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| Specifications | white paper |
| Business section |
| Specifications | white paper |
| Suggested Link Details/Purchase | |
| Content | The Benefits of Using a Decentralized Architecture Combined With PolySwitch PPTC Devices for Automotive Harness Protection Compared to conventional fusing, this approach is yielding significant weight/cost benefits while enhancing flexibility and reliability Guillemette Paour, TE Circuit Protection Today’s automobile manufacturers are actively working toward vehicle weight reduction in an effort to help reduce CO2emission levels and increase fuel efficiency. Consequently, design engineers are seeking new technologies and design techniques that will help lower wire harness weight. To remain competitive in today’s market, manufacturers must also reduce warranty repair costs and improve user satisfaction. As a result, automotive designers are confronted with the challenge of finding new ways to reduce vehicle weight without sacrificing system reliability. These industry trends are leading designers to revisit their approach to protecting automobile power functions against damage from high-current fault conditions. Despite the clear weight advantages of using a decentralized harness technique www.circuitprotection.com and PPTC (polymeric positive temperature coefficient) devices for overcurrent protection, many continue to use traditional—and ultimately heavier — fusing techniques. This paper presents the significant benefits of employing a decentralized architecture and TE’s PolySwitch devices to help protect automotive wiring harnesses, as compared to using a traditional centralized architecture with fuse protection. It also describes the unique device characteristics of PolySwitch devices, and provides specific application examples of how these devices, used in a decentralized architecture, can facilitate development of lighter, more flexible, and more reliable designs. Introduction Although a decentralized approach to harness protection that utilizes PPTC devices has been available since the 1990s, its adoption has been slow among OEMs. In fact, as electrical and electronic content has continued to add functionality, many wire systems in today’s automobiles have become bigger, heavier and more complex than ever. In addition to a resistance to changing traditional design methods, the benefits of using PPTC devices may have been hampered by the thicker wires historically used in vehicles. In the past, mechanical strength dictated that the smallest wire used in the vehicle was 0.35 mm²(22 AWG), which could carry current from 8-10A. This limitation cancelled some of the benefits of using PPTC devices for low-current signal circuits (e.g., <8A). Today, emerging wire material technologies are enabling much smaller-diameter wires with more current-carrying capacity, including wires as small as 0.13 mm²(26 AWG) with a maximum 5A capability. This advancement has led to additional weight savings when used with a PPTC-protected distributed architecture. One study, employing a decentralized architecture and TE’s PolySwitch devices, on a mid- to high-range passenger vehicle showed an estimated 50% savings in the weight of copper wires alone. Additionally, by using a decentralized architecture and replacing fuses with resettable PolySwitch devices, system reliability and design flexibility were significantly improved. Trends in Harness Protection In a car, current flows to the various electrical loads through several major and minor wire assemblies, which are distributed throughout the vehicle. Circuits typically carry 0.10A to 30A of current at system voltages of 14V for 12V battery systems (28V for 24V battery systems found in most trucks and buses). The wiring harnesses must be protected from damage caused by catastrophic thermal events, such as a short circuit. The challenge for designers is to add circuit protection devices that help protect against potential overload conditions in the electrical system, while simultaneously reducing total cost and weight. Since a typical vehicle may contain hundreds of electrical circuits and more than a kilometer of wire, the complexity of the wiring system can make conventional circuit design techniques difficult to use and may lead to unnecessary overdesign. Automobile Harness Protection WHITE PAPER |
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