Why choose a modular high voltage connector for an electric vehicle?

Traditional connectors can often fall short in meeting the diverse requirements of commercial EVs. You can easily end up with a large inventory of different types just for a single design, making assembly and maintenance unnecessarily complicated.

This is where modular high voltage connectors emerge as a superior choice, offering unmatched flexibility, simplified assembly and enhanced reliability. This article delves into the specific benefits of modular high voltage connectors and highlights why they are becoming indispensable in commercial EV design.

What are modular high-voltage connectors?

Modular high-voltage connectors are designed with flexibility and adaptability in mind. Unlike traditional connectors that come in fixed designs, modular models have interchangeable parts or sections that can be changed to fit specific needs and requirements. It is this customizability that provides EV designers with enhanced freedom and flexibility when integrating connectors throughout their design.

The benefits of modular high-voltage connectors for EV designs

Minimised inventory

High-voltage connectors in commercial EV designs require various different headers and screw orientations to ensure secure and safe connections. This leads to large inventories of different connectors to accommodate these different requirements across an entire design. With modular high-voltage connectors, you can easily interchange their headers and screw orientations when needed. As a result, you can minimise your overall inventory of connectors to streamline the design process and save valuable space.

Simplified assembly

As an additional benefit tied to minimised inventories, modular high voltage connectors significantly simplify the assembly process by reducing the need for multiple different connectors during assembly. Instead of sourcing various connectors with different headers and screw orientations, you can easily modify a single modular connector to fit your needs. This flexibility minimises the complexity of the assembly process, speeds up production and reduces the likelihood of errors, ensuring a more efficient and reliable manufacturing process.

Ease of maintenance

Modular connectors also simplify maintenance and upgrades. Given their design, individual modules can be replaced or upgraded without overhauling the entire system. This not only reduces downtime but also lowers maintenance costs. For instance, if a specific part of the connector system fails or requires an upgrade to meet new standards, only that module needs attention, making the process more efficient.

TE’s PowerTube connectors: a balance of performance and modularity

When discussing modular high-voltage connectors, TE’s PowerTube connectors stand out as a leading solution. Available in variants like the PowerTube 1000 and PowerTube 1400, these connectors are engineered to meet the rigorous demands of commercial EV systems.

• High performance: TE’s PowerTube connectors are designed to handle high voltage levels efficiently, ensuring reliable power transmission even under strenuous commercial and industrial conditions. They support voltages up to 1000V, making them suitable for a wide range of EV applications.
• Durability: Built to withstand harsh environments, these connectors feature materials that resist corrosion and can handle extreme temperatures. This durability translates to fewer failures and a longer lifespan, crucial for both passenger and commercial EVs that operate in diverse conditions.
• Modular design: The modular nature of PowerTube connectors allows for easy customization and scalability. This flexibility means that as EV designs evolve, the connectors can be adapted without needing a complete redesign. Maintenance and upgrades are straightforward, thanks to the modular approach, which further enhances their practicality and appeal.

Integrate the perfect connector for your EV

For EV designers, particularly those working on commercial vehicles, the advantages of modular high voltage connectors are clear. They offer flexibility and ease of integration with a balance of high performance and convenience. By integrating these connectors, you can minimise your inventory, simplify assembly and shorten maintenance times.

At Dalroad, we provide a comprehensive range of these high-performance connectors 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, ensuring your EVs are equipped with the best solutions available.

Contact us today to explore our catalogue and discover how we can support your journey towards creating superior electric vehicles. Together, we can drive the future of electric transportation towards greater efficiency and sustainability.