Working principle of new energy vehicle connector

    The automotive industry is the largest market for connectors, accounting for 23.70% of the global connector industry. In terms of automobile, the largest plate of connector application, new energy vehicles are the biggest bright spot. Subject to the problems of technology, safety, standard certification and so on, the adaptive connectors of traditional vehicles have always been controlled by foreign high-end enterprises, and the barriers for Chinese connector enterprises to enter the field of traditional vehicles are high. With the rise of new energy vehicles, Chinese connector enterprises have successfully entered the new energy vehicle industry chain. Chinese brands of new energy vehicles occupy the main market in China. AVIC optoelectronics, a connector enterprise in China, has successfully supported Tesla, JAC, BYD and other new energy vehicles.

    There are nearly 100 kinds of electronic connectors required by traditional vehicles, and the connectors used by a single model reach about 600, which are mainly used in engine management system, safety system, entertainment system and so on. Compared with traditional fuel vehicles, the demand for connectors of new energy vehicles has increased significantly. The value of low-voltage connector used by traditional fuel vehicles is about 1000 yuan, while the material cost, shielding and flame retardant requirements of high-voltage connector are higher than those of traditional low-voltage connector, and the value of connector used by new energy vehicles is much higher than that of low-voltage connector. Among them, the value range of connectors for pure electric passenger vehicles is 3000-5000 yuan, and the value range of connectors for pure electric commercial vehicles is 8000-10000 yuan.

    There are many connection modes of new energy vehicle connectors, which can be basically divided into two types: connector (connected with cable) and connector (connected with printed circuit board). Crimping and pressing in are the most commonly used connection methods in the two types. This means that the word crimp can be used to express the two connection modes in Chinese. The definition of press in connector is to press the pin pin (also known as terminal) into a hole smaller than the thickness. Because with SMT (i.e. surface mounting technology is a connection technology), it has the advantages of low cost, high efficiency, simple operation, high reliability, communication and computer industries.

    Electroplating plug (terminal) and injection molding (rubber shell) have two connection modes: independent plug and combined plug. In the connection mode, the manufacturer usually requires to detect whether all plugs are missing and correctly positioned in the assembly stage. In addition, the assembly of connectors also challenges the test speed of the automatic test system as in the conventional test and stamping stage. Most assembly lines are photographed once or twice a second, but for each connector passing through the camera, the vision system usually needs to complete many different inspection items. Therefore, the detection speed has become an important performance index of the system.

    The actual position refers to the distance from the front end of each plug to the specified design reference line. The visual inspection process system must be the inspection of the correct position, which is another requirement of the connector assembly for the inspection system. Make this imaginary reference line in the detection image, measure the actual position of the front end of each plug, and judge whether it reaches the quality reference. The reference point for delimiting the reference line is often invisible in the actual connector, or appears on other planes and cannot be seen at the same time of the same lens. In some cases, the plastic of the connector box must be ground off to replace the position of the reference line.

    The lithium battery used by new energy vehicles has a large capacity and lasts for 400km under normal conditions. The power consumption of 100km is 14kwh. The calculated charged capacity is 56kwh and the weight reaches 350-400kg. The range of its working voltage rises sharply from 14V of traditional vehicles to 400kwh. Therefore, the connector of new energy vehicles provides high-voltage connector, which is the heaviest V connector of new energy vehicles and needs the corresponding high-voltage connector.

    With the continuous improvement of automotive intelligence, in addition to the original engine management system and other equipment that need connectors for data connection, the demand for connectors is becoming stronger and stronger for more and more advanced on-board entertainment systems and intelligent driving systems.

    The development of automobile connector industry is closely related to the maturity of automobile industry. Generally speaking, the automobile industry in developed countries and regions such as the United States, Europe and Japan started earlier and is in a competitive position with long-term technology and customer accumulation. With the increasing improvement of China's manufacturing level, the domestic automobile connector manufacturers' ability in mold development and product R & D and production is continuously enhanced, and the industry competitiveness is continuously improved. In the domestic automotive connector segment, the main enterprises are Lixun precision, AVIC optoelectronics, Derun electronics, Changying precision, Shenglan Co., Ltd., Hexing automotive electronics, Yonggui electric appliance, Laimu electric appliance, etc.