TRANSPORTATION SOLUTIONS FOR FUTURE MOBILITY

Transcription

1 TRANSPORTATION SOLUTIONS FOR FUTURE MOBILITY PRODUCT NEWS 2015 EVERY CONNECTION COUNTS

2 SAFE GREEN CONNECTED

3 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS TABLE OF CONTENTS EVERY CONNECTION COUNTS About TE Connectivity 5 SENSOR SOLUTIONS Sensor technology 30 TRANSPORTATION SOLUTIONS Solutions for future mobility 5 INDUSTRIAL & COMMERCIAL TRANSPORTATION Termination systems for harsh environments 38 HYBRID & ELECTRIC MOBILITY SOLUTIONS Hybrid and electric vehicle solutions 7 TE APPLICATION TOOLING Complete solutions from start to finish 46 CO 2 EMISSION REDUCTION Innovative connector and termination systems from TE Connectivity safeguard major trends 18 IMPRINT 48 POWER CONNECTIVITY Connectivity for evolving vehicle architectures 24 GLOBAL CONTACTS 50 Press Contact Robert Donohoe Director, External Communication (717) robert.donohoe@te.com

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5 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS ABOUT TE CONNECTIVITY TE Connectivity (NYSE: TEL) is a $14 billion global technology leader. Our connectivity and sensor solutions are essential in today s increasingly connected world. Our 80,000 people, including 7,500 design engineers, partner with customers in over 150 countries across a wide range of industries. We collaborate with engineers to transform their concepts into creations redefining what s possible using intelligent, efficient and high-performing TE products and solutions proven in harsh environments. We believe EVERY CONNECTION COUNTS SOLUTIONS FOR FUTURE MOBILITY The pace at which the E&E architecture of vehicles is being innovated is one of the major challenges facing the automotive industry. An increasing number of electric and electronic systems enriches modern vehicles and makes them more attractive. At the same time, reliability is one of the automotive industry s core strengths. Within this area of potential conflict, everything depends on constant innovation and proven technology. Is that a contradiction in terms? Not for us. It s part of our DNA to reconcile innovation and reliability. To do that, we have invested in modern R&D and testing infrastructure. We will show you how leading-edge passive components can contribute to vehicle function enrichment, better efficiency and greater comfort. Transportation Solutions, which is part of TE Connectivity, is a company driven by technology. With this philosophy, we have become one of the world s largest manufacturers of passive components.

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7 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS HYBRID AND ELECTRIC VEHICLE SOLUTIONS Electric mobility marks a technological turning point. There s a lot more behind it than just providing the required propulsion energy in a rechargeable battery instead of a fuel tank. It s time to reinvent the wheel, from design to use especially in urban areas. From the beginning, TE Connectivity has been one of the driving forces in the development of components for hybrid and electric vehicles. With more than 50 years of experience in automotive connectivity systems and components used on all vehicle voltage levels, we can deliver electric mobility without compromising security, reliability, and efficiency. Groundbreaking innovations for various industries means TE Connectivity is well-prepared for new challenges. You can count on expertise in: Safety experienced in extra-high-voltage applications (800 kv+) Reliability tested in very tough environmental conditions High efficiency high-voltage connectivity systems with finger protection Engineering excellence development and production worldwide

8 8 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 AMP+ CHARGING INLET FAMILY FOR PLUG-IN HYBRID AND ELECTRIC VEHICLES To charge their batteries, plug-in hybrid and electric vehicles share the need to connect to the electrical infrastructure. TE Connectivity (TE) offers a complete product range of compatible charging inlets for worldwide hybrid and electric vehicle applications. We satisfy the key requirement to have dedicated charging inlet packages that can be fitted to vehicles intended for different markets. These have virtually no impact on the vehicle bodies. TE Connectivity s AMP+ charging inlets are a modular system, sharing similar parts between the three inlet types. Priority was given to technological compatibility, allowing vehicle makers and system suppliers to fully harmonize functionality across their different ranges. TE Connectivity s AMP+ charging inlets are validated and certified to conform to all applicable standards. Key features of our AMP+ Charging Inlets Standardized connector interface for EMEA (Type 2), USA (Type 1) and China (Type GB) available Flexible charging inlet assembly at the manufacturer thanks to our similar part concept Simple assembly method using a small number of parts Identical crimp junctions and crimping tools for all charge inlet types Cable exit direction can be adjusted as needed between 4 and 8 o clock orientation Type 1 inlets can be configured with or without connector locking device Type 2 inlets can be fitted with a connector locking device at three different positions Identical electrical and mechanical function of the connector locking devices for all inlet types Ajay Bhargava (248) ajay.bhargava@te.com

9 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS AMP+ CHARGING CABLE The batteries for plug-in hybrid vehicles can be recharged externally, just like those of electric vehicles. TE Connectivity has developed a charging cable that meets the requirements of the international charging standard IEC /-22. This defines the on-board vehicle type 1 interfaces for the US and Japan, as well as type 2 for Europe. The latter provides for two charging modes: With mode 2, charging can take place wherever there is no special charging infrastructure available at home, for example. If there is a high-performance charging station available, the mode 3 charging cable is used. If this method is used for transmitting higher voltage and current, the charging time is decreased compared to charging using mode 2. The range of cables is distributed such that the differences in the available power density can be used. Certifications and tests for the country variants are necessary. An integrated current circuit breaker as well as compliance with the norms and standards currently in force ensure a high degree of safety for the user. The temperature monitor of the power plug ensures the protection and safety of the infrastructure connection. Chadwick Taylor (248) chadwick.taylor@te.com

10 10 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 EVC 250: NEXT GENERATION ELECTRIC VEHICLE MAIN CONTACTOR FOR HYBRID AND ELECTRIC VEHICLES TE Connectivity introduces the EVC 250 Main Contactor (EVC 250), a next generation product that has specifically been designed for use in hybrid, full-electric and fuel cell vehicles, as well as in vehicle charging systems and functions without pressurized contact chambers. Product highlights Compact high-voltage main contactor Voltage rating up to 450 VDC Continuous current up to 250 A at 85 C Short-circuit carry currents up to 6kA The new EVC 250 features larger contact gaps, optimized switching dynamics, high-performance arc suppressing magnets and other measures to effectively control the switching arc. Typical applications DC high-voltage applications as main contactor in Hybrid vehicles Full-battery electric vehicles Fuel-cell cars DC battery charging systems The contactor achieves continuous current ratings of 250A, which ensures a safe short-circuit carry capability of 6kA and complies with the demanding switching requirements in hybrid and electric vehicles. This innovative design allows for compact dimensions of only 93x55.3x49.8mm (3.7x2.2x2.0 ). Due to the contactor s simplified construction with optimized parts, the EVC 250 can allow for a fully automated production. A standard version features separate coils for pull-in and hold with automatic, internal switch and a second version features a single coil for pulsed excitation (PWM). The EVC 250 fulfills the insulation requirements of IEC Roman Dietrich +49 (0) roman.dietrich@te.com

11 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS OPTIONS TO MATCH YOUR VEHICLE ARCHITECTURE: AMP+ HVA 280 LOW-MEDIUM CURRENT CONNECTORS AND HEADERS TE Connectivity s AMP+ HVA 280 finger-proof, touchsafe 2- or 3-position low-medium current connectors and headers are designed for flexibility with options needed for various hybrid/electric vehicle device applications. With a current carrying capability up to 40A and a cable range of 2-4mm 2, the AMP+ HVA 280 connectors and headers can be utilized with multi-core or individually shielded wire. The system provides multiple latching options and an integrated internal HVIL allowing for package size optimization and routing flexibility. The discrete header design is an industry unique solution to improve packaging and manufacturing efficiency. The two-stage floating latch creates safety in the system. Multi-bay header option also available. Overview of main technical points Terminal Size/Style: AMP MCP 2.8, MQS 064 Wire Range: 2 5 m m 2 multicore and individual shielded cable Voltage Rating: up to 600 V individual shielded cable, up to 750 V for multicore shielded cable Temperature Range: -40 C to 140 C Current Rating: C ambient temperature IP Rating: Mated: IP67, IP6k9k Unmated: IP2xb HVIL: Integrated internal - shunted or pass-through CPA: Yes The spectrum of options available for the HVA 280, more than 3000 combinations, provides a solution for a wide variety of device and wire harness applications like Battery Pack, DC/DC Converter, On-Board Charger, Electric Heater, Electric Air Conditioning and High Voltage Power Distribution. Ajay Bhargava (248) ajay.bhargava@te.com

12 12 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 AMP+ HVA POSITION: THE HIGH-VOLTAGE CONNECTOR FAMILY FOR MEDIUM-CURRENT CAPACITY High-voltage applications like Onboard Chargers (OBC) typically require sealed and shielded two-position DC connectors and headers. Therefore, TE Connectivity has developed the AMP+ HVA 630 product family. The standard contact system AMP MCP 6.3/4.8 is a well- proven contact system in the industry. The shielded multicore wire is designed for conductor cross-sections from 2.5 up to 6.0mm 2. This allows currents of 40 A at 140 C ambient temperature and voltages of up to 850VDC. The AMP+ HVA 630 product family is touch-safe and provides CPA (Connector Positioning Assurance), as well as HVIL (High Voltage Interlock) functionality. Overview of main technical points Pin number: 2 (+2 HVIL) Contact system: AMP MCP 6.3/4.8 Conductor cross-sections: 2.5mm 2-6.0mm 2 from LV216-2 Voltage range: 850 V DC Operating temperature: -40 C up to 140 C Current carrying capacity: C ambient temperature IP rating: Plugged: IP6k7, IP6k9k; Unplugged: IP2XB HVIL: Bridged in the connector CPA: Yes Ajay Bhargava (248) ajay.bhargava@te.com

13 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS AMP+ HVA POSITION The increasing battery capacity of plug-in hybrid and electric vehicles requires a higher amount of charging power to make charging times of less than four hours possible. The AMP+ HVA position connector allows for a three-phase charging current of 32 A and meets the relevant IEC type 2 standard for a maximum charging capacity of 22 kw. The connector provides finger protection and is designed for multi-shielded conduction according to LV It is sealed, shielded 360, includes High Voltage Interlock functionality and is based on synthetic material with V0 inflammability classification. Due to its lever control, the necessary mating force is less than 70 N. Overview of main technical points Number of contacts: 5 (+2 HVIL) Contact system: AMP MCP 6.3/4.8 Cable cross-sections: 4.0mm 2 and 6.0mm 2 according to LV216-2 Voltage range: 750 V DC Operating temperature: -40 C to 140 C Current load capacity: C ambient temperature IP rating: Plugged: IP6k7, IP6k9k; Unplugged: IP2XB HVIL: Bridged in the connector CPA: Yes Fire classification: V0 Ajay Bhargava (248) ajay.bhargava@te.com

14 14 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 AMP+ HVP 800: THE HIGH-CURRENT CONNECTOR AND HEADER SERIES FOR HIGH-VOLTAGE APPLICATIONS In bringing high performance to your hybrid or electric vehicle, it is essential that the high currents and voltages are safely transported from the battery to the inverter and E-Motor. TE Connectivity s AMP+ high-current connectors and header designs meet AK 4.3.3, LV215-1 specifications and are also touch-safe. The AMP+ HVP 800 feature an integrated internal HVIL (High Voltage Interlock) function and EMI (electromagnetic interference) shielding. The connectors are watertight and their robust design optimizes package size and plug and header selections to create multiple wire harness assembly routing options. TE Connectivity s AMP+ HVP 800 features include: Pole number: 2- and 3-pole connectors with optional 90 and 180 wire exit Connector interface set as standard in LV215-1 with common header design for plugs (90 and 180 ) Terminal system 8mm round terminal Current rating up to 250 A Cross wire section 16.0mm mm 2 LV216-2 Ambient temperature: -40 C to 140 C IP Rating: Mated: IP6k7, IP6k9k Unmated: IP2XB The AMP+ HVP 800 product family features current-carrying capability of up to 250A (continuous) on 50mm 2 wire, as well as a wide temperature and wire range. The touchproof 2- or 3-position AMP+ high-current connectors and headers are engineered with 90 or 180 plugs and multiple keying options for use in many hybrid and electric vehicle applications. Assembly is simplified with a lever assist for low insertion force. Ajay Bhargava (248) ajay.bhargava@te.com

15 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS THE SHIELDED TERMINAL IPT (INTERNAL POWER TERMINAL) FOR MEDIUM AND HIGH CURRENTS IN HYBRID, ELECTRIC AND FUEL-CELL VEHICLES TE Connectivity presents the next generation of the AMP+ IPT (Internal Power Terminal) product family. The design is based on the requirements of the German AK standard and is ideal for use in contact e-motors, inverters or batteries for hybrid or electric vehicles. Maximum operating voltage is specified at 850V. The AMP+ IPT is available with 1 3 pole housings and the single-shielded cables offer a cross section range from 16 to 50mm 2. At an ambient temperature of 120 C according to DIN EN , it achieves currents up to 230 A. The cable shielding is applied 360 and the contacts are sited in the sealed area. This ensures maximum shielding efficiency (EMI) over the lifetime of the vehicle. Key technical features Housing: 1-, 2- or 3-pole Terminal system: Ring tongue Wire cross-section: 16.0mm mm 2 2LV216-2 Current rating: up to 230 A Ambient temperature: -40 C to 140 C IP Rating: Mated: IP6k7, IP6k9k Thanks to the robust design of the housing, as well as the threaded aggregate connection, it achieves maximum vibration performance (engine mount). The threaded ring tongue can be applied on different lengths, according to customer needs. This enables easy and flexible adaption of the IPT to various applications. Ajay Bhargava (248) ajay.bhargava@te.com

16 16 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 TE CONNECTIVITY PRESENTS: MINI K HV COMPACT PRECHARGE RELAY The Mini K HV supports the connection and disconnection of the traction battery in switching assemblies for hybrid and battery electric vehicles. As a compact precharge relay, the Mini K HV takes over the charging of the filter capacitors over a precharge resistor directly before the operation of the main relay, protecting the main relay s contacts from extreme inrush currents. With significantly reduced dimensions of 25.5 x 20.7 x 19.3mm for the PCB version, the Mini K HV represents a major innovation compared to current precharge relay solutions. Product highlights Compact high-voltage relay for precharge applications up to 450 V Precharge currents up to 20 A Limiting break currents up to 20 A Available with PCB and plug-in terminals Typical applications DC high-voltage precharge applications in hybrid vehicles full battery electric vehicles fuel-cell cars Our optimized design of the switching contacts enables this miniature relay to switch loads of up to 20A at a system voltage of up to 450V. Even under fault conditions, it is able to reliably disconnect the precharge circuit from the traction battery. In addition to the standard version with printed circuit board terminals, it is also available as a plug-in relay with quick-connect terminals. Benjamin De Roo (336) benjamin.deroo@te.com

17 TRANSPORTATION SOLUTIONS /// RODUCT NEWS INTELLIGENT CABLE TECHNOLOGY FROM TE CONNECTIVITY ENABLES WIDE- RANGING AND COST-EFFECTIVE EXPANSION OF CHARGING INFRASTRUCTURE Energy storage using battery technology that is currently available is weight-, space-, and cost-intensive when compared with oil-based fuels. Many studies show that a large proportion of vehicles only cover a distance of under 100 kilometers each day. This means that the installation of electrical storage capacity that provides for the same kind of range that modern vehicles with combustion engines offer would appear to be unreasonable. Using mobile metering and billing technology makes it economically feasible to configure a comprehensive network of charging spots in the foreseeable future, since the system outlets optimized by TE Connectivity reduce the technical expenditure on the infrastructure side to a minimum. Furthermore, no additional costs would be incurred for metering point operation and access management at the charging spot. Additionally, a more precise consideration of use profiles indicates that vehicles, particularly those with electrical propulsion systems, don t spend most of their time driving. Therefore ample time is available for charging. However, there isn t a large number of publicly available charging stations covering a broad area. The system functions fully automatically, thus allowing for cost-effective charging at work without the need for the employer to put management structures into place for it. This is also internationally scalable. TE Connectivity and the Berlin-based company ubitricity are working on a charging system that will make the existing electrical infrastructure more usable for electro mobility. The two companies and their partners have developed a system outlet for this purpose, as well as an intelligent charging cable that can fulfill all necessary functions, such as providing a secure connection, cost-effective measurement of the energy collected, and transmission of the transaction-sharp usage data to the energy source. The recording method, so-called Mobile Metering, comes from ubitricity. TE Connectivity s cooperation partner has developed a technology for charging electric vehicles that facilitates charging points where a power supply already exists, such as the power supply to street lights. The intelligent charging cable is outfitted with the IEC type 2 plug from TE Connectivity, as well as an electronics system and supports the charging mode 3. The technology is downward compatible, so that the intelligent charging cable is universal - able to charge anywhere from system outlets to standard charging columns.functions are activated when an appropriate system outlet is detected. A robust display keyboard interface facilitates communication with the user and secure data transfer through the mobile internet. The interface also reads the energy source and optimizes charge management. ubitricity is a trademark Chadwick Taylor (248) chadwick.taylor@te.com

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19 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS INNOVATIVE CONNECTOR AND TERMINATION SYSTEMS FROM TE CONNECTIVITY SAFEGUARD MAJOR TRENDS IN VEHICLE MANUFACTURING To further reduce fuel consumption, car manufacturers are redoubling their efforts in lightweight construction and not just for bodies, drive systems and chassis. There is also room for weight reduction in the on-board electrical system. The weight of the cable harness in a midrange passenger vehicle can be reduced by several kilograms by using aluminum wires instead of copper for cross-sections of 0.75mm2 or greater and with lower material costs. However, the terminals must be designed for aluminum conductors to ensure long-term reliable electrical contact. TE Connectivity s LITEALUM crimp termination system is specifically designed for automotive use and has been validated to customer requirements. As with previous systems, LITEALUM crimp termination processes can be fully automated and are therefore cost-neutral with regard to the production process. In addition to lighter materials, vehicle weight reduction can be achieved via less material. As the trend for electronic component miniaturization continues, TE Connectivity offers automotive-proven, miniaturized interconnection systems to meet our customers needs. New challenges for developers of electrical connection technology are also arising from another trend in the automotive industry: motor downsizing. This yields higher power-to-weight and torque-to-weight ratios, but it also creates very high vibration stresses that vastly exceed previous levels for connector systems. TE Connectivity s answer to these significantly more demanding requirements is an innovative connector system based on the HPF 1.2 termination system. The system is compatible with the VDA interface and can be used without any restrictions. It ensures reliable contact with motor components exposed to high vibration levels, such as throttle body actuators or injection valves. Newly developed surface coating systems are also available to make the connector system suitable for use with future temperature and vibration profiles.

20 20 TRANSPORTATION SOLUTIONS / /// RODUCT NEWS 2015 LITEALUM CRIMP SOLUTION FOR FULLY AUTOMATED TERMINATION OF ALUMINUM STRANDED WIRES IN THE CAR TE Connectivity has developed a crimping solution to the challenges of terminating stranded aluminum (Al) wires in vehicle applications. The LITEALUM terminal, its surface topography, and crimp geometry have been specially tailored to the material properties of Al conductors. Among other things, the durable electrical connection is not based on the residual stress in the crimp barrel. Instead, it is the cold-welding of Al and copper (Cu), brought about during the crimping process, which ensures the interconnection. As the residual stress of the barrel is below the threshold that could cause creep, a potentially problematic shrinkage of conductor material from the contacting area is avoided. LITEALUM crimps offer vehicle manufacturers, suppliers and harness makers a fully automated termination solution for Al stranded wires. Aluminum plays an important role in the vehicle E/E architecture because it offers weight benefits over Cu conductors. From a wire cross section of 1.5 mm 2, LITEALUM crimping meets the valid automotive pull-out force requirements. By giving the crimp barrel and finished crimp connection a conical shape, any notching effect on the Al wire is prevented. As a result, the LITEALUM crimp has an excellent bending fatigue strength. The cold welding is caused by sharp-edged serrations on the inner surface of the crimp barrel. During the crimping operation, the edges of the serrations break up the thin oxide layer on the conductor and enlarge the interconnection area. During the cold-forming, the cross section is greatly reduced by typically >50 per cent to establish a solid intermetallic connection between Cu and Al with excellent electrical properties. By including the wire insulation in the crimp at the rear end of the barrel and compressing sealant deposits at the barrel s front end, the finished crimp withstands cyclical salt spray tests combined with thermal shock environmental conditions, which would cause electrochemical corrosion of the aluminum. TE Connectivity s LITEALUM wire crimp termination technology is a new generation of wire crimps that connect aluminum wires to standard, proven copper alloy terminals in motor vehicles. Our technology enables a seamless transition from copper to aluminum wire, while protecting against galvanic corrosion and providing a stable, secure electrical connection, said Kianusch Lindenberg, Product Manager Aluminum T&C Portfolio. Aluminum wire provides the benefit of being lighter than copper wire, effectively reducing vehicle weight for greater fuel efficiency and lower emissions. David Fleak (336) david.fleak@te.com

21 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS NEW TE CONNECTIVITY AUTOMOTIVE PLUG-IN LATCHING RELAY HELPS REDUCE BOTH ENERGY CONSUMPTION AND CO 2 EMISSIONS TE Connectivity presents its first bistable automotive plug-in relay in the maxi class. The power relay F7 A latching is a bistable single-coil version realized with a permanent magnet. It expands the TE bistable relay portfolio with a plug-in version in the maxi class. Bistable relays only need a short pulse of energy applied to the coil to change the switching state. It is not necessary for power to remain applied in order to maintain the switched state. Power consumption is significantly reduced, especially for applications that must remain switched on over a long period of time. Power relay F7 A latching and other bistable relays offer several advantages over monostable (non-latching) variants. One such advantage is the decreased coil power requirement in bistable relays translates to reduced temperature rise. Product highlights Magnetically latched ISO plug-in relay One coil with set and reset function Plug-in terminals based on ISO 7588 part 1 60A continuous current at 85 C Customized versions available Typical applications Cross carline, e. g.: Power outlet switch-off Start-stop Energy management This means at the same ambient temperature a bistable relay can conduct higher continuous current than a monostable relay. If a bistable relay and a monostable relay are carrying equal continuous currents, the bistable relay may be used at higher ambient temperature. Additionally, the vehicle s energy consumption and CO 2 emissions are considerably reduced. Given that relays consume up to 10 % of a vehicle s electric power, the power relay F7 A latching offers considerable energy saving potential within the vehicle. Katharina Biehl +49 (0) katharina.biehl@te.com

22 22 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 WHERE ROBUSTNESS AND RELIABILITY COUNTS: HPF 1.2 CONTACT SYSTEM FOR HIGH-VIBRATION APPLICATIONS TE Connectivity (TE) recently released a new highvibration contact for engine mount applications the HPF (High Pressure Flat) 1.2 contact system. To withstand harsh environments, TE added innovative design features like a meander structure for compensation of external forces and movements. Vibration levels in engine mount applications have dramatically increased over the last few years. To meet these requirements TE created the new HPF 1.2 contact system. The design is similar to HPF 1.5 contact system but adapted to the standard 1.2mm Interface. The suitable tab size is 1.2 x 0.6mm. The HPF 1.2 contact is compatible with the VDA interface of 1.2mm. High-contact normal forces characterize the HPF 1.2 contact system, compared to standard automotive contact systems. The contact system is available as a sealed version from 0.35mm 2 up to 1.00mm 2 with a silver surface and temperature range of up to 150 C. A full-automatic or semi-automatic termination process with process control is also possible as a manual handling at the harnessmaker similar to actual contact systems In addition to the new contact system, TE also released the mating receptacle housings with 2 pin counts. A 3-way version will follow early in The housings are also compatible with existing VDA 1.2mm interface. Thorsten Eisele +49 (0) teisele@te.com

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25 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS CONNECTIVITY FOR EVOLVING VEHICLE ARCHITECTURES Evolving vehicle architectures are changing the landscape of automotive connectivity. Automotive OEMs will soon introduce a second co-existing 48V system to support the power demands for future vehicles. With the improved dynamic of power transfer from or to the battery, 48V is the enabling technology to increase the recuperation effect, allowing implementation of new fuel saving technologies like electrical super chargers. 48V also facilitates transfer of current 12V applications including heated front and rear windscreen, HVAC systems, cooling fans, electrical power steering, start-stop systems, PTC heater, damping systems and pumps to the lower load currents. Switching power loads under 12V and 24V is a known and safe practice in passenger and commercial vehicles. Under 48V, the load current will be reduced by a factor of 4, but the possible occurrence of severe arcing at higher voltage levels must be considered for power connectivity. To switch such loads under 48 V, TE Connectivity is offering a portfolio of relays that are especially optimized for higher voltage levels. For the physical components in a wiring harness like connectors, TE Connectivity is offering a portfolio of existing sealed connector systems including the sealed HDSCS connector series. In addition, TE Connectivity is recommending a secured routing for the wiring harness with access restriction and central switch off when the 48V system is under maintenance. With cost factors driving the need for a 48V system, a common test specification and a principle damage avoidance for vehicle architecture and physical components under 48 V is mandatory to obtain cost efficiencies. TE Connectivity is addressing these trends today, as well as working on solutions for future architectures in support of distributed load control and intelligent power management.

26 26 TRANSPORTATION SOLUTIONS / /// RODUCT NEWS 2015 AMP MCP 6.3/4.8K RECEPTACLE TERMINAL: SOLUTION FOR DIRECT MATING TO MEDIUM FUSES TE Connectivity has developed a new AMP MCP 6.3/4.8K receptacle terminal to specifically meet the requirements for direct mating to medium fuses (compliant with ATO fuse technology) in fuse- and relay box applications in vehicles. The requirements for the medium fuse pushed the development of a new AMP MCP 6.3/4.8K receptacle terminal. Two main technical differences between the medium fuse and standard tabs triggered the need for a new product; the medium fuse tab thickness is 0.64mm (standard tabs are 0.80mm) and the base material of the medium fuse tab is a Zn-alloy which is a softer material than that used for standard tabs (standard tabs mainly use CuSn, CuFe or CuZn as base material). The new AMP MCP 6.3/4.8K receptacle terminal is designed to be used for tab sizes of 0.64 ± 0.04mm (thickness) and from 4.8mm to 6.3mm ± 0.1mm (width). The base material is a CuNiSi alloy with a top spring of stainless steel and the surface finish is selective silver in the contact area. The new terminal has been validated to meet the requirements according to LV 214. Application tooling used when crimping the new terminal to wires are the same as the existing AMP MCP 6.3/4.8K receptacle terminals. TE Connectivity s new AMP MCP 6.3/4.8K receptacle terminal for medium fuses is an extension of the AMP MCP terminal product line. The new terminal fits to the same connector cavity as the existing AMP MCP 6.3/4.8K receptacle terminal and it also meets the requirements of the LV 214 specification, said Joakim Mattsson, Product Manager AMP MCP T&C Portfolio. Our new terminal enables a desirable transition from older products to use state-ofthe-art technology for direct mating to fuses in fuse- and relay box applications. The softer base material of the medium fuse also required a new design of the receptacle terminal and the engineers at TE Connectivity have developed a new wave-form shape instead of the four contact points of standard AMP MCP 6.3/4.8K receptacle terminal. ATO is a trademark. Joakim Mattsson jmattsson@te.com

27 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS WHERE POWER AND RELIABILITY COUNTS: MCON 8 CONTACT FOR HARSH ENVIRONMENTS TE Connectivity (TE) recently released a new member of the MCON contact family the MCON 8 contact system. With the MCON 8 contact system, TE closed the gap to meet existing cavity and interface specifications of the automotive industry, i.e. for cooling fan applications. To withstand harsh environments, TE added innovative design features like overstress protection of the contact elements, as well as a new surface technology to be compliant with high temperatures up to 180 C. The contact system is available in sealed and unsealed versions from 2.5mm 2 up to 16mm 2 (sealed 16mm 2 is planned). The MCON 8 contact system is compatible to the tab contact dimensions 8.0mm x 0.8mm / 9.5mm to 0.8mm / 8.0mm x 1.2mm and 9.5mm x 1.2mm. Redundant designed contact points ensure the electrical integrity of the MCON 8 contact system and make it rugged and versatile. Thorsten Eisele +49 (0) teisele@te.com

28 28 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 SAFE CONNECTION AND DISCONNECTION: 48V RELAYS FROM TE CONNECTIVITY When switching electrical loads under 48V conditions with automotive relays, the quadrupled voltage requires that the contact systems be adapted as, in principle, steadily burning DC arcing can form. This mainly depends on the contact spacing. If the distance is too small, the electric circuit might not be interrupted when the contacts open and the continuously burning arc would destroy the relay. If single interruption with a given contact spacing is not sufficient to switch off the circuit, various options for the design of the switching contacts are available to increase the arc burning voltage: TE Connectivity offers a series of relays that with the help of such measures have been optimized to switch higher voltages. In addition to these solutions for the 48 V on-board electrical system, products for use in hybrid and electric vehicles with nominal voltages of up to 450 V are available. Larger contact spacing Multiple interruption by utilizing a bridge contact that divides the arc into several partial arcs in series Lengthening the arc column using a special electrode shape (e. g. classic horn shape) with/without additional isolation ribs Arc extinguishing plates: Separation of the arc into several partial arcs (addition of voltage drops of several drop areas: Deion Principle). Hereby the arc is driven into the arc extinguishing plates of an appropriate plate chamber and is divided into partial arcs, resulting in a substantially increased total voltage drop Cooling the arc using cooling or insulating material chambers Benjamin De Roo (336) benjamin.deroo@te.com

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30 30 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 SENSOR SOLUTIONS

31 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS SENSOR TECHNOLOGY Electronic control systems in modern vehicles rely on sensor signals such as travel, angular, pressure, speed and temperature information, as a basis for control activities. Automotive sensors provide this data under harsh ambient conditions with a high degree of reliability. TE Connectivity is a leading global source of automotive sensor solutions and supports customers in selecting the appropriate sensor technology, optimizing and designing the sensing and electrical circuit and finding the most suitable mechanical design with an optimized electrical interconnection system. Our latest innovation is a 3D Hall Effect sensor with increased performance and a design that meets ISO safety level B. This product works with small trigger magnet sizes and is extremely robust in terms of mechanical air gap tolerances. Other technology highlights include pressure sensors for very harsh environments, such as brake booster or gasoline direct injection applications, and the single-coil resolver for hybrid and electric vehicles using a synchronous machine as part of the power train. In addition to individual standalone sensors, TE Connectivity has broad experience in sensor-integrated modules that incorporate different sensor functions into one package for typical applications such as automatic transmissions. TE Connectivity s sensor solutions are proven in dualclutch and other gearbox systems, regenerative and electro-hydraulic braking systems, stop/start systems, clutch position detection, rear axle steering and many more applications.

32 32 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 RELUCTANCE RESOLVER FOR HYBRID AND EV APPLICATIONS New emission legislation and the trend towards energy-efficient transportation are driving increased development in the area of hybrid or electrical propulsion for all kinds of vehicles. When braking, the energy is converted and stored in the batteries. When the vehicle accelerates, the available electric energy is used to help the car speed up by releasing this energy into a controlled electric motor. More advanced systems may continuously drive the cars electric motors. To keep the efficiency of the electrical motors at a maximum level, the position of the drive shaft must be continuously monitored. TE added new features to this resolver market by developing an innovative winding scheme and component layout that provides a more cost-efficient production process without reducing the high accuracy of the resolver. To meet different market needs and application conditions, the resolver was developed as a product platform. Because of this, it is now possible for customers to choose the ideal fitting diameter and pole number without increasing development lead times. The currently available pole pair numbers are 2-, 3-, 4-, 5-, 6-, 10-, 12-, and 18-speed. TE Connectivity (TE) has developed a breakthrough inductive sensor known as reluctance resolver that helps reduce fuel consumption. The reluctance resolver is part of a system to measure shaft angles. It consists of a stator (non-moving) part with radially placed coils, and a rotor (rotating center part) made out of a laminated core with a specific geometry. Primary coils on the stator are generating a magnetic field, influenced by the rotor. On the same poles there are also secondary coils, where output voltages are induced by the variable magnetic field. The rotor geometry is designed to transfer the angle position into a sine and cosine signal. With standardized electronics, the angle of the drive shaft is measured accurately. This enables the control system to optimize the efficiency, torque and power of the electrical motor. Two product families are available: the Multi Coil Resolver (MCR) is made with several coils assembled on the stator, connected with a PCB. It is typically used for smaller E-Motor diameter in dry applications. Single Coil Resolver (SCR), with winding directly on the stator, is designed for applications in oil. The SCR is mainly used for larger diameters, has a reduced thickness and can also work at extreme temperatures. Both the MCR and SCR are typically protected with one or two covers and are available with cable and connector. Additional sealing is possible. The complete assembly is fully tested and designed to simplify installation onto the electric motor. TE s experience in magnetic fields and winding technology is the foundation for innovative solutions in this application area. Scott Phillips (248) scott.phillips@te.com

33 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS NEXT-GENERATION NEUTRAL POSITION DETECTION FOR START-STOP SYSTEMS Today, many automobile manufacturers have integrated a start-stop system into their cars to meet the latest legislative requirements for fuel consumption and CO 2 emission reduction. TE Connectivity was the first company to integrate a non-contact position sensor into the transmission, based on PLCD technology, to enable the detection of gear lever neutral position. Overall, this next-generation neutral detection sensor can reduce system cost on the manufacturer side through enhanced functionality. At the same time, it provides a highly reliable (due to non-contact technology) sensor signal in the harsh environment of automotive transmissions. Because the sensor can detect linear and rotary movements of the shifter shaft at the same time, it may also be suitable for other applications such as automated manual transmissions. The next generation of neutral position sensor, developed by TE Connectivity, is based on 3D Hall Technology. Instead of simply detecting the neutral position, this sensor is now able to detect all gear positions, including reverse. In addition to expanded functionality, this next generation sensor supports a variety of electrical interfaces, including analog, PWM and even the digital SENT protocol. Scott Phillips (248) scott.phillips@te.com

34 34 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 TRAVEL, ANGLE AND SPEED PLATFORM CONCEPT FOR AUTOMOTIVE SENSOR APPLICATIONS In the automotive industry, development time is a key factor for successful market positioning. TE Connectivity s answer is a platform strategy for non-contact travel, angle and speed sensors. Standardized designs and production processes offer short-term availability of fully functional sensors for system testing and low-volume production. Depending on the field of application, different technologies will be used. The first platform is the PLCD travel and angular sensor for measurement ranges up to 55mm or 120. Thanks to the system s robustness, the possibility of large-scale integration and the high linear performance of PLCD in high-vibration and high-temperature applications, this technology is preferred for harsh environment systems (e.g. transmission, clutch). The second platform TE Connectivity can offer is the Hall technology based travel and angular sensor for measurement ranges up to 40mm or angle up to 360. Travel and angle measurement can be realized within one sensor package. It also enables the opportunity to incorporate 12V board net supply, ISO safety level B and up to three outputs, which can operate as programmable linear or switch outputs. Compared to inductive systems, TE Connectivity s hall sensor platform needs minimal space and makes more cost-effective production possible. Our platform sensors are all suitable for IP class 6K9 applications, which makes them suitable for harsh automotive environments. At the same time, the Hall platform sensors can be programmed to suit customer specifications regarding measurement range and electrical interface (PWM or analog). Our third platform is the speed sensor for gear speed measurement. This pre-biased Hall sensor is triggered by ferromagnetic gear wheels. Thanks to its compact and robust packaging with integrated sealed connector interface (IP6K9), it can be used for all kinds of application (e.g. transmission). The sensor also provides diagnostic functionality, thanks to 2-wire technology, and is validated for a temperature range from -40 C to +150 C. The Hall technology used is a 2D/3D measurement principle that results in a significant measurement performance increase compared to existing Hall sensors. This sensor exhibits high performance related to linearity error and temperature drift. Scott Phillips (248) scott.phillips@te.com

35 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS NEXT-GENERATION POSITION SENSOR FOR PNEUMATIC TURBO ACTUATOR TE Connectivity has developed a second generation of linear position sensors to measure the stroke of a pneumatic actuator. This sensor features full contactless design and is based on innovative 3D Hall technology. Pneumatic actuators can work with vacuum or compressed air and are often used in the motor compartment, especially in the exhaust gas system to regulate waste or exhaust gas recirculation valves and variable turbo nozzles. Potentiometers and other mechanical designs (e.g., with guided magnets), have limited durability and lifecycles and are generally not suitable for such harsh environments. By eliminating mechanical wear, TE Connectivity s contactless position sensors combine high durability and performance with an almost unlimited number of cycles over the product s lifetime. Sensor packaging can be adapted to the specific application. For example, measurement stroke, piston angle deviation and actuator diameter can all be modified according to customer needs. The sensor can be included in the upper cover of the actuator as a full plastic cover design, or delivered as a separate part with a sealed mechanical interface to the actuator. Layout of the magnetic circuit, design of the magnet clip and delivery of the magnetic target are also included; not only during development but also in serial phase. This means that the customer is buying a complete functional system, not just a stand-alone sensor. These sensors generally require an analog ratio metric interface to the ECU, but can also be programmed according to the PWM protocol. Scott Phillips (248) scott.phillips@te.com

36 36 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 VACUUM BRAKE BOOSTER SENSOR Current brake actuation systems consist of a brake booster and master cylinder. The systems are typically used with traditional internal combustion engines, which generate a significant vacuum in the intake manifold and the vacuum can be used to amplify the brake force applied by the driver via the brake pedal to activate the vehicle s hydraulic brakes. With an increasing number of today s vehicles using direct injection, diesel, hybrid electric or full electric technologies to improve powertrain efficiency, there can be insufficient vacuum available to provide full braking assistance to the driver. Vacuum also becomes mandatory for various vehicle/brake performance features like Start/Stop, Engine Cold Start Support, Failed Boost or Over Boost Support. To fill this gap, an electric vacuum pump can be used to maintain vacuum amplification or provide extra levels of power in order to stop the vehicle if vacuum is depleted. This vacuum pump is controlled by the brake system, which uses information from the vacuum sensor to supply on / off command signals to the pump in order for sufficient amounts of brake boost to be delivered to maintain braking performance. The vacuum sensor is mounted to the brake booster and detects the level of vacuum inside the booster s vacuum chamber. TE Connectivity can offer a MEMS (Micro Electro Mechanical Systems) technology-based vacuum pressure sensor which is located on the booster check valve measuring differential pressure between ambient pressure (atmosphere) and brake booster pressure. The advantages of this design are flexible calibration of the transfer function, high accuracy and temperature stability and a flexible housing, connector and mounting design. In addition to the pressure information, the sensor provides diagnostic functionality information through the SENT output which fulfils Automotive Safety Integrity (ASIL) Level C according ISO This technology is also suitable for different applications in the low pressure area. Scott Phillips (248) scott.phillips@te.com

37 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS GASOLINE DIRECT INJECTION / PRESSURE SENSOR Gasoline direct injection (GDI) represents one of the most promising concepts for reducing CO 2 emissions produced by combustion engine vehicles. A substantial part of the development activity is aimed at meeting current and future emission standards. GDI engines generate the air/fuel mixture in the combustion chamber. During the induction stroke, only the combustion air flows through the open intake valve. The fuel is injected directly into the combustion chamber by special fuel injectors. TE Connectivity (TE) Sensor Solutions has developed a new GDI Pressure Sensor to help control the important fuel injection pressure. The sensor uses Piezoresistive technology, thin deformable metal diaphragms and resistors that are connected in a unique configuration. The result is a durable, highly reliable sensor with a desirable level of sensitivity. The GDI pressure sensor achieves a functional range of bar and an overpressure up to 460 bar on a temperature range from -40 C up to +140 C.The new technology is already automotive qualified, approved and in production with various OEMs. With this innovative product, TE is able to provide a key solution for future applications and internal engine management systems. Scott Phillips (248) scott.phillips@te.com

38 38 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 INDUSTRIAL & COMMERCIAL TRANSPORTATION

39 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS TERMINATION SYSTEMS FOR HARSH ENVIRONMENTS Whether in an excavator standing in mud up to its wheel hub or in a freight truck that covers hundreds of thousands of kilometers every year, the components of an on-board power supply system must be able to handle as much punishment as the mechanics of the vehicle. TE Connectivity s Industrial & Commercial Transportation (ICT) business unit is one of the world s leading providers of relays, sensors, and connectors that can withstand even tough operating conditions. Additionally, ICT also serves manufacturers of long-distance and city buses, agricultural machinery, and all kinds of leisure vehicles from quad bikes to jet skis. All of these applications present high demands on electrical systems service life, vibration resistance, environmental sealing, and thermal behavior. ICT offers a product portfolio tailored to every need. A crimp termination system throughout the segment ensures that economies of scale arise despite the great variety of variations, which simplifies production as well as after sale business. New regulations and growing demands in the market mean that the degree to which utility, agricultural, and construction vehicles are equipped with complex electrical systems will continue to grow. Increasingly strict regulations on usage and CO 2 emissions will result in drivetrains becoming hybridized and equipped with sophisticated electrical systems. Consumer demand for convenience, safety, and information systems is also driving vehicle manufacturers to develop more advanced electrical systems. In the future, the complexity seen in the electrical systems of modern cars will be found in the industrial and commercial transportation markets. The need for dependable and reliable connectivity products that are designed to withstand harsh environmental conditions has never been greater. TE Connectivity is prepared for these trends. The Industrial & Commercial Transportation business unit builds on over 50 years of experience in the development and production of connection systems for these kinds of specific applications and benefits from the company s expertise in the automotive industry.

40 40 TRANSPORTATION SOLUTIONS / /// RODUCT NEWS 2015 LEAVYSEAL CONNECTOR SERIES Building upon the strengths of TE Connectivity s robust AMP MCP contact family, LEAVYSEAL connectors are suitable for commercial vehicles, agricultural machinery, and construction equipment, and are designed to withstand extreme conditions such as dust, moisture, and vibration. LEAVYSEAL connectors are wire-to-wire and wire-toboard connectors intended for a variety of uses including signals and higher current applications. The LEAVYSEAL connector series is particularly suitable for high-vibration locations such as on the bulkhead, engine, transmission control, and on door modules. The connectors casing design allows for a protection rating of up to IP 6K9K. Seven different casing forms are available with cavities arrangements ranging from 15 to 120. Several connector options are also available, including reverse polarity protection, flange mount, keying options, PCB mount variations, and an option with each connection individually sealed. In order to meet requirements for fire load reduction in the driver s cab, TE Connectivity also offers LEAVYSEAL in flame-retardant class UL94 V-0 material, which can be easily identified by the connector s unique red locking latch. Additionally, TE Connectivity has expanded the company s corresponding multiple, sealed adapter plate offerings up to four bays. The lever-actuated LEAVYSEAL connector series uses contact sizes AMP MCP 1.5, 2.8, and 6.3 contacts, which carry between 20 and 40 A and have conductor cross-section ranges from 0.2 to 6mm 2. Philipp von Wedelstaedt +49 (0) pvonwedelstaedt@te.com

41 TRANSPORTATION SOLUTIONS /// RODUCT NEWS HDSCS CONNECTOR SERIES The heavy duty sealed connector series (HDSCS) is based on the AMP MCP contacts. HDSCS connectors meet manufacturers new, increased test requirements and are designed for use in a vehicle s chassis, engine compartment, and gear box. These heavy duty connectors are optimized for temperature resistance, vibration, as well as mechanical resilience. The heavy duty connector series features over 200 different components with arrangements ranging from 2 to 18 cavities. HDSCS connectors accommodate AMP MCP terminals in sizes 1.5, 2.8, or 6.3 and can be equipped with cable that exclusively transfers signals, cable that exclusively carries current, or a combination of both cable types. The connectors feature a secondary locking device for the terminals and four keying options with corresponding colored markings to reduce assembly errors. HDSCS connectors can be painted and the connector s tri-lipped seal has now been placed on the inner surface of the pin housing, an area better protected from mechanical damage. The seal achieves protection class IP 6K9K. The connector s casing consists of class V-0 flame-retardant material. Due to its impressive characteristics and the application of modern flat contacts, the HDSCS connectors distinguish themselves from other connectors. Many manufacturers of agricultural and construction vehicles are turning to the HDSCS as their choice of connector. The HDSCS also includes a new locking mechanism that uses less space and makes it easier to open and close the lock. The new design allows for the connectors to be grouped together closely. Philipp von Wedelstaedt +49 (0) pvonwedelstaedt@te.com

42 42 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 DEUTSCH DT SERIES CONNECTORS TE Connectivity s DEUTSCH DT series environmentally sealed electrical connectors are general purpose connectors that provide reliability and performance on the engine or transmission, under the hood, on the chassis, and in the cab. Designed specifically for cable-to-cable applications, DT connectors are used in harsh environment applications where even a small degradation in connection may be critical. The DEUTSCH DT series thermoplastic housings offer a wide operating temperature range and silicone rear wire and interface seals allow the connectors to withstand conditions of extreme temperature and moisture. DEUTSCH DT series connectors provide field-proven reliability and rugged quality. The DEUTSCH DT design strengths include optional flange mounting, multi-pin arrangements, and design flexibility. DT series connectors offer the designer the ability to use multiple size 16 contacts, each with 13 amp continuous capacity, within a single shell. Contact insertion and removal does not require any special tools and the connectors may be populated with either solid or stamped & formed style contacts. Contacts are retained in locked position by dielectric fingers which are molded as an integral part of the housing. Secondary wedgelocks are assembled at the mating interfaces to confirm proper contact positioning. Accessory items are available to complement the connectors including boots, backshells, gaskets, dust caps, and mounting clips. Accessory items cover a wide array of design requirements such as assisting with mounting, providing additional protection, and offering enhanced aesthetics. Several modifications to enhance the design flexibility and meet application specific needs are also available. Options include enhanced seal retention, flanges, and connector body color just to mention a few. By combining the DEUTSCH DT series connectors with the available modifications and accessories, the design possibilities are immense. Philipp von Wedelstaedt +49 (0) pvonwedelstaedt@te.com

43 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS HIGH-CURRENT RELAYS (HCR) FOR AUTOMOTIVE APPLICATIONS: TE S HCR 150 AND HCR 200 With the high-current relay 150 (HCR 150) and highcurrent relay 200 (HCR 200), TE Connectivity offers two ideal solutions for all automotive applications, where particularly high load currents must be handled. While the HCR 200 with its normally-closed contact is primarily utilized in applications such as start-stop systems with a focus on interruption of high-currents, the HCR 150 with a normally-open contact or a changeover contact covers a wide variety of different applications in the automotive environment. Along with the continued increase of electrical and electronic driver assistance systems, the demand for relays, that can not only carry and switch such high loads, but also ensure a reliable function at temperatures up to 110 C, is continually rising. TE Connectivity s high-current relays HCR 150 and HCR 200 represent an ideal solution for these application fields. Georges Ngongang +49 (0) georges.ngongang@te.com

44 44 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 UNIVERSAL HIGH-CURRENT RELAY BATTERY DISCONNECT SWITCH A (BDS-A) TE Connectivity s battery disconnect switch BDS-A represents a latching high-current relay that has been developed for system voltages of up to 48V. For the constantly increasing number of relay applications with particularly high-power requirements, the BDS-A allows a continuous current of up to 190A at 85 C. Thanks to its bistable (latching) switching mode, it does not consume any permanent power on the coil side. This enables this relay to be used under ambient temperatures of up to 85 C. Other important performance features include a peak current capability of up to 1800A and a maximum shock load of up to 40g. In addition to the connection and disconnection of vehicle batteries, start-stop-systems, high performance electrical heaters, drives and pumps are some typical applications for the BDS-A. Georges Ngongang +49 (0) georges.ngongang@te.com

45 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS NOTES

46 46 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 APPLICATION TOOLING Michael Emenheiser (717) mremenheiser@te.com

47 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS COMPLETE SOLUTIONS FROM START TO FINISH: TE APPLICATION TOOLING, A BUSINESS UNIT OF TE CONNECTIVITY When you acquire tooling and equipment from TE Application Tooling for processing connector products from TE Connectivity, you re making a good choice. You can be sure that you have the right tool for the job simply because we design them around our own TE Connectivity crimp specifications. An example would be small cable cross-sections, which are now more and more commonly used in the automobile industry and require precision tools that can be used to create sealed crimp connections without damaging the fine conductor. TE Application Tooling provides a broad range of equipment, depending on what is needed by the customer in terms of volume production. It spans a broad spectrum, ranging from specialized hand crimping tools to applicators with a pneumatic or mechanical contact feed all the way up to complete block loading systems. The crimp quality can be documented during automatic processing with monitoring systems that are precise enough for the smallest cross-sections. Furthermore, TE Application Tooling offers standard equipment as well as customer-specific processing solutions for the entire connector market in almost every industrial sector, for every technology, and independently of the connector manufacturer. TE is a world leader in tooling, with more than 50 years of experience in tool development and processing. High quality standards in various working technologies, as well as efficiency and the economical service life of equipment are some of the hallmarks of our quality. Highly qualified technicians are available to professionally install your equipment, repair it, and perform maintenance. In order to maintain long-term high production quality of your machines and tooling, we offer training programs for machine operation, setup, and maintenance, as well as programs that provide your employees with the most up-to-date technical knowledge in the various technologies related to connection technology.

48 48 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 IMPRINT Product_News_Battery_Show_2015.indd :13

49 TRANSPORTATION SOLUTIONS /// PRODUCT NEWS Disclaimer Trademarks While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information in this catalog, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. TE reserves the right to make any adjustments to the information contained herein at any time without notice.. AMP+, AMP MCP, DEUTSCH, EVC, LEAVYSEAL, LITEALUM, MCON, MQS, NanoMQS, TE, TE Connectivity, TE connectivity (logo), and wevery CONNECTION COUNTS are trademarks. ubitricity is a trademark. ATO is a trademark. TE expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications. Other product names, logos, and company names mentioned herein may be trademarks of their respective owners. Picture Credits Page 17 by courtesy of ubitricity. Copyright 2015 TE Connectivity family of companies. All rights reserved.

50 50 TRANSPORTATION SOLUTIONS / /// PRODUCT NEWS 2015 GLOBAL CONTACTS For further contact information or countries not shown please go to: Product_News_Battery_Show_2015.indd :13