Whether industrial connectors can be widely used
in new energy vehicles
Although it seems that new energy vehicles still have drawbacks such as insufficient power, low safety, and inconvenient charging, in general, new energy vehicles have become a new industrial growth point and become a new development trend that is unstoppable. This general trend must be a rare new opportunity for our connector industry. Experts estimate that 600-1,000 electronic connectors will be used per car in the future, far more than the number used today. On the other hand, in the era of new energy vehicles, the use of large-capacity lithium batteries is a common point in the design of new energy vehicles and hybrid vehicles, so it requires a comprehensive improvement of the automotive electronic and electrical architecture, and connectors bear the brunt.
This growth rate shows that manufacturers of new products such as electric vehicles, home and road charging stations, and charging cables are facing huge market opportunities. The trend towards electric vehicles comes with a change in vehicle fuels, and while conventional cars still rely on fossil fuels, avant-garde electric vehicles will be connected to a new, more efficient power transmission infrastructure – the Smart Grid. As more and more electric vehicles and related equipment are launched one after another, in order to meet the increasing market needs, more software and hardware and applicable components have also emerged, but in addition to pursuing faster research and development speed, if the related industrial supply chain wants to gain a foothold in this emerging market, the primary consideration should still be whether consumers have confidence in the safety of electric vehicles and related application parts.
The connector of the electric vehicle refers to the combination of plug and socket, and the combination of connector and connector, its main function is to transmit power from the outside of the car to the car, and the device will contain a rubber shell contact as a connection for power, grounding, communication and navigation control. Just SAE J1772 today? It has been designated as a standard device in the United States, but other devices with different configurations may still be allowed. In addition, the housing material used in the connector must be polymer insulating and must have specific combustion class, electrical and heat resistance characteristics.
To ensure the safety of drivers and service technicians in high-voltage environments, we must consider a series of complex factors of the electrical system to ensure reliability and optimality. The connection system is a key component of high-voltage electrical connection lines, especially the connection wire design of high power lines. From a safety point of view, there are two aspects to pay attention to in the design of high-voltage connection systems, namely high-voltage interlock loops (HVIL) and environmental sealing of connectors (to avoid short circuits between high-voltage terminals when used in vehicles).
Since unsealed lines can lead to failure modes such as short circuits, sealing of high-voltage lines is critical. As we all know, water and electricity are incompatible. The use of wire ring seals and connector perimeter seals allows the connector to be truly sealed, ensuring that moisture cannot enter and does not cause overheating or sparks. Compared to traditional 12V systems, high-voltage systems require a stronger seal because the higher the voltage, the greater the chance of ignition.
High-voltage interlock loops (HVILs) are a feature of high-power connection systems and are necessary to avoid live disconnect flashing of connectors used in power electronics. Special considerations must be taken to ensure that the connection system does not disconnect when charged. When the connector is about to be disconnected, a high-voltage interlock loop sends a signal to cut off the power supply in time. This feature is necessary in the event of an accident or when maintenance personnel need to disconnect power for vehicle maintenance, and it helps protect passengers, maintenance personnel or first responders to accidents.
In short, the development of new energy vehicles is a rare opportunity for the industrial connector industry.
