Challenges for a Wiring System Manufacturers3.mentor.com/iesf/2011_IESF_Auto_LEONI_Wiring.pdf ·...

Challenges for a Wiring System Manufacturer

The Quality Connection

Agenda

1. AUTOMOTIVE TRENDS

� Green Trend : Less emissions

� Green Trend : Electrical Car

� Vehicle range : Ultra Low Cost Cars ... to High Technology Cars

2. IMPACT ON ELECTRICAL ARCHITECTURE

� Cost and Weight savings pressure

IESF Conference - 02JUN2011 2

� Cost and Weight savings pressure

� New technology : new needs and links with others domains (infrastructure)

� Compacted Development Schedule

� More connection points

� Increasing Electrical Architecture Diversity with Standard ECU

3. IMPACT ON ELECTRICAL ARCHITECTURE DESIGN & CHALLENGES

AUTOMOTIVE TRENDS


AUTOMOTIVE TRENDS

Green Trend : Less emissions & less fuel consumption

1. Regulations : High pressure on C0² emissions to anticipate fleet increase

Role of Transportation in Climate change : 18% Number of Vehicles : Trends (source Michelin)


2. Competitiveness on Low Emission & Fuel ConsumptionCO² Emission

(g/km)Bonus/Malus (€)

<60 -5000

61-90 -1000

91-110 -500

111-120 -100

121-150 0

151-155 +200

156-190 +750

191-240 +1600

240 +26002011 Bonus/Malus in France Incremental Oil demand 2006-2030

Green Trend : Electrical Car

1. NEW TECHNOLOGIES IN THE CAR

2. CONNECTION TO INFRASTRUCTURE (PLUG-IN CHARGE)


3. MORE MARKET PRESSURE = COMPACTED DEVELOPMENT PROCESS

� 2011

� 2012-2015…

Wiring Systems – Technical data

Wire length: more than 2 miles

Number of wires: up to 1,500

Number of terminals: up to 3,000

weight: up to 110 lbs


Umsatz: 1,22 Mrd. €

Beschäftigte: 43.000 weltweit*

Märkte: Automotive

– Pkw

– Nutzfahrzeuge

– Automobilzulieferindustrie

Vehicle range : Ultra Low Cost Cars ... to High Technology Cars

From Ultra-low-cost vehicle, with less and less functions…

…through low-cost vehicle

No air conditioningNo power steeringNo power windowsNo airbag…


… to very-high-end vehicles, with more and more functions

Night visionWifiAdaptative cruise controlRoad sign detectionEntertainment systems…

More and more gap between vehicle ranges

IMPACT ON ELECTRICAL ARCHITECTURE


IMPACT ON ELECTRICAL ARCHITECTURE

Impact on Electrical Architecture

Less Emissions & Fuel Consumption ��

Electrical Car

� New technologies �

Cost savings pressure

Weight savings pressure

New components

New Standards/Specifications to build


� Links to Infrastructure �

� Market Pressure �

More Ultra Low-cost Vehicles ��

More Functions on Vehicles ��


Compacted development schedule

Weight & cost savings pressure

Low-Cost Architecture (breakthrough)

More and More connection points

Electrical Architecture with Standard ECU

Cost and Weight savings pressure

Weight savings pressure�Electrical Architecture (Harnesses, FRB) : from 20 to 110 lbs

Clips

3%

Tube

3%

Connector

7%Cable

64%

Fiber Optics or

Assemblies

2%

Fuse box

4%Bracket or Formers

6%

Grommet

3%

Tape

8%

Weight (lbs) of midsize car

� Cable 56.0

� Tape 6.8

� Connectors 6.4

� Formers 5.1

� Fuse box 3.5

� Clips 2.8

� Grommets2.6

� Tube 2.4

Harness : the key-component in

E/E Architecture


Cost savings pressure�Electrical Architecture : $70 to $1100

�Increasing Copper material cost

� Tube 2.4

� POF & data cables 2.0

� Total 87.6

LME Copper

E/E Architecture for

weight & cost savings

0.5 mm² 0.35 mm² 0.22 mm² 0.14 mm²

Vision of downsizing

Possibility of higher density connector

systems

Downsizing of signal wiring system with new conductor materials

Possibility to use more wires in the same overall

bundle diameter

Reduction of wire cross sections for

Minimized space and weight


Reduction of control unit dimensions

materials

Reduction of cable channel and grommet

dimensions

Alternative conductors to copper wire for signal & low current application



Electrical Car

� New technologies�



New components



� Links to Infrastructure�

� Market Pressure�









Electrical Cars

New technology : new needs and links with others domains (infrastructure)

� New Electrical Architecture requiring new components


� Standards/Specifications to be developed

Compacted Development Schedule

� HEV markets pressure requires development of optimized solutions in 1-2 years

Plugging charge :

Universal Standard? Not on the way…Automotive or Consumer Mass market?



Electrical Car

� New technologies �



New components



� Links to Infrastructure �

� Market Pressure �









Ultra low-cost vehicle:

� Optimized electrical architecture to match cost requirements

• Breakthrough in design / back to the past solutions

High Technology Car

� More and more connection points

• BMW S5 : > 1600

�

Ultra-low-cost vs. more & more functions

Tata Nano with low-level ECU


� Less and less space within the vehicle

• 3D tools required

Increasing Electrical Architecture Diversity with Standard ECU

� Electronic Architecture : Standard ECU (“commodity”)

� Electrical Architecture : to be adapted per vehicle

� High flexibility required

Eg. : Dashboard Harness : up to 150 variants

Tata Nano with low-level ECU

BMW S5 with high-level ECUs

Electrical and ElectronicDistribution System

EEDS Electronic Components

BODY CONTROLLERS (1 to 3)

EEDS Electrical Components

HARNESSESFUSE/RELAY BOXES

• weight > 40 lbs

R&D Challenges– EEDS Key Components: Weight/Cost Savings


• weight: 1.0 to 3.5 lbs• cost < 20% of total • standard for Multi-vehicles

Wiring harness: Key priority for cost and weight improvement

• weight > 40 lbs• cost > 80% of total• Specific to one vehicle

HYBRID / ELECTRICAL OPTION

• Cost + 50% vs standard vehicle

+

IMPACT ON ELECTRICAL ARCHITECTURE DESIGN




COST & WEIGHT SAVINGS

�� Tools for Architecture optimization

MORE AND MORE FUNCTIONS AND VEHICLE VARIANTS

�� Tools for high diversity management

LESS SPACE WITHIN THE VEHICLE / COMPACTED DEVELOPMENT SCHEDULE

�� 3D tools adapted to harness (“flexible” component with 2000 connection


�� 3D tools adapted to harness (“flexible” component with 2000 connection points)

Compacted Development schedules increase use of simulation tools

MAIN TOOLS CHALLENGES :

��Increase added value of the tools

�� Create gateways between Tools (2D-3D-PDM)

Challenges for a Wiring System Manufacturers3.mentor.com/iesf/2011_IESF_Auto_LEONI_Wiring.pdf ·...

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