A guide to connectors for power distribution units (PDUs)

PDUs are the heart of a commercial EV circuit, intelligently managing power quality between electric motors, motor control units and other vital components. By managing and distributing this energy, PDUs are crucial in maximising energy efficiency and driving range whilst preventing safety risks from overcurrent and short circuits.

In order to perform their role, PDUs require reliable connectors to feed power to the rest of the EV. In this article, we will go over the important factors when choosing connectors for PDUs, and use examples of high-performance solutions for different commercial EV designs.

What role do connectors play in the operation of PDUs?

PDU Connectors are the arteries feeding electricity to the rest of the EV circuit, ensuring that electrical power is transmitted efficiently and reliably to various vehicle components. These connectors must accommodate variable power loads, withstand harsh environmental conditions and ensure safe connections over time. Given the high stakes, the choice and integration of connectors in PDUs are critical for the performance and safety of EVs.

Key connector integration factors for PDUs

• Environmental factors: Commercial EV connectors in PDUs are exposed to a variety of environmental challenges, including temperature fluctuations, humidity, vibration and corrosion. These factors can compromise the integrity of electrical connections, leading to potential failures and safety hazards. As a result, rugged and resilient connectors are required for particularly challenging application environments.
• High electrical requirements: PDUs supply variable loads and voltages depending on the power demand of different vehicle components and systems. This can range from high loads for traction motors during acceleration to lower loads for lighting systems. It is critical to integrate connectors that can manage both the highs and lows of power demand to avoid overheating and potential fire hazards.
• Safety and scalability: Safety and scalability are crucial factors when it comes to integrating connectors with PDUs. Connectors need to handle high voltages and currents reliably with robust insulation to prevent electrical arcing and short circuits. At the same time, the connectors need to be able to support future upgrades and increased power demands without needing significant redesigns or replacement.

Choosing the perfect connector for your PDU

Having explored the essential role of connectors in Power Distribution Units (PDUs) and the key factors to consider for their integration, it’s important to understand how specific connector products can meet these demands. Below, we discuss four exceptional connectors from Dalroad’s catalogue, each excelling in particular integration considerations, and how they can be the perfect choice for your PDU design.

PowerTube connectors
The PowerTube connectors from TE Connectivity excel in managing high power loads. These connectors support up to 1000A and 1000V, making them ideal for high-power applications within PDUs. Their robust design ensures stable and efficient power transmission, crucial for handling the high current demands of traction motors during acceleration. The modular construction of Powertube connectors also facilitates easy installation and maintenance, providing a reliable solution for managing variable power loads in EVs.

IPT-HD high-voltage connectors
The IPT-HD high-voltage connectors are specifically designed to ensure protection from environmental elements. These connectors are built to withstand harsh conditions such as extreme temperatures, humidity, and chemical exposure. Featuring advanced sealing technologies, IPT-HD connectors prevent moisture ingress and corrosion, ensuring long-term durability and reliability. This makes them an excellent choice for PDUs operating in challenging environments, maintaining high performance despite adverse conditions.

HVA HD400
The HVA HD400 connectors are exceptional in enhancing the overall safety of PDUs. These high-voltage connectors include touch-proof designs and high-grade insulation materials to prevent electrical arcing and accidental contact. Additionally, the HVA HD400 connectors are equipped with multiple locking mechanisms to ensure secure connections, significantly reducing the risk of disconnections or failures that could lead to safety hazards. These features make them a prime choice for applications where safety is paramount.

HC-STAK 25
The HC-STAK25 connectors are designed with a focus on scalability with design. They offer flexibility in application, allowing for easy integration into various PDU designs. Their compact and modular nature supports future upgrades and expansions without extensive redesigns. The HC-STAK25 connectors can handle substantial power loads while providing the adaptability needed for evolving EV technologies. This makes them ideal for PDUs that require scalable solutions to accommodate future technological advancements.

For high-performance connectors, think Dalroad

Selecting the right connectors for PDUs is vital for ensuring the efficient, reliable, and safe operation of electric vehicles. Each connector type offers distinct advantages tailored to specific PDU integration needs. By considering factors such as environmental protection, power load management, overall safety and scalability, you can optimise the integration of PDUs for peak performance with your commercial EV design.

At Dalroad, we provide a comprehensive range of high-performance connectors that address these critical integration considerations. Our products are designed to enhance the resilience and lifespan of your EV systems, supported by our team of specialists who are ready to assist you in finding the perfect components for your specific design requirements. To learn more about our extensive catalogue and receive expert guidance on choosing the right connectors for your PDU, contact a member of our team today.