Page 1 - NEW NETWORKS FOR COMMERCIAL VEHICLES

PUBLISHED ARTICLE

NEW NETWORKS FOR

COMMERCIAL VEHICLES

Information networks drive new opportunities for
commercial vehicles—both conventional and electric

BY DAN PRESCOTT | MOLEX INCORPORATED

There are a host of commercial vehicles Internal-combustion engines produce power

that require complex interconnect systems, that can be difficult to control in certain

such as agricultural vehicles that precisely situations. When the driver accelerates,

monitor sprayer output; commercial buses the vehicle tends to burst forward, and

with Wi-Fi networks and plug-and-play the immediate torque produces wear on

entertainment systems for passengers; gears, bearings, wheels, and tires. Electric

school buses with multiple security engines, on the other hand, can be more

and driver-assist camera systems; and finely controlled when under acceleration,

emergency vehicles that process critical leading to reduced wear.

data from patient monitoring equipment.
In addition, regulation of commercial

As a result, many commercial vehicles vehicles in the US, Europe, and China
™
The HSAutoLink interconnect system from Molex
employ sophisticated interconnect systems is becoming stricter, and vehicle
is an unsealed, USB-based system based on
shrouds and latches that meet USCAR standards, with high-speed shielding that are capable manufacturers are being tasked with
while HSAutoLink II uses fully protected perimeter of processing data at speeds in the Gb/s reducing the levels of pollution their
seals and wire seals rated to IP67 and IP69K to range. Moreover, these interconnect vehicles create. One of the best ways to
protect the system in off-road environments.
systems are evolving to meet the specific accomplish that is to convert at least part of
Connectors used in commercial vehicles needs of commercial vehicle designers. commercial vehicle fleets to electric motors.
have always needed to provide higher For example, one available interconnect As a result, manufacturers are looking for
performance under more rugged conditions system is an unsealed, USB-based system help from suppliers to reduce the costs of
than those used in passenger cars and that has been proven in conventional manufacturing commercial electric vehicles.
trucks. Now they must also facilitate automotive applications. Typical USB In discussions with customers, all are
advanced networking under harsh connections are passive, unlatched, asking for industry-standard products for
conditions, providing all the benefits of plug-in connectors, but automotive USB electric vehicles that will help drive needed
high-speed networks found in standard applications must be latched. As a result, manufacturing cost reductions.
automobiles as well as greater protection this new system is based on shrouds and
from vibration and fluid ingress. They also latches that meet USCAR standards. Designing electrical systems for electric
must accomplish this while housed in more commercial vehicles can be challenging.
complex and denser packages. However, commercial vehicles—particularly For one, they typically require 4/0 gauge
those involved in off-road applications— wires, which have bare diameters of 0.46
HIGH-SPEED
COMMUNICATIONS may require sealed systems that offer inches, so designers have the challenge
additional protection against vibration and of configuring large cable assemblies with
Systems that combine high-speed fluid ingress. For that reason, a version of many turns and bends. Alternating-current,
connectors and cable technology are the same system, but for a commercial multi-phase motors also create EMI, as do
required to deliver the high volumes of vehicle customer, provides fully protected 4/0 gauge wires that carry 400A of current.
information needed in today’s connected perimeter seals and wire seals rated to IP67 As a result, components must be shielded,
commercial vehicles, including semi- and IP69K for use in off-road environments. which complicates cable and connector
autonomous and fully autonomous ones. AN ELECTRIFYING FUTURE design. Also, when electrical motors run
These communications systems typically at full power, current resistance can lead
include devices such as video cameras Another trend driving expanded networking to overheating, so these vehicles require
and sensors that produce large volumes of is the growth of hybrid and full-electric extremely low-resistance electrical systems,
high-speed data. Also, some commercial commercial vehicles – particularly for typically with resistance measured in micro-
vehicles have complex sensor and control construction and mining – based on the ohms.
systems that assist drivers with crucial need for more efficient power application
tasks, such as automatic braking. and reduced vehicle emissions.
Originally published in Connector and Cable Assembly Supplier (October 2015)