Study On The Design And Key Performance Of High Voltage And Heavy Current Connector Of Electric Vehicle

The development of new energy vehicles has been supported by countries around the world,especially electric vehicles that have become the focus of research and development,when the global energy and environmental system face great challenges.The power system of electric vehicles is usually designed with high voltage of more than 300 V and high current of more than 200 A.The high voltage and high current connector of 200 A,as the key component of high voltage electrical system,plays the role of connecting the energy source and power device of new energy vehicles.It is an important subject on how to reasonably design the contact pair of high voltage connector,i.e.,the core component,to ensure the key properties of the connector.Through the theoretical research on three key properties of high current contact pair,namely insertion force,contact resistance as well as temperature rise,the structure and characteristics of contact pair of high current connector for common electric vehicles were analyzed in this paper to study the improved version of L1 terminal based on the hyperbolic cage structure developed by a company.Meanwhile,the processing process of torsion reed of L1 terminal was also analyzed in order to obtain the shape of reed after a certain torsion angle through finite element simulation and obtain the inner diameter dimensions of the socket reed to determine the appropriate torsion angle via the simulation analysis of insertion force.Then the contact resistance of L1 terminal and the temperature rise of the connector were analyzed by finite element simulation.Finally,three key properties were relatively designed and tested,and the test results met the design standards which proved the rationality of the design.This paper provides certain theoretical guidance for the reliability design of high current connector by studying three key properties of connector,namely insertion force,contact resistance as well as temperature rise.During the design process of L1 terminal,the finite element simulation has changed the blind experience in the design of traditional high current connector,improved the design efficiency and reliability of high current connector greatly,and reduced the loss of numerous material and financial resources and time.