汽车 2024-01-15
汽车减重之CCA应用
客户: Global Automotive Manufacturer
15%
减重
8%
成本节约
+2%
燃油效率提升
挑战
在保持电气性能标准的同时减轻车辆重量
解决方案
在整个车辆电气系统中实施CCA布线
成果
减重 15%，成本节约 8%，燃油效率提升 2%
项目时间线
1
评估
分析50+ kg线束的替换候选方案
2
验证
通过ISO 6722振动、温度和盐雾测试
3
量产
无缝集成到现有压接工艺
详细报告
## Background
Modern vehicles are packed with electronics, leading to massive wiring harnesses that can weigh over 50kg. Reducing this weight is crucial for fuel efficiency and emissions targets.
## The Challenge
Replace copper wires in non-critical signal and low-power circuits without introducing new failure modes like galvanic corrosion or crimping issues.
## The Solution
Raytron CCA wire for automotive applications (ISO 6722 standard).
- **Terminals**: Used standard terminals designed for copper, as the CCA surface is copper.
- **Crimping**: Optimizing crimp height and force to ensure gas-tight connections with the aluminum core.
- **Corrosion**: The metallurgical bond prevents inter-layer corrosion.
## Results
- **Weight**: 15% reduction in total harness weight.
- **Cost**: 8% reduction in BOM cost.
- **Validation**: Passed automotive validation for vibration, temperature humidity, and salt spray.
