The role of connectors in maintaining power quality in electric vehicles

Commercial electric vehicles (EVs) rely on high power quality to operate efficiently, safely and reliably. High-performance connectors are crucial in maintaining this power quality, ensuring that all vehicle components function optimally.

This article explores the importance of connectors in upholding power quality, the challenges affecting it and how advanced connector technology addresses these challenges to enhance EV performance and longevity.

The importance of power quality in EVs

Power quality in commercial EVs is the stability of the electrical power being delivered to various components of the vehicle. It encompasses factors such as voltage stability, frequency stability and the minimisation of electrical disturbances. High power quality ensures that all the vehicle’s systems, from the battery management system to the propulsion system, operate efficiently and effectively. Maintaining a high power quality in commercial EVs is critical for a number of reasons:

• Efficiency: Ensures that the vehicle operates at optimal performance, maximising the range and efficiency of the EV. This is crucial for long-haul applications.
• Longevity: Reduces the wear and tear on electrical components, thus prolonging their lifespan.
• Safety: Minimises the risk of electrical failures that could lead to safety hazards.
• Driver experience: Ensures smooth operation of the vehicle, providing a reliable and comfortable driving experience. For long-haul distances, this is particularly important.

Factors that affect power quality in EVs

Environmental conditions

Environmental factors such as vibrations, thermal changes and exposure to moisture and road salts can degrade the performance of electrical components. Vibrations can loosen connections, leading to intermittent electrical contact, while thermal expansion and contraction can cause wear and potential failure of electrical connections. Corrosion spurred by moisture can degrade contact points, increasing resistance and the likelihood of short circuits. Each of these aspects greatly affect overall power quality. All of these factors are multiplied with commercial applications.

Load variability

The varying electrical load during different driving conditions can affect the stability of power delivery. For instance, sudden accelerations or the use of multiple high-demand systems simultaneously can create fluctuations in power requirements, challenging the system’s ability to provide consistent and stable power. This is especially true for commercial applications that operate with high variations of power.

Battery management and power distribution units (PDUs)

Effective battery management and efficient PDUs are crucial for maintaining power quality. Inconsistent charging and discharging cycles, improper thermal management, and inefficiencies in PDUs can lead to fluctuations in power availability and distribution. Ensuring that the battery operates within optimal parameters and that the PDU efficiently manages power distribution is essential for delivering consistent and stable power.

How high-performance connectors ensure high power quality

Enhancing durability and ruggedness
Connectors are engineered to withstand harsh environmental conditions that can degrade their performance. High-performance connectors use advanced materials and designs that resist vibrations, thermal changes and corrosion:

• Vibration resistance: Robust connectors feature locking mechanisms and flexible designs that prevent connections from loosening due to vehicle vibrations. This ensures a stable and continuous electrical contact, minimising the risk of intermittent power delivery.
• Thermal stability: High-quality connectors are made from materials that can withstand significant thermal expansion and contraction without degrading. They maintain reliable connections even when subjected to extreme temperature fluctuations, ensuring consistent power quality.
• Corrosion resistance: Advanced coatings and corrosion-resistant materials protect connectors from moisture and road salts. This prevents the degradation of contact points, reducing resistance and the likelihood of short circuits.

Providing consistent power delivery
Connectors are crucial for ensuring that power is delivered consistently and efficiently to all vehicle systems, including those managed by battery management systems and power distribution units:

• Stable electrical contact: High-performance connectors ensure stable and secure electrical contact, minimising fluctuations in power delivery. This is essential for maintaining voltage and frequency stability, which are critical for optimal EV performance.
• Efficient power distribution: In conjunction with PDUs, connectors facilitate efficient power distribution from the battery to various subsystems. This helps in managing the electrical load variability, ensuring that all systems receive consistent and clean power.

Secure EV power quality with Dalroad’s high-performance connectors

High-performance connectors play a pivotal role in ensuring the efficient and safe operation of EVs. Despite the challenges posed by environmental factors, load variability and the demand for long-term reliability, innovations in connector technology continue to advance. High-performance connectors exemplify the industry’s commitment to overcoming these challenges, ensuring that EVs remain a sustainable and reliable mode of transportation for the future.

At Dalroad, we provide a wide range of components that are designed to enhance the resilience and lifespan of EVs. 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.