Automotive HV (High Voltage) and LV (Low Voltage) Connectors, Terminals
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Automotive HV connectors and terminals, which have high current capacity (up to 400A), safety interlocks, and EMI shielding, manage 60–1000V systems in EVs. LV connectors prioritize cost-effectiveness, compactness, and vibration resistance by supporting up to 60V for sensors, ECUs, and lighting. Both adhere to international standards such as USCAR and ISO and employ crimped connections with weatherproof sealing.
Functioning of Automotive HV (High Voltage) and LV (Low Voltage) connectors, Terminals
High Voltage (HV) Connectors and Terminals:
- Transmit high-voltage power (60–1000V) in EVs/HEVs.
- Connect battery, inverter, motor, charger, and DC-DC converter.
- Provide safety with HVIL, shielding, and touch-proof design.
- Ensure high current handling (up to 400A).
- Maintain insulation and thermal performance in harsh conditions.
Low Voltage (LV) Connectors and Terminals:
- Distribute power (up to 60V) to lights, sensors, ECUs, infotainment, etc.
- Support communication networks (CAN, LIN, Ethernet).
- Ensure signal integrity and low-resistance connections.
- Allow modular and compact wiring in vehicle systems.
- Withstand vibrations, temperature changes, and moisture.
Advantages of Automotive HV (High Voltage) and LV (Low Voltage) connectors, Terminals
HV Connectors and Terminals
- High Power Handling: Safely transmit high currents (up to 400A+) and voltages (up to 1000V+).
- Enhanced Safety: Integrated HVIL and touch-proof designs prevent electric shock and ensure safe disconnection.
- Robust Environmental Protection: IP67/IP69K sealing protects against water, dust, chemicals, and vibration.
- EMI/RFI Shielding: Minimizes electromagnetic interference to sensitive vehicle electronics.
- Thermal Stability: Withstand high temperatures (up to 125°C or more) without degradation.
LV Connectors and Terminals
- Compact and Lightweight: Designed for dense wiring harnesses and tight spaces.
- Cost-Effective: Mass-produced with standardized sizes for economical assembly.
- Versatile Applications: Support a wide range of low-power devices, sensors, and communication protocols.
- Excellent Vibration Resistance: Ensures signal integrity in harsh automotive environments.
- Easy Assembly and Maintenance: Plug-and-play connectors with locking features speed up repairs and manufacturing.
Components of Automotive HV (High Voltage) and LV (Low Voltage) connectors, Terminals
| Component | Description | Typical Materials | Function / Purpose | Notes (HV vs LV) |
|---|---|---|---|---|
| Connector Housing | Outer casing providing mechanical protection and insulation | High-temp thermoplastics (PBT, PA66) | Protects internal parts, insulates, supports locking | HV often orange-colored for safety; sealed for high IP rating |
| Contacts / Terminals | Metal conductors that mate with counterpart terminals | Copper alloys with tin/silver/gold plating | Conduct electricity; crimp or soldered to wires | HV terminals designed for higher current, voltage, and insulation |
| Seals and Gaskets | Rubber components ensuring environmental sealing | Silicone, fluorosilicone rubber | Prevent ingress of dust, water, chemicals | Required for both; HV demands higher sealing standards |
| Secondary Locking | Internal mechanisms that secure terminals inside the housing | Plastic locks/inserts | Prevent terminal back-out under vibration | Present in both, critical for reliability |
| Keying Features | Physical coding to ensure correct connector mating | Molded plastic shapes | Avoids incorrect or mismatched connections | HV connectors have distinct keying for safety |
| Cable Strain Relief | Mechanical part securing the cable to connector housing | Plastic or rubber components | Protects wires from bending or pulling damage | Important in both HV and LV connectors |
| HVIL (Interlock Loop) | Embedded safety loop circuit detecting connector status | Electrical circuit embedded in connector | Cuts off HV power if connector is unplugged or tampered | Exclusive to HV connectors |
| Shielding | EMI/RFI protection layers inside connector and cable | Metal foil, braided copper | Reduces electromagnetic interference | Primarily critical in HV systems |
Types of Automotive HV (High Voltage) and LV (Low Voltage) connectors, Terminals
Automotive High Voltage (HV) Connectors and Terminals
- 2-Pin HV Power Connectors: These connectors typically have two large terminals designed for carrying very high currents and voltages, such as those found between the battery pack and the inverter or motor. They are built to handle currents up to 400A or more and voltages from 400V up to 800V or higher.
- 3 or 4-Pin HV Hybrid Connectors: These connectors combine power and signal lines in a single housing, allowing power delivery along with communication or monitoring signals like temperature or voltage sensing. They are often used in battery packs or high-voltage junction boxes.
- DC Fast Charging Connectors: Standardized connectors such as CCS (Combined Charging System) or CHAdeMO allow external charging at high currents and voltages. These connectors are engineered for quick, safe high-power transfer (up to 500A and 1000V).
Automotive Low Voltage (LV) Connectors and Terminals
- Wire-to-Wire Connectors: Used to connect two separate wiring harnesses. They come in various sizes and pin counts and are used widely in sensors, actuators, and lighting circuits.
- Wire-to-Board Connectors: Designed to connect wiring harnesses directly to printed circuit boards (PCBs) or electronic control units (ECUs). They often feature low profiles and secure locking mechanisms.
- Multipin Connectors: These connectors house multiple circuits or signal lines in one unit, reducing wiring complexity. They are commonly used in engine harnesses, infotainment systems, and ECU connections.
Applications of Automotive HV (High Voltage) and LV (Low Voltage) connectors, Terminals
| High Voltage (HV) Applications | Low Voltage (LV) Applications |
|---|---|
| Battery Pack Connections | Lighting Systems |
| Inverter and Motor Connections | Engine and Transmission Control Units (ECU/TCU) |
| DC-DC Converters | Infotainment Systems |
| Onboard Chargers (OBC) | Safety Systems |
| High Voltage Junction Boxes and Distribution | Comfort and Convenience Features |
| Charging Ports and Fast-Charging Interfaces | Communication Networks |
| Thermal and Voltage Sensors |
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