Connector systems and data transmission in modern on-board networks

How automotive suppliers are adapting to the latest developments

Modern vehicles are highly dependent on electronics. Reliable, high-performance data transmission solutions and connector systems are essential in processing real-time data from sensors and cameras, especially for safety-critical functions such as braking and steering. The systems and technologies used here are examined in more detail below.  

From driver to passenger – autonomous vehicles are defining the requirements for modern on-board networks

Data transmission technologies are playing an increasingly central role in future vehicle generations. With the trend toward achieving ever higher levels of autonomous driving in the future, the need for driver assistance systems (ADAS) and therefore the number of data connections and required data rates will increase significantly. In particular, the increased use of sensors (lidar and radar) and cameras requires fast, high-precision data transmission. The resolution of cameras is continuously increasing and the HD quality used today will continue to develop. Data must be transmitted to the control units and evaluated in real time. Latency times must be very low to ensure safety in critical systems such as the collision avoidance system. In order to avoid accidents and possible personal injury and material damage, high latency times are not an option here. 

Fast, secure data transmission between vehicles and infrastructure (V2X communication) is also of vital importance. An immediate response to environmental influences is essential for the combination of intelligent traffic management systems and highly automated driving to be successful. In this way, potential traffic jams and traffic obstructions can be avoided from the outset.   

The integration of highly comprehensive infotainment systems will also cause a rapid increase in the required data transfer rates, especially when it comes to streaming media content to high-resolution 8K displays. Not only must the display itself function correctly at all times, but multimedia data traffic to and from the device must be smooth in order to avoid pixelated images or a jerky display on the monitor.

Safety and sustainability in the supply chain

Due to the increasing importance of data transmission solutions in modern on-board networks, the reliable supply of corresponding components has become a key focal point in the automotive industry. Suppliers have been facing enormous challenges in ensuring stable supply chains, especially since the coronavirus pandemic. The traditional “just-in-time” approach, which aims to keep stock as low as possible, has been severely challenged by the crisis. Bottlenecks in the supply of semiconductors and other critical materials has led to production shortfalls. To minimize these risks, companies are increasingly relying on “right shoring” strategies, where production and procurement sites are relocated to regions with a favorable cost/risk ratio. In addition to the classic “nearshoring” to Mexico or Eastern European countries, countries such as Vietnam, Thailand and Brazil are also being considered as alternative locations for the production of vehicle components. Such diversification aims to prevent bottlenecks and reduce dependence on a single region such as China. In addition, a wide portfolio of additional alternatives (2nd or 3rd source) is used as a backup in case of bottlenecks. Another important aspect of modern procurement management is the digitization of the supply chain. Companies are increasingly investing in technologies that enable real-time monitoring of supply chains. These measures provide transparency throughout the entire process, from raw material suppliers to logistics processes.  

OEMs are currently in the process of establishing common guidelines for suppliers. The guiding principle for improving sustainability in the supply chain places particular emphasis on the implementation of a closed circular economy and the raw materials used. Here, the main focus is placed on reducing the quantity of waste, reusing materials, and recycling. OEMs have even included this in their delivery conditions and specifications, which means that it will become more and more important for suppliers to conserve resources through reuse and introduce material-saving designs.

Dealing with electromagnetic interference (EMC)

The EMC issue on vehicles with conventional combustion engines is minor, as there is only a risk of the battery discharging during the start-up process. However, EMC issues are occurring with an alarming frequency in electrically powered vehicles with powerful electric motors. One reason is the different voltage levels of the built-in converters. In the worst case scenario, electromagnetic incompatibility can lead to the serious failure of electrical equipment. For example, the airbag may be triggered if certain mobile phones are held near the steering wheel. In order to increase compatibility, twisted-pair and shielded cables are preferred. As an additional solution, passive suppression chokes and combination capacitors can be used on the control unit and high-voltage side. During the component development stage, a greater focus is being placed on EMC compatibility to address the issue and optimize the component as early as the design phase, if necessary.

Trends and developments in automotive data transmission

In order to map these data rates according to aspects such as material and compactness as well as performance and safety in the vehicle, the supplier industry is faced with a series of complex challenges.

Applications such as 4K displays or high-resolution 4K cameras require suitable connector solutions that are capable of transmitting data rates as high as 20 Gbit/s, depending on the resolution. When it comes to data connectors, the trend is therefore shifting from HSD technology to automotive Ethernet technologies and connector solutions such as H-MTD and GEMnet.

Furthermore, the automotive Ethernet sector is seeing a change from 4-wire to 2-wire cables. While the maximum frequency range for HSD technology was 3 GHz and 3 Gbit/s, the spectrum for the newer connector systems extends to a maximum of 20 GHz and 56 Gbit/s. On certain variants, space requirements are also reduced by up to 70%. This significant change can also be seen in the area of ​​coaxial connectors, where much smaller, more powerful mini-coaxial systems are replacing the FAKRA connector system. The best known mini coaxial connector systems are almost certainly ADTCon-MC from MD ELEKTRONIK, MATE-AX from TE and HFM from Rosenberger. The frequency band for FAKRA was still only 6 GHz, but increased to up to 20 GHz with Mini Coax.

Developments and innovations

The current situation regarding the development of data transmission solutions in the automotive industry can be divided into three main areas:

Flexibility and implementation of hybrid solutions

The C-KLIC connector developed by MD can be used for both data transmission and power transmission. This hybrid connector can replace up to three individual connectors, which reduces space requirements by 70% as well as significantly reducing costs. Video connections such as Display Port or PCIe as well as standard USB protocols (3.x / 4.0) can be implemented as a result. It would also be possible to integrate an additional power supply for the devices.

The “modular hybrid connector” is another type of hybrid connector for integrating data and signal connections. More and more component manufacturers will be relying on this type of connector system in the future to minimize the number of plugging operations and save installation space. One additional advantage is that both differential and coaxial connector systems as well as standard contacts for power transmission can be combined into a single connector to allow the transmission of simple control signals while supplying sensors with the necessary power. Using hybrid connectors to reduce the number of components plugged into the vehicle wiring system is a further step toward greater automation and an increase in efficiency on the production side. Above all, this system is another building block for simplifying on-board networks.

MD ELEKTRONIK – Independent and versatile

As an independent manufacturer and developer of connector systems, MD can respond flexibly to market requirements while simultaneously offering innovative, customized complete solutions manufactured using components developed within the company. By developing and building its own production facilities, MD has also achieved a high degree of automation and subsequently the highest reproducible quality at all production sites worldwide, which is essential in overcoming the future challenges of autonomous driving. MD has adopted this approach to reduce dependence on suppliers and contribute to stabilizing the supply chain in the interests of our customers.