Motorsport Connectivity – the quest for smaller, faster, better
The never-ending search for the ‘winning edge’ in motorsport engineering inevitably results in constantly changing technologies with ever increasing demands on component performance and reliability. Modern high-end motorsport platforms, whether motorcar, motorbike or motorboat are complex entities where every component interacts and relies on others to provide a complete system, a system where the combined result is far greater than the sum of the individual components, and one where the performance of the system will only be as good as the weakest component. Within this fast-paced environment of change it is important to retain as much proven, dependable performance within the system as possible, allowing adequate engineering headroom for improvements without jeopardising the overall system and going backwards.
Electrical connectivity now plays a significant part in this complete system approach, with elements such as electronic controls, sensors, engine management and reliability measures all interlinked to optimise performance whether for individual race set-up or throughout the complete season, while enhanced levels of safety and ‘black-box’ data-logging are also dependant on electronics systems.
Performance and dependability are key
As a backdrop to this evolving electrical technology, there are increased demands on weight and component real estate, while increased vehicle performance can also result in higher levels of temperature, shock and vibration, and with increasing more on-board electronics the demand for electrical power grows accordingly. High-end vehicles must now pack in far more technology that has to perform at higher levels, with greater reliability, without getting heavier or bigger. These environmental demands are just one area that makes the motorsport sector a unique challenge for electrical connector manufacturers. The best connector systems will be compact, light in weight, and perform reliably under these extreme conditions and are designed especially for applications where performance, size and weight are key.
For example, the EATON Souriau 8STA series of metal circular motorsport connectors share the same materials and design features as larger Mil-Spec connectors and is rated for an operational temperature range of -55°C to +175°C, 500 mating cycles, 300g shock for 3ms (EIA-364-27) and vibration of 147m/s2 at 10 to 2000Hz. There are as many as 13 different shell sizes providing up to 128 contacts, so the very best layout can be chosen in the most compact shell size without an excess of unused cavities adding to the size and weight. The Souriau 8STA circular connectors in particular are used extensively in motorsport platforms where applications include connecting ECUs, communications equipment, sensors, data acquisition systems, fuel pumps, starters, alternators and batteries throughout all levels of motorsport. Fuel-immersible and hermetically sealed version are also available for applications where extremes of temperature, vibration and many unpleasant liquids come together to provide the ultimate integrity test for connectors.
Designers developing next generation motorsport platforms are always requesting ever more complex electrical cable assemblies and harnesses that not only have lighter and smaller connectors, but also have more contacts, a higher current capability and much faster signal and data speeds to cope with the developments in communications and hybrid power.
Connectors and accessories from leading manufacturers such as EATON Souriau, Nicomatic, Weald Electronics, Huber+Suhner, Lemo and HellermannTyton help address these needs. The ultra-miniature 8STA connector in size 01 is the smallest circular metal connector available with #26 removable contacts and is the perfect solution for size and weight reduction in extreme vibration environments, this is available in 3- and 5-way layouts. The popular 2mm pitch CMM series by Nicomatic provides engineers with a very high-performance rectangular connector that offers as much as 20% space saving when compared to standard Micro-D connector systems, while the even smaller and lighter 1.27mm pitch EMM and 1mm pitch AMM series provide further solutions where size and weight are at an absolute premium. When additional electrical power is required, the very latest motorsport connector will also provide a range of high-power contact options. EATON Souriau 8STA series provides dedicated high-power contact layouts with up to #4 contacts and the Lemo M series offers a number of specific versions that have been developed with these high-power applications in mind with a current rating up to 430A, unipole and multipole configurations, IP68 sealing, scoop-proof and with IP2X finger protection. Electrical and optical connectivity expert Huber+Suhner address many applications for high-speed and high-integrity data transmission with their extensive range of ultra-lightweight RF and optical connectors, where some solutions can even be incorporated directly into the vehicle platform structure.
With the premise that the electrical system is only as good as the weakest component, connector accessories can provide a vital role in the overall performance and reliability. Weald Electronics produces a range of ultra-lightweight connector accessories that have been developed specifically for the motorsport industry, including specialist protective caps, gaskets and nut plates. The Weald protective caps for example can provide up to 40% reduction in weight over standard protective caps and Weald also provides a custom connector modification service that takes a standard product and alters its weight and size as required. Good examples include the increasingly popular single flange receptacle which has a single hole fixing making box mounting simple, reliable and weight-efficient, while tiny nut plates are designed to make installation easier.
Lane Motorsport is the division of Lane Electronics that specialises in meeting the electronic interconnection demands of motorsport in all its forms. To achieve this, we provide the latest high performance connector technology to give our motorsport customers the competitive edge. As well as connectors, we also offer a comprehensive selection of complimentary light-weight connector accessories all designed to meet the difficult environments found across motorsport, along with specialist connector assembly tooling and high-performance adhesives and dispensers.
Our motorsport connector and accessories represents products from leading manufacturers – Eaton Souriau, Nicomatic, Weald Electronics, Lemo, Huber+Suhner and HellermannTyton. However, our relationship with a wide range of suppliers also lets us access all types of complementary products for motorsport applications including cable management accessories. We are an assembling, value-add distributor for Eaton’s high-performance EATON Souriau 8STA circular connectors, fed from our extensive range of piece-parts in stock, to allow specific connector assembly to order with very short lead times and no MOQ’s. We also supply 8STA connectors modified to customer’s exact requirements in our in-house machine shop and assembly facility on very short lead times.