High-current contacts for the drive train in the electric vehicle

Iwis smart connect presents High current contacts for the Electrification of vehicles. Fasteners named Power Connection Adapter Currents of more than 400 A.. The pluggable, vibration and temperature-resistant long-term connections ensure mechanical tolerance compensation. Such a high-current contact is easy to maintain and install.

Content of the technical article

• Requirements for the high current contacts
  • Proven contact as a basis
• Pluggable, low-vibration, temperature-resistant long-term connectors
• Further high-current contacts in prospect
  
  

With the increasing Electrification of vehicles The demands on connecting and contacting elements are also increasing, especially in the drive train. The electrical components of the drive such as the electric motor, Battery storage and power Electronics brought together from different production lines from different manufacturers. This complicates simple system integration and assembly.

Green hydrogen on the advance in Germany

Requirements for the high current contacts

Often come Screw contacts as connection systems used, which are complex in terms of handling and connection security. The high-current contacts must be screwed while monitoring the speed and torque. And during operation, the connection must not loosen when exposed to temperature and vibration. Further requirements for the connection systems are a possible blind assembly, maintenance or repair.

Pluggable connecting elements provide a remedy here. They allow mechanical tolerance compensation, are insensitive to environmental influences and meet the functional requirements of a high-current connection.

Proven contact as a basis

Basis for the Power connection adapter form the tried and tested flat contacts and round contacts. For vehicle applications, for example, they are available as cable connectors that transmit currents of up to 250 A, suitable for the engine compartment. In addition to automotive use, Iwis smart connect has a multi-part contact system for connecting several battery cells developed for home and power storage.

"Based on the experience gained in developing THT and MCS contacts to readiness for series production, a funding project was started in cooperation with users, research institutes and manufacturers," says Holger Bodenstein, Head of Development at Iwis. “The aim was to meet the increased requirements from the Automotive industry, especially with regard to higher currents. "

Pluggable, low-vibration, temperature-resistant long-term connectors

The goal, 400 A and higher currents to transfer, Iwis with pluggable and yet low-vibration and temperature-resistant long-term Connectorsachieved in a wide variety of designs. The lamella contact for connecting two busbars was tested with 300 A and exposed to a standardized motor vehicle vibration load.

The developers proceed in a similar way to other contacts as with one two-part high-current contact for connecting a bolt to a circuit board. The base body is connected to the circuit board via ten standard press-fit zones.

The contact to the environment takes place via an inserted bolt with a diameter of 7 mm. The spring contact plate allows one Tolerance compensation of ± 0,45 mm in all directions parallel to the circuit board. With this contact, currents of 300 A can be transmitted continuously with a temperature increase of 40 K.

Further high-current contacts in prospect

“These contacts are representative of ours new product family the high current contacts. Further designs and variants have been developed and are available for initial customer applications, ”says Holger Bodenstein. "As the requirements continue to increase, we are planning to expand the portfolio to include contacts with a current carrying capacity of more than 800 amperes and direct high-current contact to the electronics in the drive train such as converters or power electronics."

Components for the hydrogen drive in the mass market

As part of the Iwis Group, Iwis smart connect in Rieden am Forggensee has focused on the electrical connection technology specialized for automotive and non-automotive applications. In addition to battery contacts for electric vehicles, the company develops smart connect products for sensor technology autonomous vehicles and Connectors for the Photovoltaics. The company is part of the Iwis Group based in Munich.