Sanmina Cable solution Automotiv

THE CHALLENGE An automotive company needed a partner to co-design and manufacture a high definition camera cabling system by integrating power, video and a CAN bus. The solution had to incorporate a new water proof connector to accommodate high definition cameras and protect the fine gauge video signal wires from a harsh automotive environment including temperature variation from -40OC to +50OC, precipitation and road debris

WHY SANMINA The customer was impressed with Sanmina’s demonstrated expertise with advanced automotive cable designs operating in harsh environments. Sanmina’s cable designers also provided an understanding of design for manufacturing, and the material properties of automotive cables and connectors. These designers have designed numerous cable systems and transferred them to production in Sanmina’s twelve TS 16949 compliant manufacturing facilities.

Sanmina’s Approach ? A new connector was proposed by the OEM for use in the high-definition camera interconnection system, however it needed to be manufactured and waterproofed using an approved potting compound. ? Sanmina’s design engineers developed & fully validated the processing of the connector assembly and introduced a semi automated potting compound dispensing system to seal the connector. ? A zero PPM manufacturing process was developed using custom double crimp tooling to handle the fine gauge wires of the video signals. ? Cross section analysis and pull tests were used to verify that all crimps were gas tight. ? Sanmina developed the CAD models, schematic drawings and a working prototype was tested in vehicles. ? The CAD drawings were provided in the customer’s format. Results ? Cable system designed & prototyped in 8 weeks. ? Successfully tested in five different vehicles. ? The design successfully completed all the in-vehicle tests. ? The PPAP was successfully completed and the cable system went into production.