Bench Talk

Join journalist Tommy Cummings for a weekly look at all things interesting, new, and noteworthy for design engineers.

Design engineers are well aware of the rapid advancements in connector and component designs. To simply connect electrical conductors and create an electrical circuit, developers must continually deal with thousands of configurations with different power-handling capabilities.

All the while, developers are creating more challenging form-and-fit parameters while providing as much or increasing functionality as older connectors.

To pile on even more, you've got an accelerated electric vehicle and plug-in hybrid industry and its power infrastructure added to the mix.

This is why designers of connectors rarely leave the workbench—lots to design.

To address the simple diversity of connectors, this week's New Tech Tuesdays examines three different types of connectors and what project developers can optimize them for connection solutions.

Phoenix Contact E-Mobility CHARX Charge Inlets are ideal for EV battery charging and plug-in hybrid vehicle charging design. These connectors allow high-power charging up to 250A continuous and up to 500A on a temporary basis. CHARX inlets are versatile. They can be developed for charging standards in different regions and for Type 1 and Type 2 variants. The inlets' dimensions and mounting features are identical, giving designers the same assembly space in the vehicle.  

HARTING Han^® S Modular Battery Storage Connectors provide secure connection technology for modular battery storage systems. The sustainable use of renewable energies, such as wind or solar, can be achieved through energy storage modules because they enable time-delayed, needs-based use. HARTING connectors can accelerate the buildup of energy storage modules using lithium-ion cells. The connectors have compact and flexible lockable hoods and housings that provide space for connections with a capacity of up to 200A and 1,500V. The connectors use a red variant for the positive terminal and a black variant for the negative, similar to a car battery.

TE Connectivity's DYNAMIC D8000 Pluggable Connectors feature an audible locking system and crimping contact design. The lock design ensures safe locking while the crimping contacts save assembly time. The connectors can carry currents as high as 100A per pin for wire-to-wire (WTW) and 90A for wire-to-board (WTB). These connectors are ideal for battery test equipment, battery management systems, factory automation, and robotics.

Connectors come in all shapes and sizes and are designed for diverse uses. The traditional uses are expanding, but EV and plug-in hybrid industries are creating a new wave of connections that are changing the market. Design engineers must be aware of the connectors and contacts to keep the power flowing safely and efficiently in their projects.