Siemens VDO is debuting the next generation of engine intake manifolds at Convergence 2006 with its innovative Electrified Integrated Air Fuel Module (E-IAFM). The new engineering concept offers customers a considerable reduction in material, process and assembly costs and greatly enhances reliability by molding engine wiring into the plastic of the manifold. “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 Program Leader 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. Siemens VDO is an international automotive electronics and mechatronic supplier. The group is part of Siemens AG and generated sales of $11.3 billion in 2005.