Thinking Out of the Box to Solve the Design Challenges of ADAS

(Image source: Molex)

As vehicles become smarter, becoming part of the Internet of Things (IoT) and implementing advanced driver-assistance systems (ADAS) capabilities, more electronics and power are required within automotive designs. At the same time, the same harsh environments and the need to limit weight apply. These overarching issues are particularly pertinent to power distribution boxes (PDB).

Trend #1

As automotive designers try to fit more power and smart capabilities into vehicles, main power distribution boxes become crowded, causing both space and thermal management issues. Overcoming these constraints often complicates design efforts and can increase engineering and manufacturing costs.

Solution:

µPDB Module and MX150 Hybrid Connector. (Image source: Molex)

Molex µPDB Modules, available through DigiKey, provide automotive engineers the flexibility to design power switching and circuit protection functions outside the main PDB and closer to the specific application by leveraging the following key features and advantages:

• Sealed solution - µPDB Modules meet IP6k7 standards, allowing engineers to locate the modules in areas previously off-limits due to the unsealed nature of auxiliary boxes
• Small footprint - µPDB Modules offer compact dimensions: H 33.00 by W 47.00 by L 78.00 mm
• Customizable- Any PCB-mounted component can be added to meet customers’ design requirements

All of these features enable our customers to place the µPDB Module in a location closer to the device, optimizing the space within the main PDB. For example, an automotive OEM needed to power the third-row seats in its minivan. In order to alleviate space constraints, a µPDB Module could be placed near the backend of the vehicle pulling power from a nearby source, rather than from the main PDB.

Trend #2

The demand for more data and power capabilities typically means more cabling in vehicles, increasing the vehicle’s weight and manufacturing costs.

Solution:

µPDB Modules enable automotive customers to place power switching and circuit protection closer to the intended device, minimizing the total amount of wiring required in the vehicle. Also, the µPDB Module is connectorized, mating with the newly released MX150 8-, 9- and 10-way Hybrid Connectors, which are also available through DigiKey. This further reduces the amount of wiring needed while also enabling more efficient and economical assembly.

Additionally, the MX150 Hybrid Connector utilizes the field-proven performance of 6 MX150 terminals with a mixture of 2.8 and 6.3 terminals based on customer requirements.

Going back to the example of the minivan’s third-row seats, the placement of the µPDB Module near the backend of the vehicle eliminates the need to run wiring back to the main PDB.

Trend #3

In ADAS applications, redundancy of key systems is desired, and often required by ISO standards, to ensure safety and reliability. Designing in redundancy, however, complicates efforts to maintain strict weight limits and often means having to find innovative ways to reduce the amount and size of components.

Solution:

µPDB Modules deliver an optimum solution for redundancy in safety system applications. Their small footprint and ability to be located near devices provides redundancy without adding to main PDB space constraints. Additionally, its connectorized feature, instead of hardwiring, and compactness mitigate weight increases.

Off-the-shelf versions of µPDB Modules, through DigiKey, deliver immediate availability to automotive customers. However, many applications have unique requirements. Therefore, Molex also offers the ability to customize the content of µPDB Modules with virtually any PCB-mounted component. This option enables us to provide value to our customers by engaging upfront in the system architecture design to meet their applications’ specific needs. Some of these customized applications include:  all-wheel drive modules, PWM cooling fan control modules, urea modules for diesel emissions, and cold start modules.