E-mobility: latest connector system

In addition to the current carrying capacity, withstand voltage, shielding, contact resistance and class IP69 degree of protection, the document features further important safety specifications. These include touch protection when unmated, plug coding, reverse polarity protection and insulation. 

Environmental influences such as dirt, vibrations, extreme temperature peaks and impact loads, as well as the effects of oils and fuels, are increasing in commercial vehicles. These loads must be taken into account when developing connection technology. Stäubli says gone are the days when conventional electrical systems with 12 or up to 48 volts and a few amps of electricity were enough. Today, cables and connectors must handle several hundred volt loads, both DC and AC, and currents well over 300 amps.

The two-pole PerforMore connector’s angled version is based on LV 215 and gives vehicle developers a lot of freedom: Due to its compact design and high degree of tightness (protection class IP69), it can be used at various interfaces in the drive train such as batteries, inverters or high-voltage distribution units. The powerful 10mm contacts transmit high continuous currents with minimal power loss. High-quality 360° shielding guarantees sufficient damping even at high frequencies. The use of resistant MULTILAM contact elements ensures that the connectors are resistant to the demanding requirements of the electric drive train, such as vibrations and high operating temperatures. The two-step interlock release allows easy and quick installation and at the same time provides a safe and delayed disconnection process.

Stäubli developers have reduced the distance between pins to a level that they say is usually only possible for connectors with significantly lower current carrying capacity. As a result, PerforMore is smaller and easier to install. Despite its compact design and comfortable handling during the connection process, no compromises must be made on the power transmission. The integrated MULTILAM contact technology ensures highly efficient power transmission and a long lifespan — even under the most extreme conditions, such as in the use of utility vehicles. Therefore, the PerforMore system is suitable as a high-current connector for powerful electric cars e.g. sports cars or racers and larger commercial vehicles such as buses, trucks and specialty vehicles. The mechanical and colour coding is modular in design, and offers additional flexibility and safety when using multiple, otherwise identical plugs within a vehicle, since this prevents any risk of confusion.