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Automotive design and architecture of the nervous system of small diameter

    With the "complex" to describe today's car is nothing more appropriate word. booster cables Safety, handling, driver and entertainment is only dependent on electrical / electronic architecture part of the subsystem.
    Today's drivers want their car to infinite precision and without intermittent operation.battery clip However, the electronic control of the vehicle within the nervous system is so complicated. Today, most automotive applications for more than a mile of wire, the controller module and a few dozen serial data network to meet the needs of those currently on the market functions.

    "Architecture"tow rope of necessity.

    As the car gradually have more and more electronic control systems such as navigation systems, ratchet tie dowm satellite radio, airbags, such as temperature control and electric door, electronic / electrical structure of the development of motor transport industry has also played a pivotal role. Now more than ever, OEMs are eager to have a vendor to the needs of their analysis, design and manufacture of the entire system to be able to meet demand.

    "Architecture" is defined in the vehicle design process early in the vehicle electronics and electrical systems process. As the architect to build a house or a skyscraper, like automotive electronic / electrical engineer with a wealth of experience and proprietary design tools to create electrical / electronic architecture of the virtual model. Testing and simulation tools by computer, and then verify the design ideas to ensure they meet customer cost, weight and arrangement of such requirements.

     In the early stages of design and meticulous attention to detail to ensure that customers can build a complete electrical / electronic architecture system. Compared with the previous design, Delphi engineers have found that the overall weight of the vehicle to re-design can reduce up to 20%, the cost can be reduced a maximum of up to 30% and improve the performance of the vehicle. In addition, Delphi's electronic / electrical structure of the vehicle's reliability, ease of assembly and compatibility has also been greatly improved.

     Electronic / electrical architecture of vehicles designed to involve all areas, including harsh environments and high-density travel arrangements. Electronic / electrical architecture enables the product concept car manufacturers, but also on the performance and functionality to meet the owners expectations. Electrical / Electronic architecture also help to improve the layout of space, so that electronic / electrical components can be placed in a more narrow or more accessible. In some cases, it can even completely eliminating the need for some special parts, so that greatly reduce the cost.

     In order to reduce the cost of the product 1 to 3%, parts suppliers improve efficiency in pay have made unremitting efforts. However, if the whole car as an organic system to develop, then the cost savings throughout the system will be more. To develop the content of the future will only increase. Automotive Open System Architecture (AUTOSAR - AUTOSAR the League was established in 2003 to create an electronic / electrical structure of open standards. Members include manufacturers, electronic component suppliers, semiconductor suppliers and tool vendors) just completed The first phase of development. AUTOSAR aims to standardize the design of the software to achieve by different manufacturers to interchangeability between parts, but also can make between the different hardware features for easy transfer. BMW Group in the fourth quarter has been applied to production cars will AUTOSAR new BMW7 department. Automobile manufacturers to achieve greater flexibility, lower costs, develop new automotive electronic systems development. BMW Group's electronic / electrical and environmental systems research and development department is responsible for driving people also identified the future development goals: BMW to the production of all vehicles in the full application of AUTOSAR system.

     Energy-saving environmental protection, small diameter wire.

     From consumer electronics to automotive systems, technological advances are moving in the direction of miniaturization, to achieve smaller, lighter targets. It seems the car manufacturers to reduce weight and improve fuel efficiency and reduce CO2 emissions standards, thus achieving the requirements of current and future key government regulations. Electrical components become more compact, and now some companies have already planned to use 0.13mm2 cross-sectional area of the wire. The result is that the continuous improvement of electrical / electronic systems become smaller, lighter and more reliable.

     Product and process are inseparable link between. To get the majority of product innovation to become a reality and generate tangible benefits, usually need to develop a unique process. Automotive electrical / electronic systems application of small diameter wire as well. Can be more reliable production and processing of fine wire is important, but must also improve the harness assembly process to ensure consistent, reliable application of these wires.

     This manual wiring and connectors are usually terminal plug is a challenge: this process depends not only on cable operators to correctly identify the naked eye, but operators must also be able to see right into the connector hole. But if only 0.13mm2 start using even smaller cross-section wire (diameter roughly equivalent to the thickness of the nail), the human eye can not discern the wire coding, size and color, the same pin hole connection system is also difficult to distinguish. The finer the wire, of course, also the smaller terminal. In addition, the wire stiffness also no guarantee that the terminal plug in place. Delphi's halogen-free ultra-thin wall cable to ensure minimal 0.13mm2 manually insert the operating requirements of wire stiffness, and automated manufacturing process can improve the reliability of plug terminals.

     Automated assembly and miniaturization technology will help promote the development of the next generation of weight loss, increase flexibility of production scale and improve the quality of the first off the assembly line. For example, some applications based on case studies, the use of Delphi's cellular chip integration (waferization), automation and miniaturization technology, the traditional wiring harness and can not use any of the first connection, reducing the amount of 50% copper, but also reduce the weight of 40% of the wiring harness, and harness diameter is also reduced by 20%. It is for this reason, Delphi will be in the United States Champion, Ohio, technical center and the German city of Wuppertal City Technology Center to develop a new process to ensure the manufacturing process in terms of both flexibility and functionality to meet the small diameter wire applications. Through a unique process to design and equipment, combined with the ability of vendors to ensure process efficiency and equipment capacity, such as small cutting machines and automated matching technology. Delphi is developing a new non-crimp technology and small diameter wire.

     These are real challenges for practical solutions. Delphi's products, technology and manufacturing processes are these concepts into practical products, to achieve weight loss in terms of layout and great benefits, and thus to help vehicle manufacturers meet the needs of consumers around the world with national environmental standards required by the Government.

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