High-Voltage Automotive Connectors Product Roundup
This week’s Product Roundup highlights high-voltage automotive connectors (800V+) from leading suppliers.
High-Voltage Automotive Connectors
The LSH rack and panel connectors from Smiths Interconnect include leading-edge Hypertac hyperboloid contact technology that ensures LSH connectors are immune to shock, vibration and fretting. In addition, the polyphenylene sulfide (PPS) insulators interconnect technology features low insertion and extraction forces that are a catalyst for easy mating. The LSH Series delivers customers a life cycle that can be maintained for 100,000+ mating cycles and at an extremely low cost of ownership. The LSH Series delivers customers a high life cycle and is utilized across many different market segments including automotive, aerospace, industrial, test and measurement, and mass transit.
Lumberg‘s customized high-current contact elements for automotive applications are installed in millions of mechatronic modules and control units, especially in current electric vehicles. The phase contacts, plugged onto standard tab contacts, optimally connect PCBs that are on top of each other, particularly in tight spaces. The phase contact, which is SMT-soldered onto the PCB, or can be laser-welded onto a lead frame, makes vertical contact with a blade contact on the second PCB. Phase contacts with a mating area open on both sides are a special feature. The tab contact can optionally be inserted from above or below, or through the circuit board. As a specialist for precise punching-bending contacts in high volumes, Lumberg can also easily integrate positioning pegs into the geometry for a perfect fit on the PCB. Lumberg’s high-current contact sockets are part number 4580. Currently six standard contacts are available. The single-pole and tin-plated contact sockets of the smaller version 4580 03 mate with tab contacts of 5.3 mm x 0.8-1.0 mm or up to 5.3 mm x 2.0 mm. Depending on the PCB layout or the lead frame, rated currents (at Tamb 20 °C) up to 60 A with contact resistance < 0.5 mmΩ can be realized. In the larger version 4580 04, tab contacts up to 8 mm can be mated, then at rated currents up to 80 A with contact resistance < 1.0 mmΩ.
The KW04 Series from JAE is an EV charging connector compatible with the Type-2 CCS (Combined Charging System) electric vehicle fast charging standard. The product meets the European Conformity safety standards and is CE certified. Typical charging connectors that have reached their product life span have to be totally replaced. The KW04 has been designed in a way that allows for replacement of the plug interface only. Replacement of the interface can be done while the cable is attached to the charge unit. In addition, as a safety precaution, a double insulation structure has been adopted to protect the live part inside the connector from water intrusion, so that a short circuit will not occur even if the exterior is breached or damaged in any way by unexpected accidents. Additional information is available on the JAE website.
Amphenol UPC connectors (Ultimate Power Connectors) from PEI Genesis are designed for hybrid electric vehicle (HEV) applications. UPC connectors have a lightweight and space-saving compact plastic shell. The 2-pole and 3-pole versions use RADSOK technology to achieve high amperage, less resistance, and lower voltage drop and T-rise. These durable UPC connectors are rated to a minimum 100 mating cycles. They are field-installable and repairable. Learn more about Amphenol UPC connectors by checking out the PEI Genesis blog post, “Amphenol UPC Power Connector Solutions for HEV/EV Designs.”
LEMO’s M series connectors are lightweight triple start ratchet coupling type connectors. Originally designed for motorsports — as LEMO’s owner, Alex Pesci, has his own racing team — M series connectors are also used in avionics, aerospace, military, security, and heavy duty applications. The product is a COTS (commercial off-the-shelf) and fulfills various MIL–spec requirements and meets most of the MIL-DTL-38999 requirements. The connectors are smaller in size with the same number of pins as standard MIL-38999 products. A threaded option allows mounting a standard MIL-DTL-38999L backshell. The M series connectors are identified with a laser engraved part number and production batch number to ensure full traceability from raw materials to delivered product, with many options held in stock.
The new CHARX charging inlets from Phoenix Contact E-Mobility enable both low- and high-power charging (HPC) of electric vehicles. The Combined Charging Systems (CCS) inlets allow continuous charging at up to 250 A, and temporarily up to 500 A and 1000 V. This is the highest charge rating currently available, making it possible to charge a vehicle in just a few minutes. The CHARX CCS charging inlets have a DC cable cross-section of up to 95 mm2, which enables the higher power. Core elements of the charging inlet have been engineered to improve temperature sensing and connection technology between the cables and contacts. The vehicle can then regulate the requested charging current dynamically based on the temperature evaluation. Previous generations of CCS inlets were not capable of higher power on the vehicle side, because it led to dangerous overheating in the vehicle. The portfolio includes inlets for both Type 1 (North America) and Type 2 (Europe), designed to the same mounting dimensions. The inlets are manufactured in accordance with the IATF 16949 automotive quality management system and conform to IEC 62196 and SAE J1772 design standards.
The iPower HV connector from iConnector is designed for the electrification of commercial transportation. Current capacity includes 80A, 300A, 500A and up to 600A or even higher. The iPower HV connector is fully shielded, HVIL integrated, sealed, and unmated. An optional locking lever for high vibration resistance is available. The iPower HV is IP68 and IP69K rated, with single-, two- or three-pole configuration.
The Rosenberger HPK system can achieve 275 A at 85° C and up to 1000 V. With their excellent vibration and current capacity performance, the HPK connectors are well-suited to typical high-voltage electric vehicle applications such as the connection between battery, inverter, and PDU. The range includes one-, two-, or three-pole connectors, which can be used with copper or aluminum cables in four different cable cross sections for maximum flexibility. Straight and angled cable couplers as well as corresponding headers are available, either with or without HVIL (high-voltage interlock). The harmonized Rosenberger HVR connecting system consists of various components for power supply in the vehicle and facilitates customized configurations when designing the required cables. Application areas include the supply to batteries, AC/DC convertors, motor, and various charging systems.
EV series connectors are an Amphenol India product supported by Amphenol PCD in the U.S. market. These connectors are designed to connect power cables within mobile or stationary power supply systems and meet all the necessary specifications for commercial transportation systems. The IPX2 or TUV finger-proof design on both the plug and receptacle allows much greater flexibility when connecting “always hot” systems such as battery packs, fuel cells and capacitor packs.