Connector Solutions for Off-Highway Vehicle Electrification Challenges
Electrification, a process that has been evolving since the discovery of electricity, has become integral across many industries, including industrial, agriculture, and transportation. The transportation transformation extends to off-highway vehicles, encompassing diverse machines like tractors, mining equipment, construction vehicles, and more. These vehicles, designed for terrain beyond conventional roads, present unique engineering challenges.
Off-highway vehicles operate in more extreme conditions, from sub-zero Arctic temperatures to scorching desert heat, constant vibrations, and exposure to dust and debris. Engineers addressing these challenges recognize the need for reliable solutions, particularly in the context of electrification, which is gradually gaining traction in the off-highway sector.
The advantages of electrification in this domain are practicality and efficiency. An all-electric system potentially reduces mechanical failure points compared to traditional internal combustion engines (ICE). Electric motors provide precise torque control, minimizing wear and ensuring efficient power delivery to the application. Multiple independent motors allow vehicles to remain operational in the event of motor failure, a significant advantage in challenging off-road conditions.
In addition to these advantages, electric off-highway vehicles may contribute to environmental goals by operating without on-site emissions. This is particularly beneficial in enclosed environments like mines where clean air is especially crucial for safety. Furthermore, electric systems seamlessly integrate with software control systems, enhancing functionality and adapting to evolving technologies.
The electrification journey for off-highway vehicles, however, necessitates a comprehensive approach, acknowledging the critical role of connectors in ensuring the reliability of electrical systems. Connectors play a critical role in carrying data or powering various components such as lights, motors, battery-charging systems, and entertainment systems. In the demanding environments faced by off-highway vehicles, connectors must withstand stress, aging, and environmental exposure while maintaining high reliability standards.
Connector manufacturers offer tailored solutions to meet the unique demands of off-highway applications. For instance, double-latch waterproof connectors (Figure 1) are designed with higher retention to prevent accidental disconnection in harsh environments. These connectors find applications in scenarios requiring robust protection against water, dust, and contaminants, such as outdoor lighting, marine equipment, and industrial machinery.
Figure 1: EDAC Double-latch IP67 Waterproof Inline Connectors offer a reliable connection for rugged applications
D-Sub connectors (Figure 2), enhanced with mounting features and backshells, establish robust and stable connections, proving especially crucial in aerospace and defense applications where resilience to shock and vibration is extremely important. The inclusion of waterproof variants in the D-Sub connector range provides an additional safeguard against water, dust, and contaminants. Available in various configurations and sizes, D-Sub connectors offer versatility to suit different design requirements.
Figure 2: EDAC IP67 Waterproof D-sub Connectors are reliable and offer added EMI/RFI protection with available metal backshells
Connectors for display and ports, such as waterproof and non-waterproof USB and HDMI connectors (Figure 3), emerge as essential solutions for off-highway applications integrating advanced processing systems, displays, and human-machine interfaces. These connectors are engineered to withstand the harsh conditions often associated with off-highway environments, contributing to the seamless operation of these vehicles.
Cable assemblies and wire harnesses (Figure 4), as value-added solutions, simplify the assembly process, reduce installation time, and minimize the risk of errors or defects. Customizable in configurations and lengths, these solutions cater to specific design requirements, ensuring precise fitment for every application.
Figure 4: A connector manufacturer with the ability to provide full cable/wire solutions is important. EDAC, as a value-add, offers cable assemblies and wire harnesses for all appropriate connectors carried.
Engineers embarking on the electrification journey of off-highway vehicles can rely on these connector solutions. With almost 60 years of manufacturing and engineering experience, connector manufacturers bring a profound understanding of the intricate requirements and challenges faced by off-highway vehicles. Adhering to the highest standards ensures that these solutions meet the rigorous requirements of off-highway vehicle manufacturers, even if industry-specific standards like IATF 16949 (Figure 5) are not mandatory for this sector.
Figure 5: Automotive Quality Management Systems are not mandatory for all off-highway vehicle solutions, but EDAC holds itself to the highest standards with IATF 16949 for products. Contact EDAC for additional IATF 16949 certification details.
Whether designing custom connectors or integrating standard products, experienced connector manufacturers bring valuable capabilities to the design process. As the off-highway sector embraces electrification, connector solutions are critical, enabling the seamless integration of electric propulsion systems into the diverse array of off-highway vehicles.
To learn more, visit EDAC Inc.
Connect with EDAC’s solution engineers for your next connector project here.
Like this article? Check out our Transportation Market Page, and our 2024 and 2025 Article Archives.
Subscribe to our weekly e-newsletters, follow us on LinkedIn, Twitter, and Facebook, and check out our eBook archives for more applicable, expert-informed connectivity content.
