The automotive industry is rapidly transforming with megatrends such as environmental awareness, fuel efficiency, and autonomous driving. At the center of this transformation are the automotive cables that make up the "nervous system" of vehicles . With the limits of traditional copper cables being reached, engineers and manufacturers are turning to a new generation of cable technologies. These innovations offer a wide range of solutions, from reducing vehicle weight to increasing data transmission speed and withstanding harsh engine compartment conditions.
1. Lightened Cable Solutions: Weight Reduction and Efficiency
Vehicle weight is a critical factor in terms of range and energy efficiency, especially in electric and hybrid vehicles. As the importance of every gram has increased, there has been a need for significant weight reduction in cabling systems.
- Thin Section Cables: By optimizing the conductor cross-section of the cable, it is possible to provide the same current carrying capacity with a thinner wire. This can be achieved by using higher performance copper alloys or aluminum conductors. Thanks to advanced manufacturing techniques and insulation materials, high mechanical strength and electrical performance can be achieved even with smaller diameter cables. For example, an existing copper cable with a cross section of 0.50 mm² can be replaced by a cable with a cross section of 0.35 mm² and with the same performance.
- Aluminum Conductor Cables: Aluminum, which is much lighter than copper, offers an attractive alternative, especially in power cables that carry high current. However, due to aluminum's susceptibility to oxidation and its lower conductivity than copper, special alloys, surface treatment techniques (e.g. tin plating) and connection technologies (ultrasonic welding, special terminals) are required. These cables provide significant weight savings on heavy power distribution lines in the vehicle, such as battery and engine connections.
- Composite Cables: In some applications, composite conductors (e.g. copper-clad aluminum – CCA) can be used, which combine the advantages of copper and aluminum. Such cables offer a balance of both light weight and good conductivity.
2. Fiber Optic Cables: High-Speed Data Transmission and EMI Immunity
Autonomous driving, advanced infotainment systems, and in-vehicle sensor networks all need gigabit-level data transmission speeds. Traditional copper cables may struggle to meet these requirements due to signal loss at high frequencies and sensitivity to electromagnetic interference (EMI). That's where fiber optic cables come in.
- Data Transmission Speed and Bandwidth: Fiber optic cables can transmit audio, video, and data signals in the form of light pulses, carrying data at much higher speeds and bandwidths than copper cables. This makes it ideal for large data streams from camera data, radar and lidar sensors in autonomous driving systems.
- Immunity Against Electromagnetic Interference (EMI Immunity): Fiber optic cables are completely unaffected by electromagnetic interference (motor, electrical components, external sources) because they do not carry an electrical signal. This ensures interference-free and reliable data transmission, especially near the engine compartment and high-voltage power lines.
- Lightweight: They are lighter and thinner than copper cables, which contributes to reducing the overall vehicle weight.
- Application Areas: Today, fiber optic cables are used in automotive, especially in infotainment networks such as MOST (Media Oriented Systems Transport) and certain ADAS (Advanced Driver Assistance Systems) sensor connections. In the future, with the widespread use of autonomous driving, its usage areas will expand even more.
3. High Heat Resistance: Resistance to Extreme Conditions
Areas such as the engine compartment and battery packs are exposed to high operating temperatures. It is critical that the cables in these areas are resistant to prolonged heat and temperature fluctuations.
- Silicone Insulated Cables: Silicone offers excellent flexibility and electrical properties over a wide temperature range from -60°C to +180°C. It is also resistant to ozone, UV and chemicals. It is ideal for sensors near engine compartments, exhaust systems, and other components exposed to high temperatures.
- PTFE (Polytetrafluoroethylene) Coated Cables: PTFE, commonly known as "Teflon", is a superior insulating material with very high temperature (over 200°C) and chemical resistance. It also has a very low coefficient of friction. It is used in harsh environments (e.g. fuel systems, turbocharging areas) where there are extreme temperatures, aggressive chemicals or corrosion.
- XLPE (Cross-Linked Polyethylene) Developments: In addition to standard XLPE insulations, special XLPE formulations with higher temperature resistance and improved mechanical properties are also being developed. This helps to meet high temperature requirements while providing a more cost-effective solution.
Automotive Cables of the Future: Smart and Integrated Solutions
Next-generation cable technologies will not be limited to conductivity and durability. Automotive cables of the future:
- Smart Cables: Sensor-integrated cables that can self-diagnose and report anomalies such as temperature or damage.
- Modular and Plug-and-Play Solutions: Modular cabling systems that are easier to install and maintain, rather than complex wiring harnesses.
- Thinner and Lighter Connections: Further reduction of weight and volume at cable ends with advances in connector technologies.
These innovative approaches will shape the future of the automotive industry, making vehicles safer, more efficient, and more connected.
