Automotive connectors: "connectors" for industrial upgrading, new opportunities under the wave of new energy

In the complex and intricate mechanical world of automobiles, although automotive Connectors may seem inconspicuous, they play a crucial role in connecting like the neural network of the human body. It works silently to ensure smooth communication between various parts of the car's electrical system, allowing the car's various functions to function properly. Today, let's delve into the key role of automotive connectors in the automotive industry.

1、 The function of automotive connectors
Automotive connectors essentially play the role of the "nerve conduction officer" in the automotive electrical system. These precision components are like relay stations for electronic signals, establishing transmission channels for energy and information between independent electrical circuits. When the current needs to pass through a specific path to achieve the preset function, the connector takes on the key task of circuit connection.
The higher the intelligence level of modern cars, the more significant their dependence on connectors. In the field of powertrain, every critical link from ECU control module to precise ignition of spark plugs, from millisecond response of fuel injection system to energy management of hybrid power system, requires reliable electrical connections. In the safety system, core functions related to life such as ABS anti lock braking, ESP vehicle stability control, and airbag triggering rely on the efficient operation of connectors for signal transmission. In the intelligent cockpit, from the multi screen interconnected infotainment system to seat memory function, from automatic air conditioning to panoramic sunroof control, behind these configurations that enhance the driving experience, there are hundreds of Micro Connectors silently working.
According to statistics, the wiring harness system of a high-end intelligent electric vehicle will use over 3000 connection points. These connectors not only have to withstand extreme temperature changes in the engine compartment, but also withstand continuous vibrations during driving, and ensure stable transmission performance for more than ten years. It can be said that automotive connectors are the fundamental components that support the transformation of modern cars from mechanical products to intelligent mobile terminals, and their technological level directly affects the safety and intelligence of the entire vehicle.

2、 Systematic classification and characteristics of automotive connectors
1. Classified by Connection Technology
1.1 Plug in connector
Technical features: Adopting a plug and socket plug-in structure, supporting fast plugging and unplugging operations
Core advantages: assembly efficiency increased by 30%, maintenance operation time reduced by 50%
Typical applications: Electrical nodes that require frequent replacement, such as in vehicle ECU and sensor modules
1.2 Crimp type connector
Technical feature: Utilizing cold crimping technology to achieve physical bonding of metal conductors
Reliability index: Contact resistance ≤ 5m Ω, anti vibration level up to 10G@2000Hz
AppliCable scenarios: Vibration sensitive areas such as engine compartment wiring harnesses and chassis control systems
1.3 Welded connectors
Process requirements: Must meet IPC-A-610 welding standard
Mechanical properties: Tensile strength ≥ 50N, bending resistance>1000 times
Application limitation: Repair requires specialized tools, suitable for fixed installation positions such as instrument panel assemblies
2. Classified by functional system
2.1 Power transmission system
Environmental requirements: able to withstand temperature changes of -40 ℃~150 ℃, IP6K9K protection level
Special design: gold-plated contacts, dual locking structure, fuel corrosion resistant shell
Typical components: engine wiring Harness Connector, OBD diagnostic interface
2.2 Vehicle Control System
Protection features: IP67 waterproof design, anti micro corrosion treatment
Connection density: 0.64mm pitch miniaturization design, multi-channel integration
Application examples: door control module connector, electric seat connector
2.3 Security Protection System
Reliability standard: Meets ISO 26262 ASIL-D functional safety requirements
Special certification: The airbag connector must pass the USCAR-2 impact test
Technical parameters: Signal transmission delay<10ns, failure rate<1ppm
2.4 Intelligent Interaction System
Transmission performance: Supports USB 3.2/HDMI 2.0 protocol, with a speed of up to 20Gbps
Electromagnetic compatibility: Complies with CISPR25 Class5 radiation standard
Innovative applications: HUD projection connector, intelligent cockpit fiber optic interface

3. Trends in Technological Evolution
To meet the demand for upgrading the high-voltage electrical architecture of new energy vehicles, connector technology is undergoing innovation and breakthroughs. Through material innovation, aluminum alloy shells are used to replace traditional copper alloys, achieving a 40% reduction in product weight while maintaining excellent conductivity; Integrating temperature and humidity multi-dimensional sensor modules with intelligent technology to build an intelligent connection system for real-time environmental monitoring; In response to the trend of high-speed vehicle networking, we have taken the lead in laying out high-speed connection solutions that support the 10BASE-T1S Ethernet protocol, promoting the iterative evolution of FAKRA/Mini Fakra Connectors towards higher transmission rates, and fully meeting the composite technical requirements of intelligent electric vehicles for power transmission and data communication.

In terms of technological development trends, connector products are moving towards "miniaturization," "high-speed mobility," and "intelligence. In the rapid development process of China's automotive electrical connection component industry, there are still several key constraints that urgently need to be overcome. Some local manufacturers have exposed the shortcomings of lagging customer service concepts and dull market insights. Compared with the systematic solutions of multinational enterprises, there are not only gaps in engineering capabilities and weak quality control systems, but also significant gaps in customized service response and full lifecycle management dimensions.
The customized advantage of China's automotive electrical connector industry is continuously releasing value through deep integration into the local ecological chain. Faced with the industry characteristics of rapid iteration of new energy vehicle platforms, local enterprises have established a full chain response mechanism of "demand perception agile development scenario verification".
In the context of accelerated iteration of in vehicle electronic systems, taking the domestic customization capability of low-voltage harness terminals as an example. It is now becoming a key breakthrough in breaking the monopoly of foreign investment. Traditional solutions often cause signal attenuation problems due to insufficient bending radius of wire harnesses caused by large terminal volume. Local suppliers optimize the design based on the spatial layout data of the vehicle factory, customize the stamping process, reduce the terminal width while maintaining a current carrying capacity of 15A, and use coating technology to stabilize the contact resistance within 0.5m Ω. This deep customization not only solves the wiring problem of irregular structure car machine panels, but also reflects the unique advantages of domestic customization.