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%.