High voltage connector is widely used in electric vehicles. As the link of each functional module of electric vehicles and an essential part of high voltage circuits, it is crucial to analyze and select the types of high voltage connector.
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Here is everything you need to know about the type of high voltage connector in Electric Vehicles.
High voltage connector is a functional component that connects the circuit by an electrical signal or mechanical force. It consists of a fixed-end electrical connector (socket) and a free-end electrical connector (plug).
Usually, we classify high-voltage connectors according to their structure, termination method, and installation method.
Structure: terminal, seal, bracket, shell, shielding structure, insulation structure, butt lock structure, positioning structure, high voltage interlock structure, etc.
Termination Method: welding, crimping, screw connection, over-hole connection.
Installation Method: panel type, cable type, nut type, through-wall type.
We generally design the high voltage connectors from the overall and internal structures.
Overall Strctures: Operation space, anti-misoperation structure, connection in place indication, etc.
Internal Structures: Removability of terminals, type, and structure of terminals, etc.
Regarding product performance requirements, high voltage connectors are pretty different from low voltage connectors. Usually, we have higher requirements for electrical performance, mechanical performance, and environmental performance of high voltage connector.
Electrical properties include operating voltage, rated current, contact resistance of inner and outer conductors, characteristic impedance, voltage standing wave ratio, shielding performance, anti-interference performance, etc.
The electrical performance of high voltage interlocks generally has the following requirements.
Mechanical performance includes vibration shock, mechanical life, single hole separation, total separation force, etc.
Generally, the high voltage connector plugging and unplugging times and connection locking method is reliable to determine whether its mechanical properties meet the requirements.
Environmental performance includes temperature, humidity, vibration, shock, salt spray, dust, and sealing (water pressure and rain).
According to the actual needs of using the high-voltage connector selection, designers must consider a vital issue.
Here we explain the type selection of high voltage connector from three aspects.
The whole vehicle’s high-voltage system includes power battery, motor/motor controller, PDU, DC or AC charging system, electric heating, electric air conditioning, DCDC, and other electric accessories.
First of all, we need to know the voltage of the entire high-voltage system and the amount of power distribution of each device to determine the load capacity of the high-voltage connector.
Then, according to the layout of the practical electric equipment, determine whether the connectors used are single-core or multi-core.
Here are 4 standard series of high voltage connectors.
In electric vehicles, these high-voltage connectors are mainly used for PDU, Battery, Motor, Motor Controller, etc.
Product parameters
This series of high-voltage connectors are mainly used for PDU, Air Condition, Defrosting, Electric Heating, DCDC, etc.
Product parameters
These high-voltage connectors are mainly used for PDU, Battery, Motor, Motor Controller, etc.
Product parameters
These high-voltage connectors are mainly used for PDU, Air Condition, Defrosting, Electric Heating, etc.
Product parameters
High-voltage connectors are available in many construction designs designed to meet different installation conditions.
Depending on how the high-voltage harness is lined up on the electric vehicle, we can determine what high-voltage connector is needed.
We can use linear plugs or right-angle plugs to adjust the wire direction of the harness.
After determining the electrical and mechanical properties of the high-voltage connector, we also need to determine whether the environmental performance of connector can meet the actual use of the environment.
The four high-voltage connectors mentioned above have the same environmental performance. They all have excellent water and salt spray resistance levels and HVIL function for most harsh environments.
Below are their specific environmental performance parameters.
High-voltage connector is the blood vessel and nerve of the electrical system of new energy vehicles.
This article introduces and analyzes the selection of high-voltage connectors to improve the vehicle’s reliability and safety performance.
High-voltage connector design is more delicate, structure and performance requirements are high, the future has more excellent development prospects and progress space.
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Plug connector is the core component of the wiring harness.The performance of the connector directly determines the overall performance of the wiring harness and plays a decisive role in the stability and safety of the whole vehicle.
Selecting the connector is very important as there are many features relating to it. During the selection, revise and ensure the following aspects:
· Anefficient contact with the electrical components
· The contact resistance to a minimum
· Improve reliability
· Preferred dual spring-loaded structure of the connector
According to the wire cross-sectional area and the size of the current through the rational choice of connectors.
Due to the cabin temperature, humidity and the existence of a large number of corrosive gases and liquids can get affected. For this reason, make sure to choose waterproof jacket.If it is the same harness with the same sheath, the color must be different.
Based on the overall coordination of the exterior of the vehicle, a black or dark jacket should be preferred in the engine compartment.
In order to reduce the type and quantity of the connected harnesses, the hybrid type is preferred because the assembly is easy to fix.
For the requirements of high performance airbags, ABS, ECU, etc. with the terminal connector, a preferred gold-plated pieces are preferred in order to ensure safety and reliability.
Battery connector (battery clip) is preferred for the internal cone, taper 1: 9; battery clip material is tin-plated copper, zinc-plated copper or lead antimony alloy.
Different series of connectors can carry the following current:
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· 1 series,
· 10A or so; 2.2 or 3 series
· about 20A; 4.8 series,
· bout 30A; 6.3 series
· 45A; 7.8 or 9.5 series
· 60A or so.
1. Sheath material (plastic parts)
The most common sheath materials are:
· PA6
· PA66
· ABS
· PBT
· Pp
Among others.
Design plug-ins can be selected according to different needs of different materials, but also in accordance with the actual situation in the flame-retardant plastic materials or enhancements to achieve enhanced or flame retardant purposes, such as adding glass fiber reinforced.
2. Terminal material (copper)
Copper connectors are mainly made of brass and bronze. The hardness of brass is slightly lower than the hardness of bronze.Additionally, different coating can be chosen according to different requirements.
Automotive wiring harness consists of the general use of rubber pieces to transition regarding the wear-resistant play, waterproof, sealing and so on.
It occurs mainly in the following parts:
· The engine and the cab interface
· The front cabin and cab interface (about 2), four (or back door)
· The compartment interface
· The fuel tank entrance
Commonly used materials are:
· Generally natural rubber
· Neoprene
· Silicone rubber
· EPDM
Among others.
This material is very elastic and mechanically strong, with an excellent flex resistance. Some of the factors that make it very valuable are its higher tear strength and amazing cold resistance.
Disadvantages:
· Anti-aging hasn’t shown great results
· The absence of oil and ozone
· Flammable
Neoprene is ozone resistant, it has a heat aging, oil and other properties that function perfectly. It is flame retardant and self-extinguishing.
Disadvantage:
· Poor low temperature resistance
Silicone rubber is heat and cold resistant, which is very beneficial. The weather resistance is improved as well so these problems are easily avoided.
Disadvantage:
· The absence of oil
Being weather resistant, ozone resistant, heat resistant and corrosion resistant, EPDM already offers so much. Apart from the resistance, acid, alkali and other properties are of decent quality and a great strength and high rate of expansion are also provided.
Disadvantages:
· Poor adhesion
· No natural flexibility
· Poor oil resistance
In comparison, the overall performance of EPDM is the best. Therefore, the automotive wiring harness with rubber parts generally use EPDM material because of all the benefits mentioned above.
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