As power consumption increases, what kind of connectors do cars need?

As vehicles become smarter, become part of the Internet of Things (IoT), and implement advanced driver assistance systems (ADAS) features, more electronics and power are required in automotive designs. At the same time, the same harsh environments and need to limit weight apply, and these top issues are closely related to the power distribution box (PDB).

Trend 1

As automotive designers try to pack more power and smart features into vehicles, main power distribution boxes are becoming crowded, leading to space and thermal management issues. Overcoming these limitations often complicates design efforts and can increase engineering and manufacturing costs.

solution:

μPDB module and MX150 hybrid connector. (Image source: Molex)

The Molex µPDB modules, available through Digi-Key, provide automotive engineers with the flexibility to design power switching and circuit protection functions outside of the main PDB by leveraging the following key features and benefits:

Sealed Solutions - µPDB modules are IP6k7 compliant and since the auxiliary box is unsealed, engineers can position the module in previously off-limits areas

Small footprint - µPDB module is compact: 33.00 x 47.00 x 78.00 mm

Customizable - any PCB mount components can be added to meet customer design requirements

All of these features enable customers to place µPDB modules closer to the device, optimizing space within the main PDB. For example, an automotive OEM needs to power the third row of seats in its minivan. To alleviate space constraints, a µPDB module can be placed near the rear end of the vehicle, drawing power from a nearby power source instead of the main PDB.

Trend 2

The need for more data and power capabilities often means more wiring in vehicles, increasing vehicle weight and manufacturing costs.

solution:

The µPDB modules enable automotive customers to place power switches and circuit protection closer to the intended equipment, minimizing the total amount of wiring required in the vehicle. Additionally, the µPDB modules are wired to mate with the newly released MX150 8-, 9- and 10-way hybrid connectors, which are also available through Digi-Key. This further reduces the amount of wiring required, while also enabling more efficient and economical assembly.

Additionally, the MX150 Hybrid Connector leverages the field-proven performance of the 6-pin MX150 contacts to mix 2.8 and 6.3 contacts per customer request.

Returning to the example of the third row of seats in the minivan, placing the µPDB module near the rear end of the vehicle eliminates the need for additional wiring back to the main PDB.

Trend 3

In ADAS applications, critical systems need redundancy to ensure safety and reliability, which is often required by ISO standards. However, redundant designs complicate the task of maintaining strict weight limits and often mean that innovative ways must be found to reduce the number and size of components.

solution:

µPDB modules provide an optimal solution for redundancy in safety system applications. They have a small footprint and can provide redundancy close to the equipment without adding to the main PDB space constraints. In addition, its connections are not hardwired, so it is more compact and reduces weight.

The µPDB modules are available for immediate availability to automotive customers through Digi-Key. However, many applications have unique requirements. Therefore, Molex can also customize the contents of the µPDB module using virtually any PCB mount component. This option allows us to provide value to our customers by being involved upfront in the system architecture design to meet the specific needs of their application. Some of these custom applications include: All Wheel Drive Modules, PWM Cooling Fan Control Modules, Diesel Emission Urea Modules, and Cold Start Modules.