Bridging the hybrid technology generation gap Amphenol

BRIDGING THE HYBRID-

TECHNOLOGY GENERATION GAP

Amphenol is a global leader in the design and manufacture of advanced interconnect systems and safety devices for the automotive industry. Philip Yorke talked to John Treanor, AutoMotive Group’s general manager, about the company’s latest products being developed for the evolving hybrid car industry and its expansion into new geographical markets.

The Amphenol Corporation is a global technology company that is present on every continent and with a turnover of approximately of $4 billion. The Group’s Automotive Division, is based in Germany and is a global supplier of advanced, interconnect systems for the automotive industry.

The company’s expanding portfolio of niche, on-board automotive electronics products covers a wide variety of applications ranging from communication, navigation, entertainment and telematics modules to advanced engine control sensors, actuators and lighting systems. In addition, Amphenol has developed groundbreaking solutions for hybrid electric vehicles and their drive systems, and is working with leading global automotive manufacturers to integrate these advanced interconnect products into the next generation of automobiles.

A recent example of Amphenol technology at work can be found in India where dramatic steps are being taken to offset increased pollution levels and traffic congestion. This has led to the promotion and adoption of hybrid electric vehicles in India, and Amphenol’s highly engineered products for hybrid vehicles form part of that country’s solution. For the last 12 months, Amphenol’s local engineers have worked together with Tata Motors to develop innovative, high-power interconnect systems for India’s first hybridelectric bus.

Innovation and acquisitions driving sales

Amphenol’s electronics division, dedicated to serving the automotive industry, represents a fast-growing sector within the Amphenol Group. The company operates three core business units: interconnect systems for safety applications, automotive cabling for use in hostile environments where high temperatures and vibration are issues, and Connectors and Assemblies for the Hybrid/Electric and Fuel Cell Markets.

Mr Treanor said, “There are two market forces that are contributing to our strong growth in automotive safety technology. In the emerging economies of the world and in particular in India and China, we are seeing more and more vehicles being produced with safety devices such as air bag systems, thanks to government legislation. In another effect, the latest models being produced by the world’s leading OEMs can have as many as 16–18 air bags per car. This means a growth in complete air bag systems, which is an area where we already have a significant market share and where we are seen as industry leaders in this technology sector.”

Mr Treanor added, “When it comes to innovation, we are blazing a trail as one of the first companies to invest heavily in the development of interconnect systems specifically for electric and hybrid vehicles. In fact, our pioneering technology has already been integrated in a number of new vehicles. We work in close partnership with every major OEM and tier-one supplier in the world and have located our manufacturing facilities close to our customers to increase customer service and efficiency. We will continue to grow organically and also through acquisition. We completed one purchase in April 2011 and expect to be acquiring several others within the next 18 months. We also strive to make our manufacturing plants as independent as possible, such as in Tunisia for example, where we have implemented new resources in the fields of testing, quality control and customer service to ensure the shortest route to market for our customers.”

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Setting new standards in connector technology

Amphenol’s safety restraint systems are the most advanced in the world thanks to its ongoing investment in product development and its innovative approach to providing automotive system solutions. The company also produces a wide range of high-power automotive Radsok based connectors and cable assemblies, as well as standard hybrid/electrical vehicle connectors and dedicated vehicle systems. In addition, Amphenol specialises in the design and development of multiple use electrical harnesses for lighting, sensor and steering wheel applications. At its Markt Lusteneau plant in Germany, the company produces high temperature exhaust gas cable assemblies and harsh environment engine-bay cable assemblies.

Recently, Amphenol developed a unique overmoulded RADSOK™ cable assembly system for high power automotive applications. These cable assemblies feature an environmentally sealed connection system. This latest design creates a more robust solution and broadens the scope of applications suitable for the company’s RADSOK ™ technology for use in harsh environmental applications.

Mr Treanor commented, “Our focus has always been on the development of products that help our customers to meet the challenges of tomorrow. Typically we like to be engaged in new product development at an early stage and support our customers in the development process and to be seen as an extension of their own R&D department. We like to develop customer-specific and application-specific products, on demand for our clients whenever they require our technological support.”

Amphenol also works with its customers to produce specialised LED systems for vehicle lighting. The approach is to provide a simple mechanical mounting system that is scalable according to the specific requirements of the customer, thus providing a low-cost, massmarket solution to what has traditionally been a high-cost option on luxury cars only. This approach also applies to other electrical harnesses for gearbox transmissions and diesel engines as well as for many other applications. In fact, it would appear that there is no limit to what can be achieved technologically, with the resources that Amphenol has at its disposal when it comes to developing automotive interconnect systems. n