INTERCONNECTION FEATURE Conducting power
for drivetrains G
one are the days when conventional electrical systems with 12 or 48 volts, and a few amps of electricity, were enough for motor vehicles. Today, the growing popularity of electric and hybrid vehicles means that cables and connectors have to handle loads of up to several hundred volts, both DC and AC, and currents of well over 300 amps. They also need to provide EMI shielding, low contact resistance and endurance to dust, water, hydrocarbons, vibration, temperature extremes and high impact loads. For safety reasons, it is also important to provide touch protection, plug coding, reverse polarity protection and good insulation.
CONNECTING THE WHOLE DRIVETRAIN A new connector system that meets these challenging requirements is the PerforMore, developed by Stäubli Electrical Connectors, which can carry a continuous current of 400A, or more.
Electrical connectors have always played an essential role in motor vehicles. Selwyn Corns of Stäubli Electrical Connectors outlines the new demands being placed on them
The system has been designed to connect the whole electric drivetrain, including batteries, inverters, motors and high voltage distribution units. Its low contact resistance is made possible by the company’s proprietary MULTILAM multi-contact system, which also ensures strong resistance to vibration and extremes of temperature. The PerforMore is compact, with a contact pitch only usually found at significantly lower current ratings, while maintaining the clearances and creepage distances necessary for high operating voltages. In the mated condition in particular, its low profile enables efficient use of available space. Installation is simple, while disassembly is user friendly and safe, with protection against accidental disconnection and arc flash. This is due to a two stage unlocking system that interrupts the high voltage interlock loop in the first stage, before disconnection of the live contacts in the second stage.
The two pole connector has 10mm diameter contacts and is rated at 1000V, with ingress protection to IP67 and IP69 when mated, and IP2X unmated.
Stäubli Electrical Connectors
www.staubli.com
/ ELECTRONICS
ELECTRONICS | NOVEMBER 2019
27
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