Driving the Future - Connector Systems for E-Mobility

 

The transition from combustion engines to electric vehicles is making road transportation more climate-friendly and sustainable.  This shift demands continuous innovations in connector technology. Electrical components must not only be robust, space-saving and lightweight as possible, but also capable of safe operation at high voltages and extreme currents.  Our  primary goal is to deliver the lowest possible contact resistances with optimized EMI performance characteristics while maintaining reliable quality standards. Our HV range includes highly compact connection solutions operating at up to 1000 V with continuous currents ranging up to 450 A.

Rosenberger works closely with automotive manufacturers, TIER1 suppliers, and harness makers to develop tailored or custom solutions and facilitate the integration of their products into various vehicle models. This collaboration helps in understanding the manufacturers' requirements and delivering solutions that meet those needs.

 

Standard Portfolio

Our extensive portfolio of high-voltage connectors has been developed especially for optimized power transmission in electric vehicles. For Rosenberger, the product development goal is clear: minimum contact resistance plus high power density coupled with excellent EMC performance properties. They meet customer requirements in terms of quality, reliability, performance and price.

The shielded HVR® product series includes extremely compact connection solutions up to 1000 V DC with continuous currents up to 450 A that can be operated over entire product lifetimes.

Additional Rosenberger develops and offers several unshielded HVUยฎ series, such as  HVUยฎ48, HVUยฎ50 and HVUยฎ400. These cost-effective connectors are tailored to the use case, focussing on transmitting power while maintaining high voltage safety. Current capacity ranges from 60 A, 87.5 A up to 340 A at a working voltage of 1000 V DC.

 

Features and Benefits

  • High current performance
  • Minimum installation space
  • Highest vibration classes
  • Best EMI performance
  • Qualified to national and international standards  (LV215, USCAR)
 

HV Applications

High voltage applications play a crucial role in the functioning and performance of electric vehicles (EVs). EVs rely on high-voltage systems to power various components, improve efficiency, and maximize driving range.

Key areas where high voltage is utilized in an electric vehicle include

  • Battery system
  • Electric motor
  • Power electronics
  • Charging infrastructure
  • Regenerative braking
  • Auxiliary systems
 

New Catalog E-Mobility

The current edition of the e-mobility catalog contains product series for high-voltage, low-voltage and LEV applications as well as HV components and extensive technical information such as contact systems and connection technologies. In the chapter โ€œComputational Engineeringโ€ you will find details to electromagnectic compatibility, simulation methods, contact physics and plating characterization lab.

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