December 15, 2009 -- Motorsport wiring specialist BERU f1systems has developed a way to allow 30 AWG lightweight wiring systems to be used in harsh environments. Developed in conjunction with Souriau, the new process eliminates special terminals or costly crimping tools, says the company, resulting in a wiring loom that is twelve percent lighter, sans the expensive component sand tooling of competitive offerings.
“Working closely with an F1 team, we looked at how we could use 30 gauge wire to reduce weight whilst also considering the ever increasing cost restrictions that the teams have to comply with,” says BERU f1systems principal engineer Gary Norman. “Other technologies are available but they require a tool that costs around £900, a specific 30 AWG wire that is four times the cost of our solution and they also need special terminals. These terminals also limit the range of connectors available resulting in weight or package compromises.”
BERU f1systems contends that its culture of improving all aspects of vehicle performance allowed the company to demonstrate that effective gains in loom reduction could benefit other areas of the car, without compromising reliability.
“The twelve percent weight saving achieved will allow engineers to distribute weight more effectively, increasing vehicle performance or enhancing tire wear,” claims Norman. “Testing demonstrated that our solution could withstand the SAE–39029 pull off tests, providing confidence. The team will use our solution on some of the harshest vibration applications on an F1 car.”
The firm has identified a set of components and assembly parameters and sequencing that it says allows the technicians to use standardized parts and assembly tools. This method simplifies servicing and spare part stocking during the product’s life, claims the company.
Considering “whole life cost” is another area where BERU f1systems maintains that its design and manufacturing expertise is providing additional value over simple component providers or distributors. “Many of the guys here have worked for race teams so they understand the importance of offering solutions that are simple to maintain and repair when you are far from the workshops,” adds Norman.
According to the company, the first applications for the new designs are for F1 sensor wires, used for temperature and pressure senders around the chassis and powertrain. Sensor units are low power so can readily use the smaller gauge wires; however, the company believes that solving the cost of adopting 30 AWG could see the technology migrate to other areas of the car or onto lower formulae.
“Having a solution that is both robust and cost effective will see the technology used where lightweight and minimum size are the driving factors,” concludes Norman.
