Driving Vehicle Innovation Through Advanced EV Connectors

By Austin Cronk | December 12, 2024

EV connector design plays a meaningful role in engineering breakthroughs that are adding efficiency, performance, and range to the next generation of electric vehicles.

EV connector design is revolutionizing the electric and hybrid electric vehicle markets through innovative materials, enhanced performance, and lightweight, miniaturized formats that contribute powerfully to efficiency, performance, and range. EV performance depends on electrical connections for critical vehicle operations including charging, power distribution, and communication between battery management systems, the electric drivetrain, safety and navigation features, cabin and exterior lighting, and control systems.

A reliable EV connector ensures uninterrupted power flow, efficient charging cycles, and overall vehicle comfort, reliability, performance, and safety by reducing the risk of electrical faults or failures. As these vehicles are evolving very quickly, a new generation of high-performance automotive connectors that is specifically designed for the EV and heavy equipment markets are helping the latest electric vehicles redefine performance standards. These connectors offer exceptional features like compact design, ruggedization, and high amperage capabilities.

Amphenol’s 12mm UPC (Universal Power Connector) has significantly contributed to revolutionizing the EV market, addressing crucial needs in power distribution and connectivity, enhancing efficiency and reliability in electric vehicle systems. These and other products for EV technologies from Amphenol Industrial Operations are stocked by Heilind.

Connectivity challenges

EVs and HEVs (hybrid electric vehicles) can face significant challenges related to unreliable connectors. One of the primary issues is the durability and reliability of the internal connectors that link the many components inside the vehicle’s electrical system. These EV connectors are crucial for maintaining efficient power transfer between the battery, the motor, and other vehicle systems. If connectors are not adequately robust or fail, they can lead to intermittent power delivery or complete system failures.

Another major problem is the susceptibility of these internal connectors to environmental factors such as temperature fluctuations, moisture, and vibrations. Vehicle components must be ruggedized to ensure reliable operations in a wide range of temperatures and weather conditions, and EV connectors must be able to withstand these fluctuations. Over a vehicle’s lifespan, exposure to harsh conditions can impact electrical systems, leading to corrosion, loose connections, or short circuits, all of which impair vehicle performance and safety.

The 12mm UPC (Universal Power Connector) utilizes RADSOK technology to ensure superior electrical connectivity and efficiency. RADSOK, known for its robust and high-performance contact design, offers low insertion force, high durability, and excellent conductivity.

Advanced EV connectors enhance the durability, reliability, and efficiency of power connections within electric vehicles. Robust construction ensures a secure and reliable connection even under harsh environmental conditions. Connectors must be designed to withstand extreme temperatures, moisture, vibrations, and other challenging conditions that can degrade traditional connectors. By using materials that are resistant to corrosion and wear, connectors maintain integrity and performance.

Harsh environments can introduce moisture, ice, and humidity into vehicle systems. Advanced sealing technologies that protect the internal components from moisture and contaminants must be designed into connectors to enhance the longevity and reliability of the connection, ensuring consistent performance even in adverse weather conditions. Enhanced sealing mechanisms prevent issues such as corrosion and short circuits, which are common problems in less protected connectors.

In addition to durability, new EV connectors must offer high power-handling capabilities to ensure efficient and reliable power transfer, minimal power loss, and optimal efficiency. This is particularly important as EVs and HEVs incorporate more advanced features and electronics that demand reliable power connections.

Design for repair

Cars endure a range of challenges, from weather to hard use and even accidents. As automotive engineers look for the most powerful connectivity solutions for their next generation designs, ease of installation and maintenance are important factors to consider. Connectors designed for straightforward assembly reduce the likelihood of installation errors that can lead to unreliable connections and help technicians work on the vehicle. Consumers require vehicles that are easy to maintain and repair, and connectors contribute to making ongoing maintenance easy for the owner and the repair technician. New EV connectors are designed to facilitate easier diagnostics and repairs, allowing technicians to quickly identify and address any issues related to the connectors. This helps to minimize downtime and maintenance costs, improving the overall user experience for EV and HEV owners.

New connectors are making it easier to design better vehicles by solving problems associated with unreliable previous generations of connectors. Robust construction, advanced sealing technologies, high power-handling capabilities, and ease of installation and maintenance ensure reliable and efficient connections, enhancing the performance and safety of modern electric and hybrid vehicles.

Amphenol Industrial actively supports educational initiatives by supplying the latest EV connectors to colleges participating in academic and competitive EV design projects. Inspiring the next generation of engineers to push the boundaries of EV technology contributes to the advancement of sustainable transportation solutions.

Learn more about Amphenol Industrial’s connectivity solutions for e-mobility.