What components help maximise the power efficiency of high-voltage EV batteries?

Power efficiency in high-voltage electric vehicles (EVs) is crucial in maximising their driving range for their respective application. To ensure a high level of battery efficiency, each component needs to showcase high-performance whilst minimising energy loss.

In this article, we explore how advanced terminals and high quality relays/contactors can enhance high-voltage EV battery efficiency, with specific examples from Dalroad’s catalogue of components.

Advanced terminals

Terminals are responsible for integrating and delivering electricity to surrounding components in the internal circuit of an EV. For high-power vehicles, these terminals need to handle high voltages and currents efficiently to minimise energy loss and ensure a reliable flow of electricity.

• High-voltage handling – Efficient terminals are designed to handle the high voltages used in EVs. This capability helps reduce the current for the same power, with lower current resulting in lower losses and contributing to overall improved efficiency.
• Fast charging efficiency – Advanced terminals support high-power charging, reducing the time required to recharge the battery. While this doesn’t directly affect the battery’s efficiency, it enhances the overall performance of the EV by making charging more convenient and flexible. This also extends to smart charging integration where battery temperature and state of charge are taken into account to maximise power efficiency.

Dalroad’s high-voltage terminals improve the efficiency of your EV design

PCON High-Voltage Terminals

TE Connectivity PCON terminals are specifically designed for high-voltage interconnection systems in EVs. They showcase a continuous current capability up to 400A, and are suitable for connector voltage levels up to 1000 VDC. These terminals support the increased connectivity requirements of high-voltage EV designs, and ensure the maximised efficiency of their batteries.

AMP+ IPT Shielding Ring Tongue Terminal

TE Connectivity AMP+ IPT Shielded Ring Tongue terminals showcase a robust housing design, innate vibration resistance and an operating temperature of -40 °C to +140 °C. Alongside this, they are suitable for high-voltage designs with 300A current capacity and a 800-100 VDC voltage range. This makes them an ideal choice for a wide range of high-power EV designs.

High-quality relays and contactors

Relays and contactors play a crucial role in managing the flow of electricity within an EV’s electrical system. They operate as switches that control the connection and disconnection of electrical circuits, ensuring the efficient and safe operation of each individual component.

• Standby power consumption – Advanced relays and contactors are designed to minimise standby power consumption when they are not actively being used. This helps prevent unnecessary draining of the battery when the vehicle is not in use, contributing to overall energy efficiency.
• Thermal Management – High-quality relays and contactors are equipped with thermal management systems to dissipate heat generated during operation. Effective thermal management helps maintain optimal operating conditions, ensuring batteries operate in optimal temperatures to maximise their efficiency.

Dalroad’s high-quality relays and contactors enhance EV battery efficiency

Mini K HV V23700

TE Connectivity Mini K HV relays are compact, easy to integrate and are designed for voltages up to 450 VDC and pre-charge and/or limiting break currents up to 20A. They are efficient, lightweight and reliable to enhance the efficiency of any high-voltage EV design.

IHV High-Voltage DC Contactor Series

TE Connectivity series of IHV High-Voltage DC Contactors are designed for high-voltage applications. They are rated from 450 – 750 VDC and 50 – 350A depending on the specific model and application. Their reliable performance in harsh environments make them a beneficial choice for long-term EV battery efficiency.

Integrate the most efficient components for your high-voltage EV design with Dalroad

Depending on the application and design of your high-voltage EV, you need to know which components are best suited to maximising battery efficiency. That way, you can get the most out of your vehicle in terms of driving range and overall performance.

At Dalroad, we provide a wide range of components that are designed to enhance performance, efficiency and overall functionality in high-voltage EV designs. We also have a team of specialists on-hand to assist you in finding the perfect components for your design, taking all factors into account.

To find out more about our catalogue of components and get support in choosing the right ones for your design, contact a member of our team today.