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Connector for New energy vehicles

Connector for New energy vehicles

Automobile connectors are specialised connectors that have complex use environments and high requirements on the product’s mechanical and electrical characteristics, as well as environmental resistance characteristics. Automotive connectors are basically customised products that are widely used in the power system, body system, information control system, safety system, and other vehicle equipment.

New energy vehicles have made significant progress in electric drive and electrical equipment, and their internal power current and information current are complex. In particular, the high current and high voltage electric drive system imposes higher requirements on the reliability, size and electrical performance of connectors, so the demand and quality requirements of connector products for new energy vehicles will be greatly improved.

With the rapid growth of new energy vehicle production and sales in the future, the new energy vehicle connector industry will continue to develop rapidly, and the industry market scale will exceed 10 billion yuan by 2024.

How to choose car connector?

Car connectors are an essential part of any car stereo system, allowing you to connect your phone or other music device to your car’s speakers. But with so many different types and brands of car connectors on the market, it can be tough to know which one is right for your car. You can start with the following factors

Electrical factors

Car connectors must be able to handle high currents, small currents, and signal levels. Additionally, the terminal type/contact segment size/plating (0.64mm to 8.0mm pin and pin) must be taken into account. Automotive connectors operate under three conditions: steady state, cyclic, and transient. Wire size/insulation must be able to withstand voltage drop and/or corrosion resistance. Lastly, the center distance of the connector must be determined.


Temperature: Engine compartment — Seal, ambient temperature & GT; 105oC, vibration, fluid compatibility; Passenger compartment — unsealed, ambient temperature & LT; 85oC, the main factor is size is more important

Sealing: potential high pressure spray/splash; Potential immersion; Humidity; Type of fluid; For device connectors, whether the device is sealed


Standard: Customer standard; Institutional standards; Domestic standards; The international standard Connector performance test requirements: included in system-level specifications; For GM, Ford, and Chrysler it is usually the USCAR specification » Engine related applications have relatively high vibration requirements; Other Oems generally have their own standards (similar to USCAR); Trend: DEVICE-SIDE VENDORS ARE RESPONSIBLE FOR THE PERFORMANCE OF THE CONNECTOR » DEVICES ACCOUNT FOR HALF OF THE CONNECTOR INTERFACE FITTED TO THE BOARD » DEVICE VENDORS ARE REQUIRED TO HAVE GOOD COMMUNICATION OF INFORMATION ABOUT THE CONNECTOR

Customer preference

Terminal type
Design features
Preferred product strategy: procurement led – need to reduce the cost of connector systems; Through design competition; Specific applications: Ford-door connector design competition; Ford: Preferred terminal design/supplier (focus on contact interface); General: preferred terminal design (focusing on connector holes); Chrysler: Preferred terminal/plastic supplier strategy

Regional preference

North America: USCAR drawing/Performance/Design standards »Tangless terminals, TPA’s, CPA regulations; In many cases, the wiring harness supplier has a significant influence

Europe: terminal contact design is very influential/developed with major Oems; Preference for two-piece terminals, even though cost pressures and North American transplant operations force Oems to consider North American technology; Accept Tangled terminals.” Cloning “is very common; Long term relationship between OEMS and suppliers

Asia: Traditionally influenced by Toyota. Has a long relationship with YAZAKI and SUMITOMO; The key is good character and trusted relationships; A strong focus on assembly capabilities that affect warranty (ergonomics); North America influences China to change the status quo. Low-cost solutions are the focus.

Physical factors

Size; Back to the way; The position of a match; Wiring harness docking or equipment connection; Main mechanical features: lever, bolt; Manual docking ability; Multi-type connectors for high input/output applications; The drawing requirements


Wiring harness: connector insertion force visible, audible, tactile operator feedback ergonomic high-speed manual operation quality and performance of the reliable guarantee; Implement online testing/after hours processes; TPA ‘s, CPA’ s; Maintainability; Reduce the number of pieces (phase preference).