Instead, it is the partial cold-welding of aluminium and copper, brought about during the crimping process, which ensures the interconnection. As the residual stress of the barrel is below the threshold that could cause creep, a potentially problematic shrinkage of conductor material from the contacting area is avoided.

During the crimping operation, the edges of the serrations break up the thin oxide layer on the conductor and enlarge the interconnection area. During cold-forming, the cross section is greatly reduced (typically by more than 50%) to establish a solid intermetallic connection between copper and aluminium with excellent electrical properties.

By including the wire insulation in the crimp at the rear end of the barrel and compressing sealant deposits at the barrel’s front end, the finished crimp withstands cyclical salt spray tests combined with thermal shock – environmental conditions which would cause electrochemical corrosion of the aluminium.

LITEALUM crimps offer vehicle manufacturers, suppliers and harness makers a fully automated termination solution for aluminium stranded wires. Aluminium plays an important role in the vehicle E/E architecture because it offers weight benefits over copper conductors.

From a wire cross section of 1,5 mm2, LITEALUM crimping meets the valid automotive pull-out force requirements. By giving the crimp barrel and finished crimp connection a conical shape, any notching effect on the aluminium wire is prevented. As a result, the crimp has excellent bending fatigue strength.

For more information contact Joshua Beckett, TE Connectivity, +27 (0)41 503 4500, joshua.beckett@te.com, www.te.com



Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Locking power jacks
23 October 2019, TRX Electronics , Interconnection
The new BKZ series from Switchcraft solves the common problem of accidental disconnection of a power supply by adding a sturdy twist-lock to the company’s most popular form factor. The intuitive design ...

Read more...
Waterproof Micro USB connector
23 October 2019, Electrocomp , Interconnection
As part of a new product line from GCT, the aquanex waterproof range brings together high-performance USB connectors with IP67 rated sealing. The first connector launched from the aquanex range, the USB3500, ...

Read more...
Solderable grounding seal
25 November 2019, Würth Elektronik eiSos , Interconnection
With the WE-SMGS, Würth Elektronik offers solderable seals for surface mounting. The WE-SMGS consists of a temperature resistant foam material, which combines the conductive seals with high elasticity. ...

Read more...
Waterproof Micro USB connector
25 November 2019, Electrocomp , Interconnection
As part of a new product line from GCT, the aquanex waterproof range brings together high-performance USB connectors with IP67 rated sealing. The first connector launched from the aquanex range, the USB3500, ...

Read more...
Lever-operated PCB connectors in 7,62 mm pitch
25 November 2019, TRX Electronics , Interconnection
The lever-actuated LPC PCB connectors from Phoenix Contact mark the first time that lever-operated PCB connectors have been available in a 7,62 mm pitch. The orange lever makes wiring fast and easy for ...

Read more...
Miniature Hi-Rel connectors
23 October 2019, Hiconnex , Interconnection
Nicomatic has launched a new series of 1,00 mm pitch connectors for demanding space-constrained applications in harsh environments such as aerospace and industrial equipment. Five standard layouts with ...

Read more...
Multicoax cable assemblies
23 October 2019, RFiber Solutions , Interconnection
Withwave’s high speed and high-density multicoax cable assemblies (WMX Series) provide a wide range of multiple coax connectors and flexible cable assemblies with a choice of 20, 40, 50 and 67 GHz configurations ...

Read more...
Grounding cable clips
23 October 2019 , Interconnection
Under the product name designation WE-EEL, Würth Elektronik now offers cable clips made of aluminium sheet to enable stable grounded fixation of cables of various dimensions. Cables with diameters ranging ...

Read more...
Connectors for transportation market
23 October 2019, TRX Electronics , Interconnection
The CTCS connection system is Aptiv’s solution for harsh-environment applications. The CTCS connector and CTS terminal families have been designed to meet the demanding requirements of commercial and ...

Read more...
High-power connectors
23 October 2019, Avnet South Africa , Interconnection
TE Connectivity introduced Multi-Beam Plus connectors, the latest evolution of its power connector line. The new connectors share the same low-profile dimensions and enable the same through-system airflow ...

Read more...