Factors to be considered when producing new energy automotive connectors

I believe everyone is well aware that in a new field such as new energy vehicles, high-voltage connectors are important devices, mainly composed of contacts, insulators, housings and accessories. As the operating voltage range of new energy vehicles is increased from 12V to 400V in traditional vehicles, higher requirements are placed on the quality and accuracy of connectors, which are used in vehicle and charging facilities.

New energy vehicle connector manufacturers are distributed globally, most of which are Japanese companies, including Sumitomo, Nissan, Yazaki, Toyota and so on. The strongest domestic companies are Basba and China Southern Power Grid. Domestic connector factories such as AVIC Optoelectronics, Yonggui Electric, Guangdong Konnra, etc., which have been supplied in batches, have gradually grown up. As far as the global connector market is concerned, the market is highly concentrated and basically occupied by the United States, Japan and other countries. Among them, the Tyco family accounted for more than 20%. The high-voltage connector on the vehicle is used to connect the following systems: power battery, high-voltage wiring harness, switch, electric air conditioner, DCDC, charger, DC charging port, AC charging port, motor, inverter, etc.
High insertion times, heat resistance, and current-carrying capacity are the key considerations during development. New energy automotive connector production requires the use of materials with high temperature resistance in terms of material selection. The requirements for sealing, shielding and waterproofing are also higher than those of traditional automotive connectors, so the cost is also higher. In terms of technical composition, there are many patents for electrical control and motor connectors, and there are few improvements to charging, battery connectors, and ground shielding. The working voltage of pure electric vehicles and plug-in hybrid electric vehicles exceeds 300V, and the working current is usually several hundred amperes. High-voltage cables provide a guarantee for the reliability and safety of electric vehicle operation.

Unlike the 12V voltage of traditional cars, high-voltage cables need to be considered to prevent overheating or burning, shielding performance, waterproof and dustproof, and electromagnetic compatibility with the vehicle's electrical system. In actual use, the magnetic interference generated by the high-voltage cable will affect the integrity and accuracy of the data transmission in the automotive signal line, and in serious cases will affect the safety of the vehicle. Therefore, high-voltage cables need to use shielded wires and other methods to reduce magnetic interference. The cables involved in battery pack voltage collection and temperature collection have very high requirements on the crimping process, and it is necessary to use hydraulic equipment to replace the traditional process. In order to reduce fuel consumption, it is also a technological development trend to use aluminum instead of the currently widely used copper to process into high-voltage cables.