Application and Selection Criteria of High Voltage Connectors for New Energy Vehicles

New energy automobile connectors is one of the major categories of connectors, with the development of new energy vehicles in recent years, gradually separated from the traditional high-voltage high-current and traditional low-voltage automotive connectors in a class of connectors. Compared with the traditional high-voltage high-current connectors, new energy vehicles with connectors for the use of more complex and variable working conditions, the reliability of the connector requirements are higher; compared with the traditional low-voltage automotive connectors, due to the increase in the voltage level (the voltage of the mainstream system are higher than 300V DC), increasing the risk of injury to the human body by electric shock, the connector's safety requirements are higher; therefore, the insulation of the product, protection requirements than the traditional low-voltage plug-ins are higher than those of the insulation, protection requirements. Requirements than the traditional low-voltage plug-ins have been improved.

New energy vehicles with the role of the connector is mainly to ensure that the vehicle high-voltage interconnection system, that is, in the internal circuit is blocked or isolated at the bridge so that the current flow. New energy vehicle connectors can be generally divided into: shell, seals and other auxiliary structures, insulating parts, conductive contacts on three parts. Through the plug sheath and socket sheath between the pair of inserts, mutual coordination, you can achieve the function of connecting and conductive. High-voltage connectors are mainly used in new energy vehicles high-voltage high-current circuits, and conductive cable at the same time, the battery pack energy through different electrical circuits, transported to the vehicle system components, such as battery packs, motor controllers, DCDC converter, charger and other body power unit. New energy vehicle connector selection standards and considerations (1) voltage selection needs to be matched: the rated voltage of the vehicle after load calculation should be less than or equal to the rated voltage of the connector, if the vehicle operating voltage exceeds the rated voltage of the connector for a long period of time, the electrical connector has a risk of creepage ablation. (2) Current selection needs to match: the rated current of the whole vehicle after load calculation should be less than or equal to the rated current of the connector, if the working current of the whole vehicle exceeds the rated current of the connector for a long time, the electrical connector has the risk of overload ablation. (3) cable selection needs to be matched: the vehicle cable selection matching is divided into the cable current-carrying matching and cable and connector sealing matching, about the cable current-carrying, each host factory has a specialized electrical engineer to match the design, not explained here. Seal matching: connector and cable sealing relies on the elastic compression of rubber seals to provide contact pressure between the two, thereby achieving reliable protection performance, such as IP67; according to calculations, the realization of a specific contact pressure relies on a specific amount of compression of the seals to achieve, accordingly, if you need to reliably protect the connector sealing protection at the beginning of the design of the cable has a specific size requirements; the same specification of the current-carrying cross-section, cable The same specifications of the current-carrying cross-section, the cable can have a different outer diameter size, such as shielded cable and non-shielded cable, the national standard cable and LV216 standard cable, the specific match what cable, connector sizing specifications have a clear statement, so the connector sizing need to pay special attention to the cable specifications in order to prevent the connector from sealing failure. (4) the car needs flexible wiring: for the car wiring, now the OEMs have a bending radius and slack requirements; according to the connector in the car use case, it is recommended that after the completion of the wiring harness assembly, the connector terminal itself is not subject to stress, only when the wiring harness as a whole due to automobile operation by vibration, impact and body displacement occurs when the body of the relative displacement through the harness flexibility to achieve the strain elimination, even if there is a small amount of strain to the connector terminals, the resulting stress also Even if there is a small amount of strain transferred to the connector terminals, the resulting stress does not exceed the design holding force of the terminals in the connector.

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