New Energy High Voltage Connector Structure, Composition, Standard and Application

The high-voltage connector is an important part of the electric vehicle. Its function is to ensure the high-voltage interconnection system of the whole vehicle, that is, to build a bridge where the internal circuit is blocked or isolated to allow the current to flow. The high-voltage connector is mainly used in the high-voltage and high-current circuits of new energy vehicles, and acts at the same time as the conductive cable, and transmits the energy of the battery pack to various components in the vehicle system through different electrical circuits, such as battery pack, motor controller, DCDC Body power units such as converters and chargers.

1. Composition of high voltage connectors

High-voltage connectors are basically composed of: chassis (male, female), terminals (male and female terminals), shielding cover, sealing (tail, half, wire, contact) tail protective cover, high-voltage interlock system, CPA system, etc. Structure and composition.

2. Standard for high-voltage connectors

The standards of high-voltage connectors are currently based on industry standards. In terms of standards, there are requirements such as safety regulations and performance standards, as well as test standards. Because high-voltage connectors generally cannot appear on vehicles in the form of separate products, and generally require harness wire, the standard requirements for their harness wire are also very important.

3. Application of high voltage connectors

The development of new energy in China has been 20 years, and the trend of high-voltage connectors has been iterated four or five times, gradually transitioning from the earliest industrial bulky metal connectors to lightweight plastic connectors, with more and more single functions. From the perspective of the connector itself, there are many types of connectors: for example, in terms of shape, there are round, rectangular, etc., and in terms of frequency, there are high frequency and low frequency, etc., and different industries will also have different types.

We can often see a variety of high-voltage connectors on the whole vehicle. According to the different harness wire connection methods, we divide them into two types of connections:

① Fixed type with direct bolt connection

Bolt connection is a connection method that we often see on the whole vehicle. The advantage of this method lies in its connection reliability. The mechanical force of the bolt can resist the influence of automobile-level vibration, and its cost is relatively low. Of course, its inconvenience is that the bolt connection requires a certain amount of operation and installation space. For the more and more platform-oriented areas and the more and more reasonable interior space, it is impossible to leave too much installation space, and from the batch operation, It is also not suitable from the perspective of after-sales maintenance, and the more bolts there are, the greater the risk of human error, so it also has its limitations.

② Plug-in connection

In contrast, a mating connector secures the electrical connection by connecting two terminal housings to provide a connection to this harness wire. Because the plug-in connection can be directly plugged in manually, from a certain point of view, the use of space can still be reduced, especially in some narrow operating spaces.

The plug-in connection has transitioned from the direct contact of the male and female ends to the method of contacting the material with an elastic conductor in the middle. The contact method of using an elastic conductor in the middle is more suitable for the connection of larger currents, and its better conductive material and better elastic design structure It is also beneficial to reduce the contact resistance, thereby making the connection of high current more reliable.

We can call the intermediate elastic conductor contact. There are many ways of contact in the industry, such as spring type, crown spring, leaf spring, wire spring, claw spring, etc. that we are familiar with. Of course, there are also spring type and MC strap type ODU. The wire spring type, etc. The actual insertion form also has two ways of circular insertion and chip insertion; from the perspective of cost and thermal convection, the chip type is indeed better than the traditional circular spring type, but the choice What kind of method depends on your actual application needs on the one hand, and on the other hand, it has a lot to do with the design style of each company.