Siemens VDO has shown off the next generation of engine intake manifolds with its innovative Electrified Integrated Air Fuel Module (E-IAFM).

According to Siemens VDO, the new engineering concept offers customers a considerable reduction in material, process and assembly costs and greatly enhances reliability by moulding engine wiring into the plastic of the manifold. The E-IAFM was shown for the first time during the 2006 Convergence show in Detroit which ran from 16-18 October.

"Mechanical and electrical connections for actuators and sensors are made simultaneously when the components are fitted into the manifold, eliminating many low-reliability mechanical electrical connections," said Siemens VDO advanced research and development programme head Jim Vanderveen. "In addition, the engine control unit (ECU) is integrated into the manifold's electrical connection architecture, allowing the entire E-IAFM to be quality tested as a fully integrated unit."

As with its integrated air fuel module predecessors, the electrified next generation project further simplifies the assembly at the customer engine/vehicle assembly plant, including part number reduction and improved under hood aesthetics. Currently, engine actuators, sensors and fuel injectors are mechanically attached to the intake manifold and electrical connections are made to these components and the ECU. The large amount of wiring being woven in and around the engine is often hidden by superfluous beauty covers. By eliminating the wiring harness, the E-IAFM strategy also can eliminate potential points of failure, such as loose or broken connectors, corroded terminals, burned and damaged wires, improper electrical connections and short and open circuits.

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