The electrification of new energy vehicles continues to develop rapidly, and the requirements for their internal electrical connection components are gradually increasing. Compared with traditional fuel vehicles, electric vehicles often have higher voltage and current platforms. As the "blood vessel" of new energy vehicles, high-voltage connectors are one of the core components in the high-voltage system of automobiles. They are mainly used in DC, plumbing PTC chargers, air heating PTCs, DC charging ports, power motors, high-voltage wiring harnesses, and maintenance switches. , inverter, power battery, high voltage box, electric air conditioner, AC charging port, etc.
The growth in sales of new energy vehicles in China has driven the continuous increase in the volume of high-voltage connectors. The material cost, shielding, flame retardant requirements and other performance indicators of high-voltage connectors are higher than those of traditional low-voltage connectors, so the value of connectors used in new energy vehicles is much higher than that of low-voltage connectors. In order to improve the efficiency of energy supplementation, high-power fast charging has become the focus of research and development of various car companies. Switching the 800V architecture can cut the charging time in half compared to the 400V architecture.
The increase from 400V to 800V puts forward higher requirements on the reliability, volume and electrical performance of the connector, and its mechanical performance, electrical performance and environmental performance will continue to improve. After the boost, the high-voltage connector will be re-selected, and the high-power fast charging interface and the 400V to 800V conversion interface will be added, which will drive the value of the high-voltage connector to increase.
Since the development of electric vehicles, major technological breakthroughs have been made in each module, but so far we have not formulated or released design specifications related to high-voltage and high-current connectors in China. The high-voltage and high-current connector is a key component in the electric vehicle power transmission system, and its main functional items are roughly divided into three categories: electrical performance, mechanical performance and environmental performance. High-voltage connectors for passenger cars must be guaranteed for at least 15 years (≥8,000 h operating life + 30,000 h charging life) or at least 300,000 kilometers, taking into account other specific requirements for passenger cars. High-voltage connectors for commercial vehicles must be guaranteed for at least 15 years and not less than 1 million kilometers, taking into account the operating conditions specified by the customer. The design of the high voltage connector must ensure that the entire life cycle of the vehicle is guaranteed without any maintenance and normal use.
In addition, high-voltage connectors need to meet operational reliability under expected operating conditions (heat, cold, humidity, vibration, contact with media, current load, voltage load, etc.), and be designed in the corresponding space. Generally, the maximum rated voltage of high-voltage connectors is 850V DC (the rated voltage must be guaranteed to be above 4000 meters above sea level), and it is guaranteed to meet the operating temperature requirements of -40°C to 140°C. In addition, the selection of raw materials for all components of the high-voltage connector must meet the relevant requirements of the scrap standard of the automobile industry.
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