Siemens VDO has developed an electrified integrated air fuel module for next-generation engine intake manifolds. The module is said to offer reductions in material and process and assembly costs, and to improve reliability by molding engine wiring into the plastic of the manifold.

Jim Vanderveen, program leader with Siemens VDO Advanced Research and Development, explained that currently, engine actuators, sensors and fuel injectors are mechanically attached to the intake manifold and electrical connections are made to these components and the electronic control unit. He said 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 electrified integrated air fuel module 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.

“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," Vanderveen said. "The engine control unit is integrated into the manifold's electrical connection architecture, allowing the entire E-IAFM to be quality tested as a fully integrated unit."