New developments in High Voltage Connection Systems
According to the ACEA, the production of Battery Electric & Hybrid Electric vehicles in Europe exceeded the production of combustion engine vehicles for the first time in 2024. New EU electrically chargeable bus registrations also rose by 26.8% in 2024, with their market share increasing from 15.9% to 18.5%. This positive trend positively impacts the production of the relevant EV subsystems like inverters, electric motors, battery pack and power distribution units. Connector manufacturers are supporting this trend by developing new products that support the future design requirements of specific industry segments
In the Automotive market, suppliers like TE Connectivity and Aptiv, are developing new connectors using flat blade contact systems rather than the traditional circular contacts as it provides design flexibility for the end customer. Popular products like the TE Connectivity – CSJ Series can support both copper and aluminium cables and use either crimp or ultrasonically welded contacts depending on the required cable size. Connectors can support currents up to 400A and are tested according to the LV214 / LV215 specifications required by the European car manufacturers. Furthermore, suppliers like Amphenol, TE Connectivity and Aptiv are offering CCS2 Inlets that will support current up to 500A DC which help reduce the charging time of BEV, whilst simultaneously replacing the DC Inlet cable contacts with busbar contacts to facilitate easier routing and power dissipation within the vehicle.
In the Commercial Vehicles, Agricultural and Construction Equipment markets, the primary challenge is finding connector systems that can support voltages up to 1500V and currents above 500A. Both Amphenol with their new CHD system and TE-ICT with their rugged Powertube product are helping customers that wish to use cable sizes from 95 to 150mm2 whilst Aptiv have recently introduced both metal & plastic pass-through products that can also support these larger cable sizes. Aptiv are also releasing the new HV-Duty plastic connector series to give customers a rugged lighter alternative to the metal solutions already on the market. Given the tough environmental conditions in which these products are used other innovative solutions emerging in the market include: sealed oil-proof connectors for use in electric motors and products with metal latching mechanisms to avoid issues with plastic latches breaking in rugged outdoor applications. Finally, given that larger vehicles require higher power charging solutions, both Amphenol and TE are starting to offer their first Megawatt Charging inlet products that will support currents up to 3000A at a 1500V rating.
A final design consideration for engineers is what will be their high voltage cable assembly strategy. High voltage cables are challenging to assemble and they require crimping and testing equipment can be expensive to invest in, so not all traditional harness makers will be able to produce these cables. Particularly for small volume OEM’s, engineers will need to consider upfront, if will they build cables in-house, source via a local cable harness maker or distributor, or if their volumes will be sufficient to be supplied directly by a connector manufacturer. Finding the right local partner or distributor during the development phase can make sourcing a lot simpler when their vehicle is ready to go into full production. TTI’s team of local technical development managers can help customers identify the best solutions for any new connector or cable assembly project.
About TTI IP&E – Europe
TTI, Inc., a Berkshire Hathaway company, is an authorized, specialty distributor of electronic components. Founded in 1971, the emphasis on a broad and deep product portfolio, available-to-sell inventory and sophisticated supply chain programs have established TTI as a distributor of choice to manufacturers in the industrial, defense, aerospace, transportation, medical, and communications sectors worldwide. TTI and its wholly owned subsidiaries, the TTI Family of Specialists, Mouser Electronics, Sager Electronics and Exponential Technology Group employ over 8,800 people in more than 132 locations throughout North America, South America, Europe, Asia and Africa. Globally, the company maintains about 222,000 square meters of dedicated warehouse space housing over 110,000 active part numbers. For more information about TTI, visit www.ttieurope.com.