Beru F1 develops lighter 30 AWG wiring harness

Developed in conjunction with Souriau, the process removes the need for special terminals or costly crimp tools, resulting in a wiring loom that is 12 per cent lighter, without the expensive components and tooling of competitor offerings.

Gary Norman, principal engineer, said: 'Working closely with an F1 team, we looked at how we could use 30-gauge wire to reduce weight while also considering the increasing cost restrictions that the teams have to comply with.

'Other technologies are available but they require a tool that costs around GBP900, 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,' he added.

Beru F1systems demonstrated that effective gains in loom reduction could benefit other areas of the car without compromising reliability.

'The 12 per cent weight saving will allow engineers to distribute weight more effectively, increasing vehicle performance or enhancing tyre wear.

'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,' said Norman.

The firm has identified a set of components and assembly parameters and sequencing that allows the technicians to use standardised parts and assembly tools.

This simplifies servicing and spare-part stocking during the product's life.

Considering 'whole life cost' is another area where an experienced integrator with design and manufacturing expertise such as Beru F1systems 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,' Norman concluded.

The first applications 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, Beru F1systems believes solving the cost of adopting 30 AWG could see the technology migrate to other areas of the car or onto lower formulae.