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Classification and Analysis of New Energy Vehicle Connectors
Futronics Electronic
05.15.2023 - Futronics

In the field of new energy vehicles, new energy vehicle connectors are important devices, mainly composed of contact bodies, insulators, shells, and accessories. Due to the increase in the working voltage range of new energy vehicles from traditional 12V to 400V, higher requirements are put forward for the quality and accuracy of connectors, which are applied in whole vehicles and charging facilities.

The connectors of new energy vehicles on the entire vehicle are used to connect the following systems: power batteries, high-voltage wiring harnesses, switches, electric air conditioning, DCDC, chargers, DC charging ports, AC charging ports, motors, inverters, etc. High plug and unplug times, heat resistance, and current carrying capacity are key factors to consider during development. High voltage and high current are used for power, from charging ports to batteries, and from batteries to motors, as well as inside the battery pack, In addition to power, there are also signal control, instruments, temperature, lighting, control, etc., as well as various sensors, BMS, entertainment systems, etc.

In terms of material selection, new energy vehicle connectors should use materials with high temperature resistance, and have higher requirements for sealing, shielding, and waterproofing compared to traditional vehicle connectors. Therefore, the cost is also higher. From a technical perspective, there are many patents for electronic control and motor connectors, and there are few improvements to charging, battery connectors, and grounding shielding. Pure electric vehicles and plug-in hybrid vehicles have operating voltages exceeding 300V, The working current is usually several hundred amperes. The high-voltage cable provides a guarantee for the reliability and safety of electric vehicle operation. Different from the 12V voltage of traditional vehicles, the high-voltage cable needs to consider preventing overheating or combustion, shielding performance, water and dust prevention, and electromagnetic compatibility with the vehicle electrical system.

In practical use, the magnetic interference generated by high-voltage cables can affect the integrity and accuracy of data transmission in car signal lines, and in severe cases, it can affect the safety of the entire vehicle. Therefore, high-voltage cables need to use shielded wires and other methods to reduce magnetic interference. Cables related to battery pack voltage collection and temperature collection have high requirements for crimping technology, and hydraulic equipment needs to be used to replace traditional processes in order to reduce fuel consumption, Replacing the widely used copper with aluminum to process high-voltage cables is also a trend in technological development.

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