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        SYSTEM OPTIMIZATION                  instead of copper wire. Another option
                                             might be to move to single-mode glass or
        Because of these challenges, electrical
                                             plastic fiber optic cable. One fiber optic line
        system optimization is vital. Some available
                                             can replace multiple copper wires. Also,
        systems provide more shielding and current
                                             some manufacturers are using flat cabling
        density and can operate in the extreme
                                             because it can be mounted flat to the sides
        shock and vibration conditions found in fully
                                             of the vehicle and does not have to be
        electric and hybrid commercial vehicles.
                                             bundled like traditional wiring (a bundle of
        Also, as mentioned above, components that   wires creates a circular cross section with
        reduce disruptive EMI and RFI are essential   a larger diameter, whereas flat cable does
        for electric vehicles. Some are designed   not).
        for high-frequency switched-mode power   FULL VEHICLE VIEW
        supply (SMPS) applications, to significantly
        reduce EMI and RFI. These assemblies   Finally, a commercial vehicle network
        allow OEMs and end users to connect high-  must be designed as an integrated system
        power electrical cables directly through an   based on system speed requirements,
        enclosure wall, simplifying the installation   desired protocols, number of required ports,
        process.                             connector attachments, cable design,
                                             cable shielding levels, and performance
                                             expectations. As a result, the connector
                                             supplier must also be a systems designer,
                                             working closely with the customer early
                                             in the design process. And while some
                                             commercial vehicle developers have a staff
                                             of experts overseeing electrical system
                                             design, others may rely on their connector
                                             suppliers for that knowledge. A good
                                             connector supplier should be capable of
                                             engaging the customer early in the process
          Woodhead  MAX-LOC Plus Shielded Cord-Grip   to ensure that a commercial vehicle’s
          Assemblies are designed for high-frequency   networking system can do the job. For the
        switched-mode power supply applications.
                                             high-power applications typically found
        MAKING A GOOD EXIT                   in electric or hybrid vehicles, a similar
                                             approach must be used to select the right
        In addition to standard body and chassis
                                             interconnect scheme as overall resistance
        connectors, a commercial vehicle engine
                                             and shielding of the system are critical to
        may have more than 40 sensors in it, not
                                             meeting system requirements.
        to mention multiple high-speed shielded
        cables and high-voltage cables for power
        and telematics in the vehicle. A large
        number of wires and connections are routed
        to control modules that can be the size of a
        pizza box. Just trying to get the mixture of
        straight and right-angle entry wires routed
        through the vehicle is a challenge.
        As a result, smaller, lighter, and more
        flexible connectors that allow easier cable
        exits are required. For example, a 1.5mm
        terminal may need to be downsized to
        1.2mm, and 18- or 20-gauge wire replaced
        with 22-gauge wire. Likewise, smaller
        insulation diameters and lighter-weight
        aluminum wire may need to be used

        Order No. 987651-3811                         Printed in USA/GF/2015.10                             ©2015 Molex
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