R E L AY S & S W I T C H I N G M O D U L E S

G L O B A L A U T O M O T I V E D I V I S I O N

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Tyco Electronics is one of the major business units of Tyco International Ltd. Headquartered in

Harrisburg, Pennsylvania, USA,Tyco Electronics is the world’s largest passive electronic components

manufacturer and a world leader in cutting-edge wireless technologies.The company has facilities

located in over 50 countries, serving customers in the aerospace, automotive, computer,

communications, consumer electronics, industrial and power industries.

G L O B A L A U T O M O T I V E S Y S T E M S- AUTOMOTIVE RELAYS AND SWITCHING MODULES

Automotive technology and integrated systems continue to develop rapidly with

electric and electronic systems in today's vehicles playing an increasingly important role

for traffic safety and traveling comfort. Automotive Relays and Switching Modules

(AR & SM) of Tyco Electronics’ Global Automotive Division offer a wide range of the

most important components for such systems and is the world's no. 1 player in this

industry sector. It is the intent of this brochure, to bring closer to you our total

competences in development, production and related technologies as well as our

unique application support thus ensuring the competitive edge for mutual business

growth on a worldwide scale.

A V I T A L P A R T O F Y O U R W O R L DTyco businesses operate in thousands of different areas of industry.The products and services we

deliver all have one thing in common.They are vital to everyday living. Individuals and companies

worldwide have critical needs. And every minute of every day, we satisfy them.

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Evolution of relay size and performance

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T E C H N O L O G Y

Tyco Electronics's relay segment has a rich history of competences in relay technology gained

over the past three decades thanks to continuous research and development. Indeed, the increased

comfort requirements and multi media equipment in today's cars, lead to increased space

constraints on printed circuit boards. During the past 10 years development efforts have

successfully concentrated on miniaturization of automotive relays.

I N S E R T M O L D I N G T E C H N O L O G Y

The structure of relays with traditional design and manufacturing concepts is characterized by

metal parts inserted into a plastic carrier or the relay base.This concept allows larger tolerances

but, unfortunately, due to its assembly can result in undesired particle contamination.As a result,

additional processes are necessary during manufacturing to ensure that particles are

removed. Insert molding is the technology used to further improve the quality and

reliability of relays.

One of the most recent developments of Tyco Electronics, the Nano relay, has been

designed using insert molding technology to produce the relay motor consisting of

coil, frame and core.This design concept ensures highest precision in the assembly and

reduces the risk of particle contamination to an absolute minimum. It also allows for

most accurate mechanical parameters and adjustment free processes. In addition, the

overmolding of the relay motor improves the heat dissipation of the Nano relay and

maximizes the relay performance.

Compared to its predecessor, the well known DMR, the Nano relay requires 50 % less area on

the printed circuit board.The Nano relay only measures L x H x W (in mm) 15.4 x 10.2 x 14.0

and as its name states, is the tiniest PCB twin relay in the class of relays suitable for motor reverse

applications.

A U T O M O T I V A T E D I N E V E R Y D E T A I LOur global automotive research centers are setting the technological landscape by developing

new technologies, products and production processes. The increasingly fast growing number of

functions in present and future cars requires a variety of powerful and versatile connection

systems.We compare existing standards with alternative possibilities in which costs, functionality,

dependability and serial production are the basics of our procedures.

Insert molded magnetic system

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B I S TA B L E ( L AT C H I N G ) T E C H N O L O G Y

Classical (monostable) electromechanical relays need a permanent coil power supply

to remain in an operating mode.The heat generated by the coil energizing has to be

dissipated in addition to the management of the load path power loss.

Bistable (latching) relays provide another smart alternative to meet the miniaturization

targets in higher ambient temperature environments, using magnetic flux of a permanent

magnet to keep the armature in operating mode without keeping the coil energized.

In comparison to monostable relays, bistable relays, such as the Micro K latching,

BDS-A, MRP2, feature three major advantages:

• Relay downscaling without sacrificing the performance

• Higher ambient temperatures at given continuous current

• Increased continuous current capability at given ambient temperature

Bistable relays are especially suited for active

power management e.g. quiescent current eli-

mination, power outlet disconnection in case

of critical battery voltage, load disconnection

during transportation or long time parking.

Furthermore, they are predestined for high

temperature applications, power supply

(clamp) loads as well as a possible replacement

of plug-in relays.

Comparison: Advantages monostable relays vs. bistable (magnetically latched) relay

Comparison: Bistable relays

Comparison: Limiting continuous current of Micro power relay K, Power relay K, Micropower relay K latching over ambient temperature

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E L E C T R O N I C M O D U L E A N D S O L I DS T A T E T E C H N O L O G Y

As the worldwide leader in relay technology, Tyco Electronics has developed a broad range of

customized electronic modules that embody our switching technology know how.

Many of these products merge our core relay products with electronics to produce modules with

custom switching functionality. Some typical examples include: custom timing modules, 24V motor

reversing modules, and custom logic controlled modules.Tyco Electronics is further expanding its

electronic module capabilities to include high performance Solid State Relays (SSR). Over the

years, electromechanical relays have become highly reliable at increased performance and low

cost, though still leaving challenges for further improvement. For certain specific requirements

Solid State Relays can become advantageous, though higher priced. In a typical application, a

traditional electromechanical relay will withstand (x) amount of cycles, whereas a Solid State

Relay will withstand 10 times as many cycles.The ability to include a variety of failure protections

in solid state devices further elevates their level of reliability for most critical types of applications.

Tyco Electronics offers both, Mini and Micro packaged Solid State Relays designed to fit most

applications.These relays are available in either ISO or 280, high side or low side switched, active

high or low, and can carry up to 30 A continuous current at 125 °C.

S TAT E - O F - T H E - A R T T E C H N O L O G YTyco Electronics AR & SM in cooperation with its customers consistently develops state-of-the-art

relay technology to further the development of vehicles for the benefit of every driver: higher

security, more comfort and improved environmental compatibility.

Micro Solid State Relay (Micro SSR) Mini Solid State Relay (Mini SSR) VRM: 24 V motor reversing module

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C O M P E T E N C E S

D E S I G N

Future success of products relative to quality and in particular efficiency, performance and

endurance starts with professional design. As the leader in relay development the name Tyco

Electronics also stands for expertise in the wide field of product design ranging from Computer

Aided Design (CAD), electronic relay measurement and simulation via analysis to mechanical

sample processing.

State-of-the-art computer assisted development software allows for design and relay simulation

in one step.

Directly linked CAD models are used to simulate electromagnetic actuator designs, nonlinear

structural analysis of springs, thermal analysis of relays with load currents and ambient conditions.

Six sigma tools are utilized to check design for relay robustness thereby minimizing quality

rejections and field failure costs. Tough design also consciously considers the uncertainties or

noise factors a relay may be exposed to. Electronic design is based on simulation of electronic

circuit behavior under normal and worst case conditions to determine the most reliable design.

Example of magnetic system calculation Expertise in CAD and electronic relay simulation

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The Finite Elements Method (FEM) is used in product design but also more and more for the

analysis of relay applications.The FE simulations cover electromagnetic, thermal, mechanical and

multiphysics analyses (e.g. electro-thermo-mechanical, electro-magnetic-mechanical). In the

product design the relay is virtually dimensioned to a stage where the computation results for the

electromagnetic, mechanical and the thermal relay behavior can be confirmed by first samples.

Due to parameter separation and the analysis of their influence the need for samples is reduced

and the development time thus shortened.The application analysis supports the customer in the

topology of the relay environment (e.g. box dimensioning, printed circuit board layout, relay

positioning, vibration and shock behavior).

New design technology advancements along with material advancements have allowed Tyco

Electronics to develop size reduced products at higher performance.The introduction of the Tyco

Electronics Micro ISO and Micro 280 High Current plug-in relay products allow customers to

decrease system size by using these products in higher current applications traditionally being

controlled by larger Mini size package relays.

Tyco Electronics has extensive assembly experience, especially in laser, resistance and other

welding operations, bonding and embedding as well as joining and staking processes. Process

validation, tests and time consuming verification operations are realized with modern PC surface

based optical measurement equipment.

Since relays are electromechanical devices designed to switch a few milliamps up to several

kiloamps, the electrical and mechanical characterization is most important.Tyco Electronics uses

various high precision force displacement systems to measure mechanical relay parameters. To

guarantee the relay life time a special test procedure to check the compatibility of all materials

used has been developed. Amongst others, test methods with ICP, FTIR, REM/EDX or light

micrographs are used.

Complete range of electromechanical devices designed to switch a few milliamps up to several kiloamps

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Line design Line design prefabrication High automated assembly module

Vibration and temperatureshock unit

Endurance test unit withtemperature chamber

Endurance test unit withintegrated climaticchamber

T E S T L A B S

All tests are performed in fully equipped state-of-the-art test labs.The core of the endurance test

labs is an electrical endurance test unit, designed and built-up in-house.

The electrical endurance test unit monitors each switching cycle of the tested relay and measures

important relay parameters such as energizing voltage, contact resistance and insulation resistance

during the test run. The relays are tested either with original loads from our customers or

simulated loads. Our simulated loads are µP-controlled resistor-decades, representing nearly

every current curve.To simulate inductive loads, variable coils are added to the load circuit.The

relays can be tested at different ambient temperatures.

Some test units have the option of different ambient degrees of humidity. In addition to the

electrical endurance test units the test labs are also equipped to perform various tests such as:

vibration (sine and random), mechanical and thermal shock as well as climatic tests. If required

the different test environments can be combined.

Additionally to the endurance test labs we have development, electronic, chemical, material and

special high-current labs. These labs, located in Berlin, Germany and Winston-Salem, North

Carolina, USA, meet the ISO/TS 16949 requirements.

Today the main competences in production are not only in sophisticated highly automated assembly

lines and production processes but also in line design itself. The competences, furthermore

comprise molding, high speed stamping, plating, automation, tooling, logistics and last but not least

engineering skills.

Tyco Electronics' European relay production plant in Évora, Portugal has gained extensive

production know how ranging from raw material processing to complete relay assembly under

one roof for more than 35 years. In the last 4 years the production has increased from annually

100 Mio relays to up to 230 Mio relays.Almost every relay series is produced in Évora, the main

production plant for automotive relays.

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C O M P E T E N C Y H I G H L I G H T S T O D A Y

M O L D I N G

• Overmolding technologies for wires and lead frames to avoid assembly processes which could

create particle contamination

• Pick and place handling directly from the mold to the packaging tube to eliminate environmental

pollution

S T A M P I N G

• Integrated riveting during the stamping process for maximum repeatability of the contact shape

and best conditioned contact surface

• Reel to reel production to minimize influence of transport handling between fabrication and

assembly line

A S S E M B L Y

• Completely automated assembly lines with 'On Line' process controls

• Laser welding for highest precision

• Arc welding for a safe electrical wire - bobbin terminal connection

• Automated 'In Line' test for sealed relays

• Laser triangulation measurement to guarantee the mechanical specifications

Q U A L I T Y M A N A G E M E N T

Fully equipped laboratory with:

F U L L Y E Q U I P P E DOur Évora plant is fully certificated to: ISO 14001, QS9000, ISO 9001,VDA 6.1, ISO/TS 16949

since 2003 and has got the Q1 Ford Motor Company award. Our Empalme plant is certified to

TS16949 and ISO14001.

• X-Ray analysis

• Contact Fritting Analysis

• Particle counter

• Armature magnetic response detection

• Microscopic Analysis and Photography

• Universal Relay Test Equipment

• Electronic Force Displacement Test Equipment

• Mechanical Endurance Test

• Melting point test for material determination

L I N E D E S I G N & P R O D U C T I O N ( T O O L S A N D D I E )Tyco Electronics' North America relay plant in Empalme, Mexico enjoys the same extensive

production know how as the Évora plant running fully automated and semi automated production

lines, supported by in house molding, stamping, and tool shop capability. Relay production is

currently being expanded in Shenzhen, China.

APPLICATION, MARKETING & SYNERGIES

Relays play a major role in automotive electrical systems. During the last decade car manufacturers

faced a strongly increased demand for new switching functions. More and more options such as

electric windows and power seats have become market standard in the automotive world. In

addition to the migration of applications in the field of convenience from high to lower class cars,

reliability and safety requirements have created new relay application areas. Protection of low,

medium and high power systems requires an understanding of system failures and their detection,

as well as safe disconnection from the power system. Relays are very often the safety

device-interface between the load and the onboard car diagnostic systems.The comprehension

and handling of possible system failures in complex hard- and software systems requires expertise.

Our Technical Application Engineers provide a unique service guaranteeing best advice with

respect to the particularities of electromechanical devices and in finding optimum solutions for

traditional and innovative applications.This special support covers all technical aspects from the

analysis of customer specifications, via support in appropriate relay selection to on site vehicle

load measurements and technical training.This service is virtually the interface between you, our

potential customer, and Tyco Electronics' Product Engineering and Marketing.A further strength

of the technical relay support is the global presence. Each region has a relay technical team,

supported by the global product marketing team. This strategy offers a dedicated technical

support in respect to regional particularities as well as a global view on product placements.

Furthermore the global product marketing responsibility allows synergies with other in-house

technologies such as Fuse and Relay Boxes, Mechatronics and Sensors thus offering all customers

a powerful range of components and services.

Tyco Electronics offers relays for every traditional application in cars and also continuously develops

relays for new application fields in cooperation with the Original Equipment Manufacturers

(OEM),Tier1 as well as with second tier suppliers or system suppliers.

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R E L A T E D T E C H N O L O G I E S

MECHATRONICS POWERDISTRIBUTION

SYSTEMS

SENSORS

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O T H E R T Y C O E L E C T R O N I C S A U T O M O T I V E T E C H N O L O G I E S

CLOCKSPRINGS HIGH SPEEDCOMMUNICATION

INDUCTIVE SYSTEMS TERMINALS &CONNECTORS

WIRELESS

Energy management module

Electronic control module

Vehicle lighting module

Electric power assisted steering module

Door module

ABS module Seat adjustment module

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T Y C O E L E C T R O N I C S “ A T Y O U R S E R V I C E ”

Internet Homepagewww.tycoelectronics.com

www.tycoelectronics.com/automotive

Electronic InternetCatalogwww.catalog.tycoelectronics.com

Electronics OnlineThe Tyco Electronics Website is more than

merely an Internet-guide. It is an innovative

and inter-active source for application tips,

product update and technical information.

With our StepSearch-Software you can easily

surf through all of our product lines.

Product InformationCenter (PIC)You can rely on our PIC Team’s support. Our

experienced staff is an additional information

source, and the team has been particularly

trained to answer your technical questions.

To reach our PIC, please contact your local

Tyco Electronics organization.

Product and MachineLiteratureFor more information about Tyco Electronics’

Global Automotive Division and its wide

range of products we offer you a variety of

literature such as product databooks and a lot

of product specific brochures. For databooks

and product brochures please contact your

local Tyco Electronics organization.

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Argentina – Buenos AiresPhone: +54-1-733-2000 Fax: +54-1-717-0988

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Mexico – Mexico CityPhone: +52-5-729-0400Fax: +52-5-361-8545

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Troy, MIPhone: +1-248-273-3359 Fax: +1-248-273-3322

Customer Service:Phone: +1-800-522-6752

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France Export Divisions –Cergy-Pontoise Cedex Phone: +33-1-3420-8866 Fax: +33-1-3420-8300

Germany – Bensheim Phone: +49-6251-133-0 Fax: +49-6251-133-1600Product Information Center:Phone: +49-6251-133-1999 Fax: +49-6251-133-1988

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+44-208-420-8343Fax: +44-208-420-8081

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Israel – Yokneam Phone: +972-4-959-0508 Fax: +972-4-959-0506

Italy – Collegno (Torino) Phone: +39-011-4012-111 Fax: +39-011-4031116Product Information Center:Phone: +39-011-4012-360 Fax: +39-011-40287360

Lithuania – Vilnius Phone: +370-5-2131-402Fax: +370-5-2131-403

Netherlands – ’s-Hertogenbosch Phone: +31-73-6246-246 Fax: +31-73-6212-365 Product Information Center:Phone: +31-73-6246-999 Fax: +31-73-6246-998

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Poland – Warsaw Phone: +48-22-4576-700 Fax: +48-22-4576-720Product Information Center:Phone: +48-22-4576-704 Fax: +48-22-4576-720

Romania – Bucharest Phone: +40-21-311-3479 + 3596 Fax: +40-21-312-0574

Russia – Moscow Phone: +7-095-926-55-06…09Fax: +7-095-926-55-05

Russia – St. Petersburg Phone: +7-812-718-8192 Fax: +7-812-718-8193

Slovenia – Ljubljana Phone: +386-1561-3270 Fax: +386-1561-3240

South Africa – Port Elizabeth Phone: +2741-503-4500 Fax: +2741-581-0440

Spain – Barcelona Phone: +34-93-291-0330 Fax: +34-93-201-7879

Sweden – Upplands Väsby Phone: +46-8-50-72-50-00 Fax: +46-8-50-72-50-01

Switzerland – Steinach Phone: +41-71-447-0447 Fax: +41-71-447-0444

Turkey – Istanbul Phone: +90-212-281-8181…3

+90-212-282-5130/5430Fax: +90-212-281-8184

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T Y C O E L E C T R O N I C S G L O B A L C O N T A C T S

A M E R I C A S

A S I A / P A C I F I C

E U R O P E / M I D D L E E A S T / A F R I C A

Tyco Electronics AMP GmbH certified according ISO 14001 and ISO/TS 16949:2002

Tyco Electronics AMP GmbH • Paulsternstr. 26, 13629 Berlin • Phone +30-386-38665, Fax +30-386-38545© 2005 Tyco Electronics AMP GmbH • AMPèrestr. 12–14, 64625 Bensheim • Phone +49-6251-133-0, Fax +49-6251-133-16001308085 - 3.5M - ST - Issued 08-05 Printed in Germany www.tycoelectronics.com