How to secure mechanical EV contacts in harsh environments

A critical aspect of commercial EV design is the reliability and durability of mechanical contacts. In harsh environments, these contacts face numerous challenges, including temperature extremes, vibrations, moisture and corrosion.

Ensuring the integrity of mechanical contacts in such conditions is vital for the safety, efficiency and longevity of EVs. This article explores the strategies and technologies used to secure mechanical EV contacts in harsh environments.

The importance of mechanical contacts in commercial EVs

Mechanical contacts in EVs facilitate the transmission of electrical signals and power between various components. These contacts are found in connectors, switches, relays and other critical parts of the vehicle’s electrical system. Their performance directly impacts the overall efficiency, reliability and safety of the EV. In the harsh environments that commercial EVs face, maintaining the integrity of these contacts is paramount to prevent failures that could lead to malfunctions or potential accidents.

Environmental challenges faced by mechanical contacts

High temperatures

Commercial EVs often operate in environments with wide temperature ranges, from freezing cold to scorching heat. These extremes can cause thermal expansion and contraction, leading to material fatigue and failure of mechanical contacts.

Vibration and mechanical stresses

Commercial and industrial EVs, especially those used in rugged terrains or high-performance applications, are subject to constant vibrations and mechanical stresses. These forces can cause loosening or wear of contacts, leading to poor connectivity and increased resistance.

Moisture and corrosion

Exposure to moisture, whether from rain, humidity, or road spray, can lead to corrosion of contact surfaces. Corrosion increases contact resistance and can eventually cause complete failure of the electrical connection.

Contaminants and dirt

Dust, dirt and other contaminants can infiltrate contact points, leading to abrasive wear and poor electrical conductivity. In harsh environments, protecting contacts from these elements is crucial.

Solutions to protect mechanical contacts in EV designs

• High-quality materials: Employing materials with excellent thermal and electrical properties is essential. Contacts made from alloys that resist corrosion and have high conductivity, such as gold or silver-plated contacts, can significantly enhance reliability.
• Protecting coatings and seals: Applying protective coatings, such as conformal coatings or potting compounds, can shield contacts from moisture and contaminants. Additionally, using seals and gaskets in connector designs helps prevent the ingress of dirt and water.
• Robust connector design: Designing connectors with features that enhance mechanical stability, such as locking mechanisms and strain reliefs, can prevent loosening due to vibrations. Ensuring that connectors are rated for the specific environmental conditions they will encounter is also critical.

Integrating high-performance connectors to ensure contact integrity in harsh environments

High-performance connectors represent a universal solution to ensure contact integrity in commerical EV designs. From high temperatures to extreme vibrations, high-quality connectors are designed with robustness in mind. A key example of this is TE Connectivity’s HVA HD400 connector.

With an operating temperature range of -40 to +140 °C combined with dust and water ingress protection ratings of IP68 and IP6K9K, the HVA HD400 connector can perform in extreme environments and handle up to 1,000 VDC and 60 A at +80 degrees Celsius. Other features include contact position assurance and the ability to withstand transmission-level vibrations, making it a robust connector for a variety of conditions.

Discover everything you need to know about connectors with Dalroad

Securing mechanical EV contacts in harsh environments is a multifaceted challenge that requires a combination of high-quality materials, innovative design and high-quality connectors. By addressing the specific challenges posed by temperature extremes, vibrations, moisture and contaminants, you can ensure the reliability and safety of your EV designs.

At Dalroad, we offer a comprehensive range of high-performance components and connectors designed to withstand the rigours of harsh environments. Our team of experts is dedicated to helping designers and engineers select the best components for their applications, ensuring that every EV operates at its highest potential. Contact us today to learn more about our products and how we can support your EV design needs.