Issue link: https://te.mouser.com/i/1524930
HOW A BESPOKE RELAY SOLUTION IMPROVED RELIABILITY IN CUSTOMER'S EV CHARGING STATION TE CONNECTIVITY / CASE STUDY 2 In the fast-paced realm of electrical vehicle (EV) infrastructure, reliability and endurance are paramount. As the demand for electric vehicles continues to surge, design engineers face the daunting task of crafting charging systems that not only meet the rigorous demands of daily use but also withstand challenging environmental conditions. TE Connectivity (TE), a pioneer in connectivity and sensor solutions, stepped up to the challenge when a leading customer required a robust solution for their AC charger's main switch relays. CHALLENGE: RELIABILITY IN HIGH-STAKES ENVIRONMENTS The customer, a prominent player in the EV charging infrastructure sector, confronted a critical issue with their AC charger design. The main switch relays, pivotal components responsible for managing electrical flow within the charger, demanded a high degree of reliability. With a target of 35 A switching current and a staggering 50,000 cycles of endurance, the challenge was clear. Furthermore, space constraints within the charger necessitated components that not only performed reliably but also dissipated heat efficiently in high-temperature environments. DESIGN REQUIREMENTS: ENDURANCE AND EFFICIENCY The primary objective was clear: develop main switch relays that could reliably handle the demanding switching requirements while enduring elevated temperatures and maintaining performance. TE embraced these requirements as an opportunity to innovate and deliver a solution that exceeded expectations. A COLLABORATIVE APPROACH: ENGINEERING EXCELLENCE IN ACTION TE's response to the challenge was rooted in meticulous engineering and a deep understanding of electrical vehicle infrastructure dynamics. Leveraging a blend of metal and plastic materials, TE designed a relay specifically tailored to meet the rigorous demands of the EV charging environment. The relay's design prioritized endurance, enabling it to withstand up to 50,000 cycles of electrical switching while supporting currents of up to 40 A. In addition to durability, TE's relay was engineered with a keen focus on temperature management. Recognizing the significance of operating under high ambient temperatures, the relay's design incorporated measures to help minimize temperature rise and dissipate heat effectively. This provided for enhanced performance even in environments with ambient temperatures reaching up to 105 degrees Celsius. Furthermore, TE's advanced approach extended to coil heating reduction mechanisms. By fine-tuning the relay's design to allow for coil holding voltage reduction, TE maximized efficiency while mitigating potential overheating risks, thus enhancing the relay's overall reliability and longevity. RESULTS: EMPOWERING RELIABILITY IN EV CHARGING INFRASTRUCTURE The culmination of TE's efforts resulted in the creation of the TE's Potter & Brumfield T9S/V relay — a testament to engineering excellence in the realm of electrical vehicle infrastructure. The TE T9S/V relay seamlessly integrates into the customer's AC charger, offering outstanding reliability and performance in demanding environments. With the ability to switch up to 40 A and enduring up to 50,000 cycles of electrical switching, the TE T9S/V relay surpasses industry standards, providing design engineers with a reliable solution they can trust. Its robust construction and ability to operate under extreme temperatures supports uninterrupted operation, even in challenging conditions. In summary, TE's collaboration with the customer exemplifies a commitment to excellence and innovation in the field of electrical vehicle infrastructure. Through meticulous design and engineering prowess, TE has not only met but exceeded the customer's expectations, empowering the advancement of EV charging technology.