Electric vehicles demand reliable connectors
An
ODU product story
Edited by the Engineeringtalk editorial team
Jul 8, 2008
Connectors have to work in a typical automotive environment and resist vibration, corrosion, water ingress and extremes of temperature.
Modec Zero Emission Vehicles of Coventry is using ODU connectors in its new generation of electrically powered urban delivery vehicles, which are now becoming the choice of many major companies such as supermarkets and distributors.
ODU's relationship with Modec started when it was developing a zero emission electric delivery vehicle offering the concept of quick replacement of the traction batteries by the customer, a feature not offered elsewhere.
Modec and the electric drive train manufacturer Zytek began the search for a connector supplier to make the concept work.
A connector was needed to operate in an automotive environment handling a combination of high-power, high-voltage and LV signals all within a compact connector design that featured easy operation, blind mating, IP68 sealing, was capable of up to 5000 reliable mating cycles and was also foolproof.
The connectors have to work in a typical automotive environment and resist vibration, corrosion, water ingress and extremes of temperature from -20 to +40C.
As well as resisting harsh environments the connectors also handle very specific electrical duties.
These include inverter connection 186-340V DC, 200A continuous with peaks up to 500A for 30s, charger connection 186-340V DC and LV control, all within the same compact housing.
According to Colin Smith, Engineering Director for Modec, the development process went very well with ODU providing all the necessary technical backup, responding to radical design changes quickly, and issuing drawings and prototypes within the desired time frame.
He added that ODU brought a high level of technical expertise to bear on the project with high levels of service.
A significant feature of the Modec system is that it can store 3-5x more energy than a conventional electric vehicle and recapture, through regenerative braking, energy that would otherwise be lost.
This has enabled many of the limitations that have traditionally held back the performance of electric vehicles to be avoided.
The design is also future proofed, and can easily adapt to new technologies and power sources as they become available.
Modec vehicles have a range of 160km, a top speed of 80km/h and a 2t load capacity.
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