Product Description:

Overview:

Tit:

Plug-in connector

Taking BMW as an example, in terms of electrical connection technology, automation and non-human intervention are considered, so the battery connection in the module is laser welding, and the high-voltage wiring harness (provided by Kostal) between the modules is plug-in. Depending on the length, you can choose to use a flexible cord and a braided cord (a braided metal connection or a laminated soft copper bar) for connection.

In this variant design, instead of the Blade insert type, the following Ring connection method can also be used. Due to the length of this hard wire, it is more suitable to pull the end of the furthest module back to the BDU.

Nut connection

Due to the very early inertia of the HEV, for cost considerations, the connection between the modules is mostly based on the nut structure.

When the distance is longer, more hard copper bars are used for stamping and bending. Compared with the crimp terminal + hard wire, the cost has a greater advantage over a certain distance. As shown in the figure below, copper wires require very high process requirements when crimping, and holes can also form after a long time without compaction, resulting in an increase in contact resistance.

The use of hard copper bars brings some freedom in cost and routing. However, the entire structure is required, and under high vibration requirements, potential structural failure of the copper bar itself may occur; certain requirements are also put forward for the assembly process.

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