As the demand for electric vehicles (EVs) continues to surge, the technology behind these vehicles is evolving rapidly to meet the demanding needs of commercial applications. At the heart of this evolution is the Motor Control Unit (MCU), a critical component that manages the operation of the EV’s motor.
Ensuring effective connectivity within these units is essential for the vehicle’s performance, efficiency and reliability. In this guide, we will explore the role of connectivity in MCUs, the challenges faced, and the solutions that ensure optimal performance.
Motor control units (MCUs) are vital electronic components in electric vehicles that manage the motor’s operations based on inputs from the vehicle’s drive system. They control the speed, torque and direction of the EV’s motor, translating the driver’s actions into responsive propulsion. Additionally, MCUs adjust the electrical power delivered to the motors, ensuring optimal performance and efficiency.
Connectivity in MCUs refers to the intricate network of electrical contacts and connectors that link various components within the unit. These connections are critical for transmitting signals and power efficiently, allowing the MCU to perform its functions accurately.
Commercial EVs operate in diverse and often harsh environments that can bring complications for contact integrity.
As EV technology advances, there is a trend towards miniaturisation. This trend requires more components to be packed into smaller spaces, increasing the need for compact yet reliable connectors. However, miniaturisation can lead to issues such as fretting corrosion due to smaller contact forces, which can degrade electrical contact over time.
Another significant challenge is managing contact resistance. High current levels can cause power losses proportional to the contact resistance between the mating surfaces of the connector. Even a small increase in resistance can lead to significant power loss and heat generation, affecting the connector’s performance and reliability. High contact resistance can also result from poor material selection and inadequate contact force, highlighting the importance of careful design and material choice to ensure long-term performance.
Using materials with excellent thermal and electrical properties is crucial. Contacts made from corrosion-resistant alloys, such as gold or silver-plated contacts, offer high conductivity and durability.
Applying protective coatings, such as conformal coatings or potting compounds, shields contacts from moisture and contaminants. Additionally, using seals and gaskets in connector designs prevents the ingress of dirt and water.
Designing connectors with features that enhance mechanical stability, such as locking mechanisms and strain reliefs, helps prevent loosening due to vibrations and maximises contact integrity. Ensuring connectors are rated for specific environmental conditions they will encounter is also critical.
High-performance connectors are pivotal in maintaining the integrity and efficiency of MCUs. TE Connectivity’s solutions, such as the AMP+ HVP 1100 Connectors & Headers, exemplify the industry’s commitment to addressing these challenges. Their connectors are made from materials that resist corrosion and can withstand high temperatures and humidity levels. Advanced engineering ensures that their smaller connectors maintain strong contact forces and resist fretting corrosion. Rigorous testing protocols simulate years of operation under various conditions to guarantee long-term reliability. Moreover, the AMP+ HVP 1100 Connectors & Headers have a current carrying capability up to 320A at 85° C with 70mm2 shielded cable and a cable range of 35-95mm2, making them perfect for particularly demanding and high-voltage commercial EV designs.
Ensuring reliable connectivity within MCUs is crucial for optimal performance and safety of commercial EVs. At Dalroad, we provide a comprehensive range of high-performance connectors designed to meet the rigorous demands of modern EVs. Our team of specialists is ready to assist you in selecting the best components for your projects, ensuring every aspect of your vehicle’s electrical system is optimised for performance and durability.
To learn more about our products and how they can enhance your vehicle designs, contact us today.
