5 POWERTRAIN REVOLUTION
According to the provisions of the Economic Commission for Europe regulation "ECE R-100, Battery-Powered
Electric Vehicles," battery-powered vehicles must, in general, be equipped with protection devices such as
fuses, circuit breakers or main contactors in case the traction battery becomes overheated by overcurrent.
At the same time, the short circuit capability could be improved versus previous designs to a level of 6kA.
When currents of that magnitude pass a pair of closed switching contacts, the associated Lorentz force
generates a levitation force that tends to push the contacts open. This force increases with the square of
the current. At 1kA, the force reaches already about 1N. If the current is high enough, the contact spring
force is compensated and the contacts will separate, immediately forming a severe arc. As a consequence,
the contacts could either weld when reclosing, or the contactor could rupture due to the excess pressure
developing in the contact chamber. With the increased levitation limit of 6kA and the unsealed design of the
contact chamber, the risk for such failure modes is significantly reduced with the EVC 250 contactor.
New generation EVCs
With the EVC 250 high voltage contactor, TE launched a new generation of high voltage automotive
contactors that work without a sealed contact chamber and without pressurized inert gas. This not only
eliminates a complex and expensive manufacturing process, but also improves the functional reliability of
the device. A potential gas loss is not an issue anymore. In addition, it eliminates the need for any preventive
actions, such as a regular replacement of the contactor during vehicle maintenance. More recently, TE
launched the EVC 175 contactor which is the latest new product in the growing contactor portfolio.
The EVC 250-800 contactor provides a solution for hybrid and electric vehicles with higher system voltages
up to 900V. The latter is based on the well-known EVC 250 contactor, but features increased creepage and
clearance distances that fulfill the isolation requirements of IEC 60664 for up to 1,000VDC.
With this lineup of innovative high voltage contactors, TE provides advanced switching solutions to the
automotive industry, supporting and enabling a continued and successful growth in the market for electric
powertrains in passenger cars as well as commercial vehicles.
Improved charging technology critical to growth
of electric powertrains
Charger cable is one of the key components
supporting the e-mobility trend. It is seen as a major
element for the satisfaction of the end customer,
considering that the complete functionality of the
car is depending on it. TE delivers to several OEMs
both Mode 2 and Mode 3 charger cables according
to the IEC 62196 standards for different regions and
countries. TE connectors are designed to survive the
harshest environment such as being able to mate
more than 10,000 times. To support this robust
design, TE connectors are ultrasound welded
for excellent sealing performance as well as
breakage resistance.
