Modern electrical systems have played a larger role in almost every industry. In vehicles, they manage safety functions such as cameras and process data in real time. In commercial kitchens, they ensure that equipment continues to operate despite heat, humidity, and continuous use. These applications share a common requirement: failure is unacceptable, and components must reliably withstand harsh environments.

At the heart of all these systems are cables and connectors that carry power and data. Without these components, sensors would shut down, control units would lose communication capabilities, and the entire system could cease operation. These cables and connectors are small and may appear insignificant—that is, until something goes wrong. However, cables and connectors play an essential role in maintaining safety and ensuring the normal operation of the machinery. Furthermore, to guarantee proper and consistent functioning, they must be tested under the most demanding conditions imaginable.

The same requirements for vehicles exist in various other environments, and lessons learned in the automotive sector can be applied to other uses. This is the idea underlying Molex's 'Beyond the Garage' series. In addition to the automotive industry, this series was designed for engineers working in industries where systems are continuously exposed to harsh environments.

Recently, I discussed how innovations implemented in the automotive sector are being applied to other industries through a Let's Talk Technical video interview with Kirk Ulery, a Distribution Industry Development Manager and industry expert at Molex.


DigiKey, a leading distributor of electronic components, plays a vital role in helping engineers across various industries identify and utilize the right solutions, offering everything from automotive connectors to components designed to withstand industrial, agricultural, and commercial environments. These components form the foundation of almost every electronic system.

■ Automobiles as a Test Stage

Expectations for electronic systems are particularly high in vehicles. This is precisely why new technologies are usually tested in the automotive sector. Vehicles do not operate in a controlled environment. Temperatures can be extremely high or low, moisture is often present, and vibrations generated during driving place continuous stress on the parts.


A vehicle's electronic systems are responsible for critical functions where failure is unacceptable. “There is an old joke between computer engineers and automotive engineers,” said Ulery. “Computer engineers say they can implement innovation faster, but automotive engineers can retort that if the ‘blue screen of death’ appears at 80 miles per hour, you’re dead.”

Because these systems are so critical, the automotive industry has become a fully verified system for the design and testing of electronic systems.

■ Expanding the application of technology to fields other than automobiles

While the specific challenges engineers must anticipate vary by industry, the need for components to withstand applied pressure and harsh conditions is similar; therefore, engineers must consider the usage environment as a starting point for design. Understanding what a component must withstand—whether it is heat, moisture, vibration, or all of these—is essential to identifying the product suitable for the application.

According to Ulery, a prime example of such a case is the Molex MX150 connector. This part belongs to Molex's largest product line sold on the DigiKey website. This connector is a medium-current, medium-voltage system used in automotive applications, including internal combustion engine fuel injector modules and anti-lock brake systems mounted directly to the vehicle's wheels. This component is regularly exposed to harsh environments, including vibration, extreme temperatures, humidity, and overall wear and damage.


While the MX150 connector has traditionally been used in the automotive sector, a manufacturer contacted Molex regarding its use in commercial dishwashers to seal the machine's control boards. These dishwashers operate seven days a week in high-temperature, high-humidity environments; previously, leaks left circuit boards exposed and unprotected, leading to costly repairs or machine failures. Using a sealed connector specifically designed for the harsh environments in which commercial dishwashers operate can protect the system. In the past, if the circuit board got wet, components would be damaged and repairs would be expensive. However, now only the exterior of the machine gets wet, so it is not a major issue. This provides great value to manufacturers.


■ Mobile modern data center

Today's vehicles integrate cameras, sensors, and safety systems, all of which must be able to communicate simultaneously. This places a significant burden on connectors and wiring that must support everything together. Many technologies are driving this innovation and are expanding into other industries.

- 48V Systems: Most vehicles today operate on 12 volts. Switching to 48 volts reduces current requirements, which means smaller wire sizes, lighter component weights, easier routing, and lower costs. While higher voltage introduces new design requirements regarding electrical safety, the benefits outweigh the drawbacks, leading other industries to test the same transition. This same principle applies wherever electrification increases system voltage, ranging from commercial HVAC to industrial equipment.
- Power supply via coaxial and HFM: Early analog vehicle cameras required five or six pins each. Power supply via coaxial changed this by transmitting power and data to digital cameras through a single coaxial cable. Currently, vehicles are typically equipped with omnidirectional cameras and advanced safety systems. The Molex High Speed FAKRA-Mini (HFM) connector is designed to handle this in a compact, high-speed package. This same solution is useful wherever multiple high-resolution feeds need to operate efficiently over a single cable.
- Single-Pair Ethernet (SPE): Standard Ethernet uses two pairs of wires. The single-pair version handles both directions with a single pair, and its particular usefulness beyond the automotive sector is due to interoperability. This method uses an automotive-grade connector at one end and an SPE connector at the other for continuous communication. This allows it to serve as a practical bridge when connecting industrial systems to vehicle-grade hardware.
- Zone Architecture: Instead of routing all sensors to a single central controller, zone architecture divides the system into multiple locally managed zones and connects these zones via a high-speed backbone. This reduces wiring length, enables redundancy, and allows the entire system to be easily updated and expanded. This same concept is spreading across complex systems that need to move away from centralized control.

Together, these technologies are critical components of modern vehicles. They are also increasingly being used in other industrial and commercial products that must meet equally stringent standards. In the automotive industry, it has been proven possible to build systems that withstand continuous wear and tear over time. While application fields may vary, the expected level of performance remains the same regardless of the field.

Visit DigiKey.com for more details and the full Let's Talk Technical content.

※ Author
Shawn Luke is a Technology Marketing Engineer at DigiKey. DigiKey is recognized as a global leader and a continuously innovating company in the cutting-edge commerce distribution of electronic components and automation products worldwide, supplying over 17.5 million components from more than 3,000 leading and famous brand manufacturers.