Thick Film Resistor in Automotive Industry

Thick film resistors are widely used in the
automotive industry due to their durability, reliability, and
cost-effectiveness. In vehicles, these resistors help ensure the proper functioning
of various electronic systems, which are becoming more complex and integrated
in modern cars. Below are some key applications of thick film resistors in the
automotive sector:

Engine Control Units (ECU)

Power Steering Systems

Battery Management Systems (BMS)

Lighting Control Systems – headlights,
taillights, and dashboard indicators.

Climate Control and HVAC Systems

Absence of Mechanical Components

Safety Systems (Airbags, ABS, and Stability
Control)

Automotive Sensors

Infotainment Systems

Electric Vehicles (EV) and Hybrid Vehicles

Danyu Electronics served more than 1000
customers around the world, we have provided thousands of thick film resistors
to our customers. Here is a case study that we help to design a customized thick
film resistor used in automotive industry.

The customer, a prominent automotive
supplier, was developing a power control system for electric vehicles (EVs).
They faced difficulties with maintaining consistent resistance in
high-temperature environments, typical in automotive applications. The power
control system required resistors that could withstand high voltage and extreme
temperature variations without compromising performance. Additionally, the
customer struggled with sourcing resistors that could fit the compact design of
their systems and met the strict automotive industry standards, such as IATF
16949.

After reviewing the customer’s specifications and understanding the demanding conditions in
automotive power control systems, we designed thick film resistors that could
withstand temperatures ranging from -40°C to 125°C. These resistors were engineered to handle high power dissipation
and resistive load in fluctuating automotive environments. For example, we
ensured that the resistors could maintain a tolerance of ±1% at elevated temperatures to ensure consistent performance over
time. 

Our engineering team collaborated with the
customer’s design team to fine-tune the resistor’s form factor and performance characteristics. We also conducted
accelerated life tests, simulating a 5-year operational period in under 500
hours of testing, which proved the resistors could handle over 50,000 thermal
cycles without failure. Each batch underwent electrical and mechanical stress
tests, and we ensured that all products were 100% traceable for quality
assurance purposes.

1. The resistors maintained high precision in
   the automotive power control systems, even after enduring extreme thermal and
   electrical stress. The customer\’s systems saw a 20% decrease in component
   failure rates, reducing warranty repair costs.
2. With our specialized resistor solution, the
   customer was able to reduce component size by 30%, allowing for more efficient
   use of space in their PCB designs without compromising performance.
3. By consolidating procurement with us, the
   customer reduced sourcing complexity and lead times, cutting overall production
   time by 15%.