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New Energy Vehicle

New Energy Vehicle

首页 解决方案 New Energy Vehicle
方案内容

For the new energy automobile industry, China has given support from terminal subsidy, infrastructure subsidy, standardization standards, government procurement and other aspects, with great efforts and clear direction. In addition to the joint contribution of technological progress and industrial chain, the new energy automobile industry has entered the track of rapid development

专家观点
  • Protection Level Requirements of Connectors for New Energy Vehicles
  • Electromagnetic Shielding Requirements of Connectors for New Energy Vehicles

  At first, the protection requirements of IPI67 can meet the needs of most customers. However, with the protection failure of connector products on the market, there are more and more cases of product leakage, insulation failure and even ablation. Therefore, the protection requirements of automakers are becoming more and more stringent. Protection requirements mainly depend on the placement of connectors on the vehicle. According to the layout of the high-voltage circuit on the vehicle, which is usually suspended under the chassis of an automobile, and considering that no high voltage device is in the cabin, most high-voltage connectors are installed on the chassis near the ground, or near the hub of the wheel, which can be impacted by water from the automobile's tires during heavy rain or severe cold. When the automobile is running at high speed and suddenly wading into the water, the instantaneous surge of water pressure to the connector will be large; however, the impact pressure of the high-pressure water gun under IP67 level is not as large as 6k9k, so IP67 sometimes fails to meet the actual usage requirements.

   The USCAR2.0 standard divides the seal into S1 and S2 grades. The S2 seal grade is clearly defined for the applicable occasions, that is, when the chassis position is low, it is recommended to be 6K and 9K; therefore, the future protection level of automotive connectors for new energy vehicles must be 6K and 9K. Of course, if the connector is not arranged in the position above, the design of IP67 can also meet the requirements of the vehicle.

  New energy vehicles have a lot of electronic components, and the current will generate a magnetic field, so the parts of the vehicle need to have the ability to resist interference. New energy vehicles are used as a carrier at present. Without electromagnetic shielding, the magnetic field generated can be harmful to people sitting in the car, so shielded connectors and shielded cables become very important for high-voltage systems. Of course, our priority should be the system level arrangement, which is a prerequisite. If the OBC in the system, and the layout, including the DCDC in the system, might have some problems from time to time, even if the connector shielding performance is very good, there will be a variety of signal interference problems. Therefore, the system level arrangement shall be considered first before the component level.

  The shielding efficiency of connector is generally realized in two ways. In the first way, for some plastic connectors, an effective 360° shield is formed by connecting the internal metal shielding case to the cable shielding layer, and then connected to the equipment box through the metal shielding case; in most cases, for the connection between the metal shielding case and the cable shielding layer, we will use the form of inner metal and outer metal rings for crimping. The shielding layer will be placed between two metal rings, and the shielding layer and the metal ring will be tightly fixed through cold pressing and deformation, as shown in Fig. 2. In the second way, for most of the high-voltage small-current connectors, there is no secondary connection inside, but connecting to the cable shielding layer is adopted directly, which is a common way, called spring contact, actually spring connection. The advantages of this structure are smaller size, smaller space and more contact points. The main representative manufacturers of this kind of structure are Baumann Springs in Switzerland, the LyondellBasell in the United States, and so on, which have a lot of real and mature applications in this field. In addition, we have another shielding way, which is to achieve connection through a structure similar to the spring lug. This structure is applied to the shielding performance of new energy vehicles, which can meet the performance requirements. This structural part is made by punching, which is cost-effective and can realize mass production.

   Autonomous driving has become a trend, and its requirement for electromagnetic shielding is only going to get higher, so this technical issue is very important.

解决方案
  • PDU
  • BDU

PDU (power distribution unit) is mainly used for the high-voltage power distribution and control of electric vehicles, which transmits the battery power to various electric equipment of the vehicle and the electric energy from the power grid to the batteries. It is connected to the electric equipment such as: the air conditioner, motor, defroster, battery heater, air pump, oil pump, OBC, DCDC, etc. and mainly installed in the front and rear cabins of passenger vehicles or the rear cabin of buses.


BDU is integrated inside of the battery pack. Due to the limitation of the battery box space, the shape is irregular generally. It is similar to PDU in function, mainly consisting of main positive, main negative, fast charging, slow charging, battery heating and precharging relays, slow charging and battery heating fuses, precharging resistor, Hall sensor, etc.

创新技术
  • 90° Outlet DC Charging Socket

IP67 waterproof (outlet), high and low temperature resistance, high mechanical strength, salt spray resistance 96H;

Low temperature rise and good stability;

The function of quick change of terminal can be configured and it is compatible with a variety of temperature sensors;

Small size, compact installation, and modular assembly;

 Multi-angle transfer can be realized;

 11.jpg 333.jpg 22.jpg

                    (1) Left outlet                                        (2) Right outlet                                         (3) Lower outlet

Rated current/voltage: 80~250A 750/1000V DC;

Applications: vehicle-mounted fast charging interface, mobile charging equipment interface;

Innovation: pinhole transfer structure (as shown below).


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