Connectors are an integral part of an EV’s design, providing components with reliable connections between multiple electrical circuits. But as EV designs increase in voltage to maximise driving range, so do the stresses these connectors face.
As a solution, high-performance connectors are becoming increasingly important to manage the challenges of modern EV designs.
In this article, we dive into the role of high-performance connectors in EV design. We explore the challenges they overcome and the benefits they can bring to your EV project.
Connectors are the lifelines of an EV’s electrical system, integrating necessary components into a holistic vehicle circuit. Alongside their primary function of energy transmission, connectors also serve a protective role. They shield the connection points between components and cable assemblies from harsh conditions where vibrations, corrosion and humidity are commonplace.
The dual purpose of connectors is vital to the operation of EVs, which becomes even more prevalent with high-voltage designs. These components face operating temperatures ranging from -40°C to +125°C and manage voltages of up to 1000V. Without reliable connectors, these EVs would face increased risks of critical failure, impacting overall safety and functionality.
The durability and functionality of EV connectors are constantly tested by environmental conditions. This is only increased when faced with higher voltage designs that face increased temperatures as a result.
To overcome these challenges, connectors must be rugged and durable as well as efficient. As a solution, modern connector technologies incorporate resilience materials and designs that are capable of withstanding these severe conditions without compromising performance.
The trend towards miniaturisation in EV and automotive design has directly resulted in a greater number of components in the same or smaller spaces. This reduction in size has reinforced the importance of size, weight and geometric flexibility for internal components. As one of these components, connectors need to be compact and lightweight as well as high-performing.
Alongside this challenge, fretting corrosion can also take place due to decreased contact force in miniaturised connectors. Overtime, this can result in poor electrical contact and reduces their overall lifespan. This reinforces the importance of balancing the challenges of miniaturisation and connector performance for your design.
EV components are expected to last for years with minimal maintenance. Connectors are no exception; they must ensure consistent performance over the vehicle’s lifespan, regardless of voltage levels, environmental conditions, or the number of systems connected. This requires innovative design and manufacturing techniques to produce connectors that are efficient, compact, rugged and reliable over long periods.
TE Connectivity (TE) leads the way in developing connector solutions that address the myriad of challenges faced by EVs. TE’s connectors are designed for durability, miniaturisation, and long-term reliability. For instance, their range includes IPT-HD High-Voltage Connectors and PowerTube Connectors (PowerTube 1000 and PowerTube 1400), each engineered to withstand harsh conditions, resist corrosion and maintain strong contact forces despite miniaturisation. TE’s emphasis on long-term reliability is backed by rigorous testing protocols, ensuring their connectors can endure years of operation under various conditions.
As electric vehicles continue to revolutionise transportation, the role of high-performance connectors cannot be overstated. They ensure the efficient operation and charging of EVs and guarantee the safety and reliability of these vehicles under challenging conditions.
Despite the obstacles posed by environmental factors, the push for miniaturisation, and the demand for long-term reliability, innovations in connector technology are keeping pace. TE Connectivity’s solutions highlight the industry’s dedication to overcoming these challenges, ensuring EVs remain a sustainable and dependable mode of transportation for the future.
At Dalroad, we provide an extensive range of components designed to enhance the resilience and lifespan of EVs. Our team of specialists is ready to assist you in selecting the perfect components for your design, taking all factors into account.
To explore our catalogue of components and gain support in choosing the right ones for your design, contact a member of our team today.
