Contacting methods for electronic devices to novel wiring harnesses

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Vehicle safety, efficiency and equipment are the key decision criteria for the purchase of a new automobile. In all areas the technological progress is mostly based on functions which are realized by electronic components. This development is also reflected in the continually increasing of complexity, weight and space of on-board network systems despite the enlarged use of advanced bus systems. As a consequence, the harness and its mechatronic components have become one of the most difficult and most expensive modules in cars. In addition to the increasing use of electronic modules, in particularthe manual assembly and installation of conventional cable harnesses is responsible for high costs, since the large number of variants, the variety of individual parts and the elaborate handling of harnesses, an automatization based on conventional technologies is practically impossible. Against this background, developments were driven to new conductor systems, such as flexible flat conductors or additively applied conductor structures which enable a cost and weight reduction on the one hand and an increase in flexibility on the other. To use the technological advantage, complementary solutions forautomated contacting of the electronic components must be found. In this context, a new contacting method was explored, which allows to contact electronic components with novel harnesses automatically and combines the sub-process steps mounting, insulation contacting in one single step. This includes a holistic conception of a universal contacting method based on the applicable testing standards in the automotive industry, the basic analysis of the contacting efficiency with respect to mechanical and electrical parameters, the comprising assessment of the long-term reliability and the development of an exemplary de-monstrator. Through customers´ desire for an individualization of vehicles, new electronics-supported functions are continuously being added. In order to meet the increasing requirements on transmittable data rates of signal lines, the contacting method is intended to be characterized with respect to high frequency characteristics in a third year of the project. Moreover, by virtue of its cost and weight benefits the alternative conductor material aluminum is getting more and more interesting and therefor the suitability for the developed contacting method will be investigated as well. Finally, a demonstrator will constitute the applicability of the electrical contacting method for an automated contacting of signal lines and aluminum conductors.