EV CONNECTORS

Connectors are essential components in vehicles, making their role obvious. However, the complexity of selecting the right connector for various parts of the electrical system is often overlooked. Factors such as resistance to shock and vibration, safety for handlers, and ease of connection and disconnection are crucial. Additionally, considerations like size, weight, power, and cost are important.

The rise of electric (EV) and hybrid electric vehicles (HEVs) has increased the need for diverse high-voltage connectors. While internal combustion engine (ICE) vehicles typically use voltages around 12V DC, EVs and HEVs operate at much higher voltages, ranging from 275V to 800V, with larger systems like buses using up to 1000V. As EV/HEV powertrains evolve, high-voltage connectors will continue to play a key role, with some systems expected to operate between 3-11 kV.

In addition to handling high voltages, connectors must transmit digital and analog signals in environments with high electromagnetic interference (EMI). They must also be safe, preventing arcing and accidental contact, while remaining easy to use and durable in high temperatures.

In fully electric vehicles, connectors primarily manage power between the motor, battery pack, charger, and power converter. Hybrid systems require even more connectors due to the additional engine and control components.

Beyond high-voltage connectors, auxiliary connectors for control units, sensors, and actuators are necessary, especially as modern systems consume more power. These requirements make early design decisions critical for EV/HEV connector selection.

EV Connector Types

EV charging connectors can be compared to phone charging cables, with different types depending on the region and charging type. EV charging is categorized into AC and DC fast charging:

• AC Charging: This is the most common type, including Level 1 and Level 2 charging. Level 1 is slower, using standard home outlets, while Level 2 offers faster charging at home or public stations. In North America, the SAE J1772 and NACS (Tesla’s connector) standards are used for AC charging.

• DC Fast Charging: This provides faster charging, ideal for quick top-ups. The common DC plugs in North America are CCS1, CHAdeMO, and NACS.

The NACS Connector

From 2025, many automakers will adopt Tesla’s NACS connector, streamlining compatibility across EV charging stations. ChargePoint, a leader in EV charging solutions, ensures all its stations work with every connector type and vehicle, making charging accessible for all drivers.

EV Charger Types

Like phone chargers, EV cables have two connectors: one for the vehicle and another for the chargepoint. The connector type depends on the vehicle and the chargepoint’s power rating. Most EVs use Type 1 or Type 2 sockets for slower charging, and CHAdeMO or CCS for DC rapid charging. Many public chargepoints come with attached cables, but EV drivers often carry portable cables for convenience.

Authorize Line(*):

• aptiv
• CUI
• 2E*
• 3M*
• Almita*
• Amp/Tyco (See TE-Connectivity)
• Amphenol*
• Amtek*
• AUK*
• Augat*
• Beisit*
• Bomar
• Bulgin
• Cambridge*
• Caplugs*
• Cinch*
• Comm-Con*
• Compel Electronics*
• Cui
• Cvilux*
• DCI*
• Delphi*
• Deutsch*
• Dragon City*
• Elco*
• Elpakco*
• Erni*
• FCI
• Greenconn*
• Harting*
• Heyco*
• Hirose
• Hoffman Products*
• IBS*
• ITT-Cannon*
• ITW-Pancon*
• JST
• Keltron*
• Klemsan Electronics
• Kycon*
• Lear Connectors
• Lemo*
• Lewden*
• Major League*
• Methode*
• Mill-Max / Preci-Dip*
• Molex*
• Mueller*
• Multi-Contact *
• Neltron*
• Neutrik*
• Norcomp*
• Oupiin*
• Pollman Elektrotechnik*
• Rosenberger*
• Samtec*
• Shogyo*
• Stewart*
• Stocko*
• Souriau
• Sunbank
• Schaltbau
• Staubli
• Switchcraft*
• Taitek*
• The Lee Company
• Toby*
• Tokyo Dip*
• Wago
• Weidmuller
• Yazaki*
• Yokowo*