![]() At the last station, a terminal body is crimped over the pair of wires, enabling the cable to plugged into a connector. And at station 10, ferrules are crimped onto each end.Īt station 11, the braid is brushed and inspected. At station 9, each end of the pair is stripped. At stations 6 and 7, the foil is perforated and removed from the twisted pair.Īt station 8, the pair is untwisted and spread apart, creating a Y-shape at the end of the cable. At station 5, the braided shield is peeled back and folded against the outer jacket. At station 4, the jacket is pulled off, and a support sleeve is crimped to the cable. It ensures that the insertion position in the crimp is correct even if the insulation is pulled forward.Īt the next two stations, the cable is oriented, and the outer jacket is cut and partially removed. This process is particularly useful when processing shielded cables or twisted conductors. In the first step, a wire is manually inserted into a fixture, and the machine pre-qualifies the end of the wire with a “zero cut” process. This allows vehicle manufacturers to run a single pair of wires to some sensors for all of their needs, reducing weight and simplifying harness design.ĭue to tight tolerances and high production volumes, Automotive Ethernet cables are typically not assembled manually, but rather, on automated systems that transfer wires from one process to another.įor example, the modular Lambda 416 from Komax automatically strips and terminates shielded, twisted pair cables in a 12-step process. PoDL can support up to 500 milliamps of power, enough for certain sensors, such as an optimized satellite camera. ![]() This is important to ensure uninterrupted connectivity for the major computing components in a vehicle.Īlso critical in vehicle networks is Ethernet’s ability to carry electrical power along with the data signal, a feature called power over data lines (PoDL), says Arpe. If there is a failure, an Ethernet router can route data traffic a different way. Shielded twisted pair wires are necessary at these speeds, but electrical frequencies in excess of 7 gigahertz may require the use of shielded parallel pair wires to minimize electromagnetic interference.Ī key benefit of Ethernet is that it is a flexible network, allowing easy reconfigurations, says Arpe. In 2020, the IEEE introduced 802.3ch, which provides for multigigabit Ethernet at standard rates of 2.5, 5 and even 10 gigabits per second over the same 15 meters. This standard will provide enough bandwidth for the next two or three generations of vehicle platforms. This means that the cables are more vulnerable to cross-talk, and engineers must keep this in mind as they manage electromagnetic noise throughout the vehicle, testing rigorously and shielding where needed. ![]() ![]() This standard shares many attributes with its predecessor, but the frequency is nearly 10 times as high, at 600 megahertz. Thus, soon after IEEE 802.3bw was finalized, the IEEE ratified 802.3bp, or 1000Base-T1, providing for gigabit speeds over shielded or unshielded twisted-pair wiring, says Arpe. But, as automotive computers incorporate higher-definition video streams and data from multiple sensors, higher speeds would be necessary, says Arpe. The data transmission speed of the IEEE 802.3bw standard can cover many initial automotive applications, so it is widely used today. ![]()
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