Our company’s 500A and 1000A series connectors, with more than 20 years of experience, were applied to lithium titanate batteries and high-voltage PDU systems in this railway project.

Why Customer’s engineers fully approved our HV connectors? I think the below main factors give us the answers:

• Reliable and safty: More than 20+ Years of experiences in design, develop and manufacture for HV connection system.
• Fast feedback: Give a response within 24 hours, 48 hours give a professional suggestion. This is how we provides an extraordinary customer experience.
• Timely and sufficient supply capacity: We will supply sample test within 1-2 days and bulk orders lead time is 15-20 days. No MOQ limited.
• Widely current options: 5A-1000A rated current, it can satisfy with the rail system HV architecture.

Customers often face different issues in the field, which can strongly affect their execution planning. Thanks to more than 20 years of experience, We could solve a major problem with one of its highly engineered connectors. During the design phase of this battery system, our engineer gives a lot of advice and solutions to deal with the severe conditions of the rail system.

Our engineers are experts in designing and supplying products for harsh environment applications bringing more than just High voltage connectors. This experience reinforces the will to offer our customers worldwide an extraordinary customer experience.

Related Hv Connectors:

High Voltage Connectors for Railway system: Dual-source locomotive for Shanmei Coal最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

The test lamp inspection method is more suitable for inspecting the wire breakage fault. The use of temporary test lamp method should pay attention to the power of the test lamp is not too large, in the test of the electronic controller control output terminal whether there is output and whether there is enough output, especially careful to prevent the controller overload damage. It is best to test the lamp with a diode.

2. intuitive inspection method

When a part of the car electrical system failure, there will be smoke, spark, abnormal sound, smelly coke, high temperature and other abnormal phenomena. Through the human sensory organs of listening, touching, smelling, looking at the automobile wiring harness and electrical appliances for intuitive inspection, and then to judge the location of the fault, thus greatly improving the speed of maintenance. For example, when the car line failure, often appear smoke, spark, abnormal sound, smelly coke, high temperature and other abnormal phenomena. Through visual inspection, the fault location and fault nature can be quickly judged.

3. Conductor bonding inspection method

Crossing method that is to use a wire will be suspected to have a fault of the line short, observe the instrument pointer change or electrical equipment working conditions, thereby judging whether there is a circuit break or contact bad fault. Crossing refers to the operation of connecting two points of a circuit with a wire, and the potential difference between the two points of the crossover circuit is zero, not short circuit.

4. instrument inspection method

The method of using comprehensive fault diagnosis instrument, multimeter, non-wave device, current clamp and other instruments to diagnose automobile circuit faults. For vehicles with electronic control system, the comprehensive fault diagnosis instrument is generally used to find the fault code to confirm the fault range of vehicles. Then use a multimeter, current clamp or no wave device to check the voltage, resistance, current or waveform of the relevant circuit to diagnose the fault point of the wire harness conductor.

How to check car wiring harness?最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

The following is the wiring harness processing process need to understand some of the related wiring harness design accuracy and standard testing, so as to ensure the reliability of the quality of wiring harness products, so that the finished wiring harness zero defect so that customers can rest assured that the use of.

1, pressure contact should be firm, in the specified tension should not be damaged and off.

2. The surface insulation of the pressing joint should be good, and the conductor should not be broken.

3. The wiring harness wrapping material should be extended within 25mm from the end of the plastic case, except for a single wire.

4, voltage drop test requirements: terminal voltage drop detailed requirements refer to standard QC/T29106-1992.

5. The pressing of the connecting nail can use the U terminal pressing and ultrasonic fusion, etc., and the special machine shall be used for pressing.

6. Wear-resistant cloth tape should be used as a fixed wrapping outside the wiring harness connection point. In the area with waterproof requirements, the connecting nail should be protected by a heat-shrinkable tube jacket.

7. The label of the industrial wire harness should indicate the location of the connection and print it correctly and clearly. The label should be affixed at about 50mm from one end of the wire harness and stick firmly.

8. Minimum drawing force test requirements: the connection between the terminal and the wire should be firm, and the tension test should be carried out on the crimped wire harness at the rising speed of 200mm/min. The minimum drawing force should meet the requirements.

The designed wire harness products, but also through the proofing, test testing, technical feasibility of multiple aspects of research, can be mass production, so designed wire harness products to meet the needs of customers, but also in the production process can reduce the waste of raw materials, reduce production costs.

Techeng main products: power system current overload connectors, silicone wires, unmanned aerial vehicle/model battery wiring harness, auto emergency start power clamp, new energy vehicle wiring harness, electronic wiring harness, transfer and so on.

How was the wiring harness designed最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

Increasingly miniaturized electronic system design, power supply demand is growing, however, it brings to the design engineer huge challenges, which means that the wind power connector accommodate two conflicting necessary condition, also is on the increase of power supply design is more compact, we when choosing wind power connector, in the face of wide variety of goods, but also do not know how to start, Look at the selection of electrical connectors to check what factors?

First, look at the current rating. 

It is mother to terminal specific heat flow for 30 ℃, 20 ℃ or to correct use of the data, in addition to must understand its testing methods, also must pay attention to its test environment, for example: some simple test two phase without installed inside a shell of female terminal and needle, it is well known that the temperature factors affecting wind power connector, including contact resistance, power flow and the cooling channels.

Secondly, from the Angle of production, most of the traditional wind power connector lathe processing, based on the stamping technology is mature, thus derived a new electric connector stamping molding, by contrast, lathe machining process is relatively simple, grinding tool setting time is short, is a more flexible production technology, stamping forming process is more expensive, but in mass producing, Its cost and lathe processing, especially stamping molding technology allows local electroplating, lathe processing can not provide the option, from the quality point of view, in the long-term mass production of the situation, stamping molding to ensure its quality stability, which is lathe processing can not be compared.

From the assembly point of view to discuss, the circuit board assembly methods are crimping, table paste or welding; Methods have the screw connection cable assembly, welding, coiling, grinding and IDC (formerly prick link or insulation displacement), to choose the right wind power connector, should not only consider the price of the connector, the more important factor is the appropriate assembly technology, welding connector nature is much cheaper than table paste and pressure coupling, because do not need high temperature resistant plastic shell, There is no need to have a special crimping area on the pin.

The key design of wind power connector lies in the contact formed by the female terminal and the male needle. Poor design, manufacturing process, and unsuitable base materials and electroplating can lead to unsatisfactory contact or even unable to form contact.

How to choose the right wind power connector?最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

Structure and product classification of wind power connectors

The basic structure of wind power connector

(1) Contact parts. 

It is the core of the connector to complete electrical connection parts, generally composed of anode and cathode contact pieces of contact, through Yin and Yang contact is inserted and complete electrical connection, anode contact pieces for the rigid parts, its shape is cylindrical, square column or flat, anode contact is generally made from brass, phosphor bronze, cathode contact element is jack, it is the key contact for spare parts, Relying on the elastic structure is the elastic deformation of the needle inserted into the elastic force and the positive contact form close contact, complete the connection, there are many types of jack structure, cylinder type, tuning fork type, cantilever beam type, folding type, box shape and double-sided surface line spring jack.

② Insulation. 

Insulation is also often referred to as the base or installation plate, its role is to make the contact parts according to the required position and spacing, and ensure the insulation performance between the contact parts and the contact parts and the shell, good insulation resistance, voltage resistance performance and easy to work is the basic requirements of the choice of insulation materials processed into insulators.

(3) shell. 

The housing, also known as the housing, is the outer housing of the connector and provides mechanical protection for the built-in insulating mounting plate and pins. And provide the alignment of the plug and socket to secure the connector to the device.

(4) in the attachment. 

Accessories are divided into structural accessories and installation accessories, structural accessories such as collar, positioning key, positioning pin, guide pin, connection ring, cable clip, sealing ring and gasket, installation accessories such as screws, nuts, screws and spring coil, etc., most of the accessories are standard parts and common parts.

Introduction of wind power connector最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

1. Phosphor bronze: copper, copper, tin, Sn, phosphorus, phosphorus, iron, lead, lead, zinc, zinc and other components, the main component is copper;

2, brass: copper Cu, iron Fe, lead Pb, zinc Zn and other components, the main component is copper;

3, stainless steel: by iron Fe, chromium Cr, nickel Ni, carbon C, silicon Si, manganese Mn, phosphorus P, sulfur S, aluminum Al, cobalt Co, the main component is iron.

What are the performance of the contact parts of the battery power adapter?

1. Yield strength, also known as yield strength, is the critical stress value of data yield. The so-called yield means that after reaching a certain deformation stress, the metal begins to transition from the elastic state to the elasto-plastic state, which marks the beginning of macroscopic plastic deformation. The influence of yield strength on the connector: the higher the metal data of yield strength is selected, the greater the positive force of the terminal is;

2. Tensile strength. When the data yield to a certain level, due to the rearrangement of internal grains, its resistance to deformation can be improved again. At this time, the deformation is indeed rapid, but it can only progress with the progress of stress, until the maximum stress. After that, the ability of the data to resist deformation is significantly reduced, and a large plastic deformation occurs at the thinest place, where the section of the specimen decreases rapidly, showing necking phenomenon, until fracture and destruction. The maximum stress (corresponding to point B) of the data before tensile fracture is called the ultimate strength or tensile strength.

3. Elongation refers to the percentage of the elongation length and the original length when the metal material is broken under the action of external force (tension);

4. Hardness. The ability of the data section to resist pressing a hard object against its surface is called hardness. Solid part of the invasion of external objects to resist the ability, is compared with a variety of data soft and hard indicators. Because all the metal data of the adapter is very thin, it is measured by Vickers hardness (HV). Vickers Hardness (HV) The Vickers Hardness (HV) value is obtained by pressing the data surface with a diamond square cone presser with a load of less than 120kg and a top Angle of 136° into it. The surface product of the data indentation pits is divided by the load value. Hardness is an important parameter for the material selection of the adapter.

5. R/T ratio. R (radius) means the inside diameter of the bend and T (thickness) means the thickness of the material. If you want to shape out of the product diameter is smaller, it is necessary to choose the R/T ratio is smaller data. Theoretically speaking, if R/T ratio is equal to zero, that is, the bending performance of this data is excellent, even if the inner R=0 of the bending, there will be no crack, but the ordinary data material proof or property table show are 90 degree bending data, rarely show 180 degree bending data. Of course, we want the R/T ratio to be as small as possible, which is beneficial to the miniaturization of battery connectors.

Performance of battery power connector contacts最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

1. Mechanical Properties In terms of connection function, the insertion force is an important mechanical property.

Plugging force is divided into insertion force and pull out force (pull out force is also called separation force), the requirements of the two are different. Maximum insertion force and minimum separation force are specified in the relevant standards, which indicates that the insertion force should be small (hence the structure of low insertion force LIF and no insertion force ZIF) from an operational point of view, and that the separation force should be too small, which would affect the reliability of the contact.

Another important mechanical property is the mechanical life of the connector. Mechanical life is actually a durability indicator, referred to as mechanical operation in GB5095. It takes one insert and one pull out as a cycle, and the connector can normally complete its connection function (such as contact resistance value) as the judging basis after the specified insert and pull out cycle.

The insertion and extraction force and mechanical life of the connector are related to the structure of the contact parts (positive pressure), the coating quality of the contact parts (sliding friction coefficient) and the dimensional accuracy of the contact parts arrangement (alignment).

2. Electrical properties The main electrical properties of a connector include contact resistance, insulation resistance, and electrical strength.

High quality electrical connectors should have low and stable contact resistance. The contact resistance of the connector varies from a few milliohms to tens of milliohms.

(2) Insulation resistance is an indicator of insulation performance between electrical connector contacts and between contacts and housing. Its order of magnitude is from hundreds of megohm to thousands of megohm.

(3) Electrical strength or voltage resistance, medium voltage resistance, is a characterization of the connector between the contact parts or between the contact parts and the shell to withstand the rated test voltage.

④ Other electrical properties.

EMI leakage attenuation is to evaluate the electromagnetic interference shielding effect of the connector, which is generally tested within the frequency range of 100MHz~10GHz.

For RF coaxial connectors, there are characteristic impedance, insertion loss, reflection coefficient, voltage standing wave ratio (VSWR) and other electrical indicators. Due to the development of digital technology, in order to connect and transmit high-speed digital pulse signals, a new type of connector, namely high-speed signal connector, appears. Accordingly, in terms of electrical performance, in addition to characteristic impedance, there are also some new electrical indicators, such as crosstalk, transmission delay, skew, etc.

3. Environmental Performance Common environmental performance includes resistance to temperature, moisture, salt spray, vibration and impact, etc.

At present, the maximum working temperature of the connector is 200℃ (except for a few high temperature special connectors), and the minimum temperature is -65℃. As the connector works, the current produces heat at the contact point, resulting in temperature rise, so it is generally believed that the working temperature should be equal to the sum of the ambient temperature and the temperature rise of the contact point. In some specifications, the maximum allowable temperature rise of the connector at the rated operating current is specified.

The invasion of moisture resistance will affect the insulation performance of H connection, and rust metal parts. Constant humidity and heat test conditions are relative humidity 90%~95% (according to the product specifications, up to 98%), temperature +40±20℃, the test time according to the product regulations, at least 96 hours. Alternating humidity and heat tests are more severe.

(3) salt spray resistance connector in the environment containing moisture and salt work, the metal structure parts, contact parts surface treatment layer may produce electrochemical corrosion, affect the physical and electrical properties of the connector. In order to evaluate the ability of electrical connectors to withstand this environment, a salt spray test is prescribed. It is the connector is suspended in a temperature-controlled test chamber, with a specified concentration of sodium chloride solution with compressed air ejected, the formation of salt mist atmosphere, the exposure time by the product specification, at least 48 hours.

Vibration and impact resistance is an important performance of electrical connectors, especially important in special application environments such as aviation and aerospace, railway and road transportation, it is an important indicator to test the mechanical structure of electrical connectors and electrical contact reliability of the robustness. There are clear provisions in the relevant test methods. The peak acceleration, duration, impulse waveform and interruption time of electrical continuity shall be specified in the impact test.

Other environmental performance according to the use of requirements, other environmental performance of electrical connectors and sealing (air leakage, liquid pressure), liquid impregnation (resistance to specific liquid), low pressure and so on.

Three basic properties of connectors最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

The test lamp inspection method is more suitable for inspecting the wire breakage fault.The use of temporary test lamp method should pay attention to the power of the test lamp is not too large, in the test of the electronic controller control output terminal whether there is output and whether there is enough output, especially careful to prevent the controller overload damage.It is best to test the lamp with a diode.

Intuitive inspection method

When a part of the car electrical system failure, there will be smoke, spark, abnormal sound, smelly coke, high temperature and other abnormal phenomena.Through the human sensory organs of listening, touching, smelling, looking at the automobile wiring harness and electrical appliances for intuitive inspection, and then to judge the location of the fault, thus greatly improving the speed of maintenance.For example, when the car line failure, often appear smoke, spark, abnormal sound, smelly coke, high temperature and other abnormal phenomena.Through visual inspection, the fault location and fault nature can be quickly judged.

Conductor bonding inspection method

Crossing method that is to use a wire will be suspected to have a fault of the line short, observe the instrument pointer change or electrical equipment working conditions, thereby judging whether there is a circuit break or contact bad fault.Crossing refers to the operation of connecting two points of a circuit with a wire, and the potential difference between the two points of the crossover circuit is zero, not short circuit.

Instrument inspection method

The method of using comprehensive fault diagnosis instrument, multimeter, non-wave device, current clamp and other instruments to diagnose automobile circuit faults.For vehicles with electronic control system, the comprehensive fault diagnosis instrument is generally used to find the fault code to confirm the fault range of vehicles.Then use a multimeter, current clamp or no wave device to check the voltage, resistance, current or waveform of the relevant circuit to diagnose the fault point of the wire harness conductor.

How to check car wiring harness最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

Compared with the traditional high-voltage and high-current connectors, the working conditions of the new energy vehicle connectors are more complex and changeable, and the reliability requirements of the connectors are higher.

Compared with traditional low-voltage automotive connectors, the increased voltage level (the current mainstream system voltage is higher than 300V DC) increases the risk of electric shock injury to human body and puts forward higher requirements for safety.

The safety of new energy vehicle connectors; As a result, the insulation and protection requirements of the product are improved compared to traditional low-voltage plug-ins.

The role of the NEV connector is mainly to ensure the high voltage interconnect system of the car, that is, to build a bridge where the internal circuit is blocked or isolated to allow the current to flow.

The composition of the connector for new energy vehicles can usually be divided into three parts: the auxiliary structure, such as the shell and seal part, the insulation part and the conductive contact pair.

The function of connection and conduction can be realized through the coordination and mutual cooperation between the plug sleeve and the socket sleeve.

High-voltage connectors are mainly used in high-voltage and high-current circuits of new energy vehicles, and act at the same time as conductive cables.

It transmits the energy from the battery pack to various parts of the vehicle system through different circuits, such as the battery pack, the motor controller, and the DCDC body power unit (such as the converter and charger).

The use environment of new energy vehicle connectors

Because metal materials have better mechanical strength than plastic. Therefore, in some harsh environments, metal connectors are more suitable.

For example, special vehicles, muck trucks and electrical connections are not protected when laying out the entire vehicle.

At this point, metal connectors are slightly superior to plastic connectors in terms of environmental impact and mechanical strength.

New energy vehicle connector shielding method

With regard to shielded connectors, since the housing of metal connectors is used for shielding, it forms a carrier for shielding protection.

In general, metal connectors provide better shielding than plastic connectors and are more compact in appearance.

Application of new energy vehicle connector in automobile最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。

Because new energy vehicles are “green” cars, connectors also require green environmental protection.

In terms of safety, because the connectors of new energy vehicles can withstand up to 250A current and 600V voltage.

The need for a high standard of shock protection is obvious, and at such high power levels, electromagnetic interference is another important issue.

In addition, the operation of plug and unplug can also produce electric arc.

This can cause serious damage to electrical connections and electronic equipment, and may cause combustion in the vehicle, all of which require special connector design and development.

New energy vehicle connectors to meet its high performance requirements mainly rely on strict design specifications.

For example, in the case of exposure to prevent high pressure decomposition of air, this requires the preservation of a certain air gap.

In the case of high voltage and large current, the temperature rise cannot exceed the rated value.

In the selection of shell materials to consider weight, strength and whether easy to process, and at different temperatures.

How to keep the material properties of the lower joint terminal stable, how to ensure the necessary electrical conductivity and so on need to be considered.

In terms of connectivity, the ability to transmit high-speed data is becoming increasingly important as automotive entertainment systems continue to expand,

For example, a camera has been installed in some models’ rearview mirrors to give drivers a wider field of view,

This requires a connector to transmit more data, and sometimes a connector to transmit both GPS and broadcast signals

The connector also needs to be able to withstand high temperatures, because the car’s engine is usually located in the front of the car, and some of the heat gets passed on despite the firewall.

In addition, the “harsh” requirements for new energy vehicle connectors are also reflected in their lives,

Connectors generally have elastic elements that lose their effectiveness after a certain number of plugs.

Therefore, the service life is generally about 3-5 years, while a car can use 10-20 years.

Therefore, the life of the automobile connector must be equal to the life of the automobile, and the requirements for the connector are quite high.

There are two types of automotive connectors最先出现在Guizhou KeRuiXi Electronic Technology Co., Ltd.。