Why connectors are important in electric vehicles
Despite the growing electric vehicle market, it faces very real competition. While petroleum-based automotive solutions have many drawbacks, their convenience is undeniable; fuel can be pumped into almost any vehicle with virtually no difficulty, unlike charging an electric vehicle. Each electric vehicle likely has its own uniquely designed industrial connectors, making connectors a serious issue for electric vehicles.
Electric Vehicle Connector Challenge
Compatibility with most electrical equipment is not a challenge, as standardized connectors and nationally standardized power supply voltages make things simple. While a reliable power grid solves the frequency and voltage issues faced by electric vehicles, connector specifications remain a challenge.
Electric vehicle manufacturers are further complicating the connector issue by utilizing various electric vehicle charging modes, including:
Mode 1: Slow charging from a typical household outlet
Mode 2: Faster charging via a specially designed household outlet.
Mode 3: Charging points on commercial streets
Mode 4: Fast DC Charging
In addition, EV connectors must incorporate several key design features: they should:
Ergonomic and easy to use
Save space
Built-in security features
Capable of providing AC and DC power
CCS Connectors: A Solution or Not?
The CCS (Combined Charging System) connector incorporates all these design features, so designers might assume that all issues related to EV connectors are resolved. However, this is not necessarily the case.
CCS connectors meet customer requirements for EV connectors, but from an electrical engineering perspective, much work remains to be done. For example, the high voltage and current present during EV charging create the perfect environment for arcing between contacts. While using pilot signals can greatly mitigate this, as any loss of continuity can immediately stop charging, it still cannot completely prevent resistor overheating or contact damage.
It's important to remember that a high-voltage arc between contacts lasting just one second is enough to burn them out, causing system failure. If this damage occurs at a charging station, it simply means replacing the connector. However, if the damage occurs on an electric vehicle, people are stranded with a broken car.
However, this situation can be mitigated with a little effort in contact design.
Consider the Amphenol RADSOK connector, which uses a specialized hyperbolic geometry to provide a robust, high-density mating between contacts. These high-power, harsh-environment Amphenol connectors are designed to drive their respective contacts to ensure a complete and reliable connection. They comprise a flat, highly conductive alloy mesh with high tensile strength properties, generating the high normal force required to achieve reliable conductivity. Furthermore, this high-conductivity mesh provides a large surface area for conductivity.
