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FEATURE CABLES & CONNECTORS
Developments in electric vehicle (EV) connectors will
improve efforts to
reach Net Zero. Dawn Rogers, European product manager
industrial at electrical connector specialist PEI-Genesis, explores the role of upgrading EV charging
capabilities to support the rising number of EVs on our roads
by 2050, according to National Grid ESO’s Future Energy Scenarios report. However, the lack of universal high-speed EV charging infrastructure continues to be off-putting for drivers, who still favour petroleum-based cars, which have lower upfront costs and come with an undeniable convenience. When it comes to EV connectors,
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manufacturers have not had to produce to an industry standard. They are therefore custom producing components to different requirements. The result of this is connector compatibility problems, with different options having different charging capabilities. Mode 1 is a charging type that directly
connects to a home outlet. This is not considered ‘smart’ technology as there is no communication between the charger and the vehicle. This is not actually allowed in the US or England and is restricted in a number of EU countries too. Mode 2 is ‘smarter’ but is still considered as
a slow AC application. Called an ‘emergency charger’, this is used mostly for private charging rather than public EV charging stations. Mode 3 is called slow and quick AC and has
several safety features to make it suitable for public use. Mode 4, meanwhile, is for rapid, direct current charging. These charge modes fall under the IEC
61851 standard and are constantly under review to ensure high levels of control and protection for the user safety. In addition to this, EV chargers must be user-friendly, safe, ergonomic and cost effective. For example, the high voltages and currents
present when EVs charge form the perfect environment for arcing between the contacts. While using a pilot signal goes some way to mitigating this, because any loss of continuity
lobal EV sales are growing. There are expected to be nearly 40 million electric vehicles (EVs) on Great Britain’s roads
TO EV ADOPTION ON THE ROAD
stops the charging immediately, it still does not fully prevent excessive resistive heating or damage to contacts.
Dawn Rogers
CONNECTOR DESIGN EV connectors must be capable of handling high power while also being suitable for public
use. Generally, CCS connectors combine all these features, however there are further requirements beyond these that EVs connectors must fulfil in order to drive enough uptake of EVs to meet the Net Zero by 2050 ambition. EV connectors should have high voltage
ratings – at least 1,000V –making them suitable for high-voltage EV applications. There is now a growing market trend for applications up to 1,500V and there are already new and emerging EV connectors to support these applications. They should also have high current ratings,
ranging from 70A to 500A, so they can meet EV charging requirements. Furthermore, they should provide protection against common environmental factors such as moisture, dust and vibration. Typically, EV
connectors have ingress protection (IP) ratings up to IP69, making them suitable for use for outdoor charging stations that must withstand varying weather conditions. IP69-level protection means that they are totally protected against dust as well as against continuous exposure to water jets, including protection against high pressure and temperature water conditions. Furthermore, EV
connectors should be made from high performance plastic that is resistant to corrosion and wear. This also helps them deal with ongoing vibration and shock, which are both common occurrences that they must contend with.
46 DESIGN SOLUTIONS NOVEMBER 2023
CONNECTOR SOLUTIONS As an example Amphenol’s SurLok Plus and RadLok ranges have a minimum durability rating of at least 100 mating cycles and use the RADSOK contact technology. These durable and robust product lines are suitable for energy storage, battery applications and even more interconnect solutions. In addition, Amphenol’s PowerLok G1 and G2 series use the RADSOK contact technology and are equipped with a secondary locking mechanism to prevent unintentional disconnects. Further options include multiple keyings, orientation options, and up to 1, 2 or 3 positions are available. All these series are designed for safety at the forefront, considering the high level of power being used in EV/HEV and power distribution applications. For heavy equipment or EVs used in industrial applications, this might be preferable given the consequences of downtime if a machine becomes unplugged. It is clear that to meet, or exceed, the goal of having nearly 40 million EVs on Great Britain’s roads by 2050 and reach Net Zero emissions nationwide, upgrading EV charging infrastructure will play a crucial role.
PEI-Genesis
T: 02380 621260
www.peigenesis.com
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