Protecting Vehicle Electronics Against Failure
The automotive interior landscape looks vastly different than it did ten, even five years ago. The push towards autonomous vehicles is changing the way automakers view the automotive interior layout. Time, and space, that was once utilized for driving will now be available for work and leisure. This presents more incentive for OEMs to improve their infotainment systems while integrating additional features such as adaptive instrument panels and adjustable seating configurations.
Utilizing 5G, AI, and IoT technologies tomorrow’s electric and autonomous vehicles will process more data, make more decisions, and send more signals than ever before. From automated climate control to gaze detection, these advancements require an increased number of sensors and electric connections. The failure of these features can range in consequence from mild irritation to legitimate safety concerns. The reliability of these sensors and connections will play a critical role in the public’s trust and adoption of autonomous technologies.
But just because autonomous vehicles are making their mark doesn’t mean that standard ICE and electric vehicles are going anywhere anytime soon. While technology advancements play catch-up and the public becomes more comfortable with autonomous driving, electric and ICE vehicles will need to step up their game to entice new customers. The vehicle is interior is one area where OEMs can distinguish themselves from the competition with added comfort and entertainment features similar to those of autonomous vehicles which means one thing – more connections.
Whether designing an ICE, electric, or autonomous vehicle, the failure of interior electronics can impact brand reputation, increase warranty costs, and affect technology adoption. In the chassis and powertrain, connectors are faced with a variety of challenges due to exposure to high temperatures and chemicals. Electrical components in the vehicle interior face a different, but equally important set of challenges.
Here are a few ways that you can improve the reliability of your interior sensors and connections.
Fretting corrosion is one of the most common causes of connector failure. Fretting corrosion is the result of micromotion caused by vibration and/or thermal expansion due to heating or cooling cycles. These micromovements wear down through the metal coatings into the base material that then becomes oxidized. As this oxide layer builds up and increases, the oxide film acts as an insulator between the contacts which creates an open circuit resulting in voltage drop across the terminal and ultimately, power failure or signal loss. All automotive connectors are constantly exposed to vibration during regular operation and are at risk of fretting corrosion unless properly lubricated.
Insertion force refers to the amount of force required to mate connectors during assembly or repair. As insertion force increases, the wear on the pin’s thin metal plating also increases. As stated previously, once the plating becomes worn, it becomes oxidized and can result in a short circuit. A thin film of lubricant can reduce mating force by as much as 80 percent. For automotive connectors that are in hard-to-reach places, a low insertion force makes assembly more efficient and ensures solid connections.
While environmental factors are a greater concern in chassis and powertrain applications, debris can still be an issue for interior automotive connectors. When contaminants reach the contact surface it introduces a source of friction which can eventually wear through metal coatings. Grease creates an environmental barrier to keep dirt, dust, and moisture away from the contact surface.
Nye’s Connector Lubricants
Nye Lubricants has a complete line of dielectric greases designed specifically to address application requirements for contact protection, insertion force, sealing, temperature limits and material compatibility. Our most popular connector greases are NyoGel® 760G, Rheotemp™ 768G, Rheotemp™ 769G, and Uniflor™ 8917.
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Properties |
||||
|
Temperature Range |
-40 to 135 °C |
-40 to 175 °C |
-40 to 175 °C |
-70 to 225 °C |
|
Base Oil |
PAO |
PAO/AN |
PAO/AN |
PFPE |
|
Fretting Wear Protection |
Excellent |
Excellent |
Outstanding |
Outstanding |
|
Dielectric Performance |
Good |
Good |
Excellent |
Good |
|
Insertion Force Reduction |
Excellent |
Excellent |
Good |
Excellent |
|
Water Resistance |
Excellent |
Good |
Good |
Poor |
|
Plastic Compatible |
Yes |
Yes |
Yes |
Yes |
|
Tin Compatible |
Yes |
Yes |
Yes |
Yes |
|
Noble Metal Compatible |
Yes |
Yes |
Yes |
Yes |
Learn More
We can work directly with your design engineers to form a partnership and assist with proper grease selection to ensure performance, avoid warranty claims and costly recalls. Contact an Engineer to learn more.
