MagnaMate ATHP Connector
From fully electric cars and trucks to emergency response vehicles and heavy-duty construction machinery, secondary electrical systems are critical to EVs’ utility. They power everything from air conditioners, seat heaters, and infotainment systems to sirens, ladders, pumps, and other critical auxiliary systems.
As the loads on secondary electrical systems increase, manufacturers have introduced higher-voltage components for connection, protection, and identification of these systems. Here’s a look at some of them.
Connectors
Amphenol MagnaMate ATHP Connectors, rated at 1000 Vdc, are a thermoplastic power connector series designed for EV applications. They have a high ingress protection rating (IP67) and are available in single or two-pole housings with rated current from 20 to 180A.
ShieldPack Connector Kit
They include optional integrated High Voltage Interlock System (HVIL) safety features and EMI shielding protection. These connectors can withstand temperatures ranging from -40° to 266° F (-40° to 130° C).
Aptiv‘s ShieldPack Connector Kits, rated at 1000 Vdc/40A, are also designed to ensure secure and reliable electrical connections in high-voltage EV systems. They are IP67-rated and have an operating temperature range of -40° to 257° F (-40° to 125° C).
These connectors are ISO-cable compatible and feature a tool-less unmating system.
Circuit protection
Contactors for EV applications
Littelfuse offers a range of high-current, high-voltage contactors for EV applications. These contactors, ranging from 48-450 Vdc, are designed for use with functions such as charging stations, battery power supplies, motor control, and other switch controls.
Littelfuse also offers a line of 500-Vdc fuses called the 10EV Series. These fuses use diffusion pill technology to provide time-delayed protection to high-voltage accessory circuits in EVs and hybrid passenger vehicles. They’re available in six different amp ratings, ranging from 10 to 50A.
Wiring ID and protection
Anti-abrasion wire harness tape
Products for identification and protection of wiring are now available in orange, the standard color for EV applications. This aids in quickly identifying EV wiring, thereby streamlining the maintenance and repair process, promoting safety and efficiency.
Tesa offers an orange anti-abrasion wire harness tape that provides excellent abrasion resistance and ensures easy identification. This tape is constructed with double-layer PET cloth coated at the edges with an advanced acrylic adhesive for lengthwise application. It can withstand operating temperatures ranging from -40° to 302° F (-40° to 150° C).
Heat-shrink tubing
DSG-Canusa‘s orange heat shrink tubing is designed to encase wiring, providing protection and insulation. It is resistant to oils, chemicals, and fungus, flame retardant, and UV resistant. When appropriate heat is applied, the material shrinks to half its original size for a firm seal around wires.
For heavy-duty protection of wires and cables, Techflex offers the Battle Braid Heavy-Duty Sleeving, a durable and reliable solution. This orange sleeving is particularly well-suited for EV applications, featuring a durable polyester construction that absorbs and dissipates energy and crush and abrasion protection.
Battle Braid sleeving
Conclusion
As the industry moves toward more electrified and mixed-voltage architectures, manufacturers continue developing optimized components and advanced technologies to support the transition and ensure the safety and reliability of automotive electrical systems.
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Filed Under: Technology News