New Connector Enhances Racing Car Performance Advantage

In Formula 1 and other racing, weight reduction is key to gaining a competitive advantage. A few grams lighter in each component can significantly reduce the weight of the car as a whole. At the same time, in order to reduce the size of the car, the design of the car is increasingly tending to assemble various electronic components in a high density. With the increase in automotive electronic components, it is natural to minimize the assembly of components to obtain the maximum space utilization. To achieve this, the wiring harness and interconnection system of the car can be used as a starting point.

Trying to lose weight through a multi-pronged approach

The evolution of TE Connectivity's DEUTSCH AS series connectors is a typical example of the continuous miniaturization of connectors. During the evolution, the stainless steel shell of the connector was gradually replaced by lightweight aluminum and even lighter composite materials. Functional components such as coupling rings are also getting smaller and smaller. As the connector shrinks, TE has also redesigned the knurling so that technicians wearing gloves can quickly and accurately connect and disconnect the connector.

Using composite materials in connector housings is a proven way to reduce weight, but when composite connectors were first used in the racing industry, they were not as rugged and durable as expected. Specifically, composite materials could not withstand contact with brake cleaners. So, the designers at the time decided not to use them.

TE's new generation of electric formula racing cars

Today, however, composites are evolving and have improved significantly, with new generations soon to fully meet the demands of racing. This necessitates a fresh assessment of their ability to reduce weight while meeting the mechanical and environmental demands of racing.

Traditionally, composite materials have enabled connector weight reductions of approximately 40% . Additional weight reductions of 10%-20% can be achieved by optimizing reinforcement materials and by introducing foams into the polymer matrix . Reinforcement means thinner walls, and thin-wall construction allows for weight reduction without sacrificing performance. Today, high-performance thin-wall cables are the standard in racing cars. Typical cables, such as TE ’s SPEC 55 cables, use cross-linked ETFE insulation and jacket materials that can withstand temperatures up to 150 ° C or 200 ° C and have excellent resistance to liquids.

Another option to try is to use aluminum wire and cable. Previously, people thought that aluminum wire was too stiff, had a lower bending radius than copper, and could experience cold creep, so there were concerns about whether aluminum wire could be reliably terminated. However, the terminals can offset cold creep to form a reliable, airtight connection. Although aluminum has only 60% of the conductivity of copper , requiring a larger conductor to achieve the same current carrying capacity, even so, aluminum connectors are only half the weight of copper.

Reliable terminals enhance the use of aluminum wire

Reduce EMI while reducing weight

In order to ensure the safety of the car during driving, designers also need to consider how to reduce EMI ( electromagnetic interference ) . Usually, EMI can be reduced from three aspects: distance, shielding and optical fiber . TE will also consider reducing the weight of the car while reducing EMI .

Usually, EMI can be reduced by increasing the distance between the EMI source and the susceptible wires and electronic devices. However, due to the high requirements of the compact space inside the car, this method may not be applicable to racing. In the field of racing, adding shielding layers and using optical fibers are more feasible.

Let’s talk about adding shielding first. Because shielding adds weight, race cars need to be designed with flexible shielding that is applied only when needed. The traditional method is to put a copper braid on the cable and terminate it to the connector backshell. In this way, the braid forms a low impedance loop to ground, thus preventing EMI . To further reduce the weight of the car, TE introduced a lightweight braid system that reduces weight by 50% more than traditional braids .

Another approach is to use fiber optics. Fiber optics are inherently EMI resistant, and the weight of the cables is significantly lighter than copper cables. Glass and plastic fiber optics are both possible materials for racing. Of course, there are some precautions when using fiber optics, such as being more careful when routing glass fiber and observing the bend radius; and when using plastic fiber optics, you need to pay attention to the temperature range.

New options brought by technological progress

One of TE's advantages in reducing weight in racing cars is that it takes a system-level perspective to realize internal interconnections. Maybe this component adds a few grams, but another component can save several kilograms. After all, our ultimate goal is to win the race, not to look at the weight of a single component in isolation.

Now, new capabilities and new material formulations are giving race cars even more options. New fillers allow enclosures to be customized to help achieve the best balance between weight and electrical, mechanical and environmental performance. Advanced molding allows standoffs, one-piece connector housings, partitions and other three-dimensional features. And selective metallization allows circuit routing, shielding and even embedded antennas to be integrated into enclosures in a very cost-effective way. In addition to the basic advantages of composites, 3D molding and selective metallization can achieve additional weight reductions.

Today, advances in interconnect technology are enabling new levels of weight reduction in racing applications. More importantly, old technologies are beginning to gain new life. While approaches such as composite connectors and housings, optical fiber, braided shielding, and aluminum wire may have fallen short in some ways in the past, these options deserve a fresh evaluation as technology advances.

What improvements do you want to see from TE? What content do you want to see? What features do you want TE to add?

Don’t just think about it, tell us and you’ll have a chance to become a lucky fan and win wonderful gifts!

TE will be at the 2016 Munich Shanghai Electronics Show. Welcome to click on the WeChat menu "Online and Offline - Munich Exhibition" to sign up in advance to visit the TE booth. Wonderful things are waiting for you!