The statutory introduction of mandatory systems such as Regulation (EU) 2019/2144, applicable from July 2024, which mandates the ex works installation of a large number of driver assistance systems, is accelerating the change in the automotive industry. The aim of the new legal requirement is not only to increase traffic safety, but also to boost efficiency and eco-friendliness and even promote the development of autonomous vehicles. A central area of this change concerns: ECUs (Electronic Control Units) which are of vital importance to the functionality and performance of modern vehicles. The increasing complexity of onboard networks and the trend towards miniaturization require new solutions such as mini-coaxial connector systems which offer considerable advantages in many respects.
The further development of control units and on-board networks
The technological change in the area of electronic control units is a key factor in the transformation of the automotive industry. In modern vehicles, these control units play a decisive role in coordinating systems such as communication, infotainment and driver assistance. The introduction of 5G connectivity and Vehicle-to-Everything (V2X) communication is enabling the seamless networking of vehicles with the traffic infrastructure, other vehicles and pedestrians. Not only is this increasing traffic safety and efficiency, but it is also creating the basis for autonomous driving functions in the future.
However, these requirements are also leading to a greater number of increasingly complex control units being needed to process the data. This, in turn, is increasing the number of cables in the vehicle that are required to connect the control units with each other and with the actuators and sensors. At the same time, costs, weight and space requirements for these systems need to be held in check so that efficient vehicles can be designed in line with market requirements. Therefore, in the area of the on-board network, solutions need to be found so that control units and cables can be made more compact and cost-effective, and at the same, to ensure safe and rapid data transmission.
FAKRA, mini-coaxial and hybrid cables as an interim solution
A major aspect when it comes to the further development of control units is the change in the way that data is transmitted. Over the last 20 years, the traditional FAKRA system has dominated the in-vehicle transmission of analog signals.
Since around 2018, this system has been further developed. Thanks to the introduction of mini-coaxial systems, connections can be made using the same data transmission technology but in a smaller installation space. The most popular suppliers of mini-coaxial connector systems in the European area are TE Connectivity with the MATE-AX and TFM systems, Rosenberger with HFM® and RMC®, and MD ELEKTRONIK with the mini-coaxial system, ADTCon-MC, that it developed itself. These new systems can integrate more functions into one cable strand, saving space and weight, while at the same time, increasing performance. This solution offers automotive manufacturers greater flexibility when designing and positioning control units. What’s more, mini-coaxial cables are easier to route through tight spaces. Their more compact and less complex design can also lead to cost savings in production as these cables require less material.
However, the complete changeover of a cable harness is a tedious process, as existing contracts with suppliers and the technical specifications of E/E components are defined over many years. So, the use of hybrid cables offers an interim solution for fully integrating the new system. This involves using mini-coaxial and FAKRA systems simultaneously in a single cable. This poses huge challenges for assemblers and cable manufacturers as, through the use of different technologies, the number of variants increases and additional OEM requirements must be taken into consideration. For each connector version, an assembler requires its own contact components and tools, which clearly increases the production effort.
Size comparison of a FAKRA connector with a mini-coaxial variant
Future perspectives for production systems
When using the usual production systems, clearly more work steps and tools are required to assemble hybrid cables than for pure FAKRA and mini-coaxial systems. This leads to longer production times and thus to higher production costs. At the same time, in global terms, automotive manufacturers are defining different technical requirements for new connector systems. In order to exist in this field and to meet the increasing quality requirements in the area of data transmission, assemblers are increasingly having to rely on fully automated, yet flexible production. Through the intelligent design of machinery, the production of complex multi-conductor and hybrid cables can be designed in a particularly efficient way and changes can be reacted to at short notice. New opportunities and challenges are also arising through the advancing digitalization of production under the catchword “Industry 4.0”. Networked production systems, real-time data analyses and digital twins are just a few examples of the technologies that will revolutionize cable assembly and the entire on-board network manufacturing process in the future. When adapting to new technological requirements, close collaboration with OEMs and Tier-1 suppliers plays a central role. Specific solutions for individual requirements are being developed in joint development projects.
Fully automated production at MD ELEKTRONIK
MD develops and builds fully automated, modular production systems, offering the highest quality standards and efficiency in production. Through the use of the latest robotic and automation technologies, MD can react flexibly to customer requirements and offer tailor-made solutions. The current high level of demand for FAKRA components is being met through fully automated production which is already being used in new plants to assemble mini-coaxial and FAKRA cables. This involves the production of cable lengths of approx. 300 mm to over 10,000 mm. The assembly of double-ended cables is not possible without additional setup work. As MD has characterized the assembly of hybrid cables from the very beginning, it has built up a wealth of experience in the manufacture of complex cables, and can offer a wide range of products.