Automotive connectors: Breaking Through the triple challenges of high voltage, intelligence, and cost Reduction

 

Amid the revolutionary wave of electrification and intelligence in the automotive industry, connectors, as the "neural network" of vehicles, are currently confronted with three core challenges: high-voltage carrying capacity, intelligent transmission, and cost control. How to break through the boundaries of technology? The industry has provided an innovative answer. Aichie Tech Electronics  Co., Ltd. is also constantly adapting to the new era and continuously updating its technologies in industries such as automotive connectors and automotive wiring harnesses.

 

 

 

I.High Voltage Challenge: Technological Breakthrough under the 800V Platform

As 800V high-voltage platforms become standard equipment for new energy vehicles, connectors need to deal with:

1.Current-carrying capacity and heat dissipation: AVIC Optoelectronics' "aluminum instead of copper" solution, through the innovation of aluminum-based contact parts, resolves the issue of electrochemical corrosion, achieving a 20% increase in current-carrying capacity and a 20% reduction in weight.

2.Insulation safety: The application of new materials such as high-density polyethylene has enabled the insulation withstand voltage level to exceed 3000V, reducing the arc risk by 90%.

3.Lightweight integration: The one-piece terminal design reduces parts by 30%, and the aluminum alloy housing is 40% lighter than traditional copper materials.

Typical case: The connector of a certain 800V fast charging model, through a three-dimensional heat dissipation structure design, keeps the temperature rise within 35K, which is 50% better than the industry standard.

 

II. Intelligent Upgrade: A Transmission Revolution in the Deluma of Data

Intelligent driving has led to an average annual growth rate of 300% in in-vehicle data transmission. The connector needs to achieve:

1.High speed and stability: TE Connectivity's 0.19mm composite cable reduces signal loss to 0.5dB/m through a multi-layer shielding structure, while reducing copper usage by 60%.

2.Anti-interference design: The combination scheme of metal braided shielding layer and magnetic filter reduces EMI interference by 70dB.

3.Multi-functional integration: The new generation of composite connectors CAN simultaneously transmit 48V power, 10Gbps Ethernet signals and CAN bus instructions, with port density increased by three times.

Technological breakthrough: The Rosenberg HFM® series connectors support 24Gbps data transmission, meeting the requirements of L4-level autonomous driving sensors.

 

III. Cost Reduction and Efficiency Enhancement: Innovative Paths under Cost Pressure

In response to the demand from automakers for an annual reduction of 8% to 12%, the industry has adopted:

1.Material substitution: The cost of conductive plastic terminals is 40% lower than that of copper products, and their performance meets the ISO 6722 standard.

2.Technological innovation: The fully automated production line has increased per capita output by 400% and reduced the defect rate to 50PPM.

3.Design optimization: The modular connector design reduces the number of SKUs by 60% and increases the inventory turnover rate by three times.

 

Effectiveness comparison: Through the integrated design of the connector system, a certain car manufacturer has shortened the total length of the wiring harness by 15 meters and reduced the cost per vehicle by 200 yuan. To assist the automotive industry in integrated design, Aichie also maintains close ties with major automakers, providing one-stop customized wiring harness solutions.

 

IV. The Way to Break the Deadlock: Three Major Directions of Collaborative Innovation

1.Vertical integration of the industrial chain: The joint research and development cycle of material suppliers, component factories and original equipment manufacturers is shortened by 30%

2.Digital twin applications: Simulation technology reduces development trial-and-error costs by 60%

3.Co-construction of the standard system: The China Automotive Connector Standards Committee has released 12 group standards

 

Future Prospects

The global automotive connector market size is expected to exceed 30 billion US dollars by 2025, among which:

1.The compound annual growth rate of high-voltage connectors is 28%

2.The penetration rate of high-speed connectors has reached 65%

3.The coverage rate of lightweight solutions exceeds 80%

 

The industry is building a new generation of technological moats through material revolutions (graphene conductors), structural innovations (liquid metal contacts), and process breakthroughs (3D printed terminals). This "big innovation" centered on "small components" will continue to drive the automotive industry towards in-depth development towards electrification and intelligence. It also provides a historical opportunity for technology catch-up players like Aichie to change lanes and overtake. By focusing on differentiated innovation in specific scenarios, Aichie is constantly updating and learning about technological innovations in high-voltage connectors to provide reliable connections for the industrial sector.

As the market explosiveness of new energy vehicles continues to increase, the market size of automotive connectors continues to expand. According to Bishop & Associates (a global connector market research organization), the global automotive connector market size will reach US$19.452 billion in 2025, of which China's automotive connector market will account for 23% of the total, with a size of approximately US$4.468 billion. China is the world's largest automobile producer and also a leading country in the research and development and output of new energy vehicles. In the next few years, the size of China's on-board connector market is expected to exceed the forecast of Bishop & Associates.

High-voltage connector technology: high standards

The so-called "high-voltage connector" is a connector that serves the high-voltage system in the car. Traditional fuel vehicles mainly rely on engines and fuel to meet the requirements of the car for mechanical kinetic energy, and do not have too many requirements for voltage; while electric vehicles use electricity as energy, and use power batteries, drive motors, and drive motor controllers to complete the kinetic energy supply of the car, which puts forward higher standards for the voltage and current carrying capacity of related components.

High-voltage connectors and electric vehicles are interdependent. In 2009, my country issued the "Automotive Industry Adjustment and Revitalization Plan" and launched the "Ten Cities, Thousand Vehicles" subsidy plan to promote new energy vehicles. Since then, my country's high-voltage connectors have continued to move forward with the pace of new energy vehicles, and have developed to the fourth generation by 2022.

 

 

Xu Ping'an, chief technology officer of Basba, told us that the newly added "secondary unlocking" function of the third-generation product can protect the core electrical parts of the product and ensure the safety of users; the fourth-generation product is smaller in size, has a higher current density, and a controllable temperature rise, providing better safety and reliability for high-power charging and discharging. Basba New Energy Technology Co., Ltd. is a company focusing on high-voltage connection system solutions for electric vehicles, with 12 years of experience in the research and development of vehicle-mounted connectors. High-voltage vehicle-mounted connectors are mainly used in lithium batteries, motors, electronic controls, DC/DC converters, OBCs, PDUs and other systems, and work together with high-voltage wiring harnesses to transfer battery kinetic energy to various components with the help of high-voltage and high-current lines. Different system components and differences in the cross-sectional area of ​​wires have different electrical performance requirements for vehicle-mounted connectors. Generally speaking, the rated voltage values ​​of high-voltage connectors range from 60v to 1500v, and the rated current values ​​range from 20A to 300A. In addition, vehicle-mounted connectors also have high requirements for the mechanical and environmental performance of products. High-quality high-voltage connector products must pass various mechanical performance tests, environmental tests, and electrical performance tests, such as terminal retention, connector plug-in and pull-out force, drop test, 960H neutral salt spray test, 1008H aging test under 125℃ environment, -40℃~125℃ hot and cold shock, etc. As electric vehicles continue to move towards fast charging and super charging, various new energy vehicle companies are constantly improving the vehicle voltage platform. 2022 will be the first year for the upgrade from 400v to 800v high-voltage platform. The new challenges brought to high-voltage connectors are still concentrated on the electrical level. Can the rated voltage and rated current be further improved? And how to deal with the high temperature hazards caused by high-power current? The fifth-generation high-voltage connector is very likely to combine with liquid cooling technology to meet electrical and temperature requirements.

 

Supply and demand side of high-voltage connectors: large market

New energy vehicles can be divided into two categories: new energy passenger vehicles and new energy commercial vehicles according to their use.

According to the data of China Automobile Association, from January to September this year, the cumulative sales of new energy passenger vehicles reached 4.363 million units, a year-on-year increase of 111.5%; the cumulative sales of new energy commercial vehicles reached 204,000 units, a year-on-year increase of 80.1%. New energy passenger vehicles and commercial vehicles are driving the continuous expansion of the market for high-voltage connectors. In the field of low-voltage connectors, due to the difference in the time of automobile manufacturing, the technical patents have long been in the hands of foreign car companies, and the gap between the domestic and foreign low-voltage connector markets is significant. If the short board of my country's on-board connectors is the low-voltage connector, then the long board is at the end of the high-voltage connector. This is due to the rapid development of my country's new energy vehicles. Domestic car companies are keeping pace with foreign car companies, and even beautifully surpassing and leading. In the field of new energy commercial vehicles, high-voltage connectors have achieved a localization rate of nearly 100%, and have also surpassed foreign countries in terms of technology. my country's high-voltage connectors used in new energy commercial vehicles use integrated panels and have developed for many generations, while similar foreign products still retain the traditional lock body structure. At the same time, my country's new energy passenger car high-voltage connectors are also constantly increasing the domestic penetration rate. At present, the major enterprises in my country that have deployed high-voltage connectors for passenger cars include Rekoda, AVIC Optronics, Basba, Yonggui Electric, and Sunco Intelligent. Basba revealed that the localization rate of high-voltage connectors for passenger cars has exceeded 60%. In addition to the localization rate, high-voltage connectors are also far more valuable than low-voltage connectors. Since the battery pack capacity of new energy commercial vehicles is several times that of passenger car battery packs, the value of commercial vehicle high-voltage connectors is higher than that of passenger car high-voltage connectors.

 

 

The future of high-voltage connectors: modularization

The technical orientation of supercharging and fast charging for new energy vehicles also affects the on-board connectors. As the battery capacity increases, the body becomes heavier and heavier, and the connectors and wiring harnesses are used more and more. Therefore, the modularization of components becomes more and more important.

The modularization of high-voltage connectors has many benefits. "Multifunctional integration and modularization can better meet the safety requirements of the whole vehicle. Lightweight, easy installation, lower cost, improved aesthetics, etc., these are the benefits of modularization and integration." Regarding the development trend of high-voltage connectors, Xu Ping'an, chief technology officer of Basba, also emphasized modularization and lightweight. In addition, the electromagnetic compatibility and volume current ratio capabilities of my country's high-voltage connectors and wiring harness assemblies also need to be continuously improved. The research and development certification of automotive-grade connectors is different from that of other types of connectors. For safety, reliability, and durability considerations, the total cycle of product self-certification plus customer certification is longer. High-voltage connectors and new energy vehicles are a "community of destiny". Riding the wind of new energy vehicles, the high-voltage connector market is soaring.