Machined Components for Automotive Connectors: Meeting the Demands of Electric Cars

Published 17 May 2023
an electric car connected to the charging station in a car parking

The interest in electric vehicles has grown immensely in the past decade or so, as the transportation industry seeks to invent more sustainable and eco-friendly mobility solutions and decrease its dependence on fossil fuels. The pace of development and the success of these solutions depends on the availability of reliable and high-quality electric mobility systems components.

Electric vehicles use a range of connector types of different shapes and in different materials, depending on their primary application: battery, motor, charging, sensor, and other connector types. Through this connector network the energy which is born in the car battery is transmitted via battery connectors to the car’s electric motor, where it is converted into power, which is then transmitted further via motor connectors throughout the car’s electric system to wheels and other subsystems. Some common requirements for e-car connectors are that they can withstand high electricity voltage and exhibit outstanding wear resistance, to ensure safe and efficient car functioning.

At DJC, we specialize in manufacturing and supplying machined components for a variety of industries, including automotive OEMs and producers of automotive equipment. Our rich machine park comprising advanced CNC bar turning and milling lathes enables us to produce different components like pins, rings, housings and sockets for a variety of connector types used in electric mobility systems. We use only the highest quality materials which provide good conductivity along with outstanding wear resistance even in harsh environments.

Here we bring you a closer look at the different types of e-car connectors and the importance of using high-quality machined connectors in electric vehicle systems.

Battery Connectors

The battery is the heart of an electric car, storing electricity used to keep the car running. Battery connectors connect the battery cells together and the battery to the rest of the car’s electrical system. Common battery connector types with bar turned components include XT60 and XT90 connectors. It is essential that these connectors be machined from the highest quality materials with impeccable surface finishes, to ensure their reliability and durability.

XT90 connector type used in e-cars as battery connector

XT90 connector type

Motor Connectors

Electric cars rely on high-performance electric motors to power the vehicle. Motor connectors connect the motor to the car’s battery and the rest of the power electronics. To ensure safe and efficient operation of the car electric system, motor connectors must be capable of handling the high current and voltage required to start the engine and power the whole system. Common motor connector types, machined by bar turning, include bullet connectors and banana connectors (banana plugs and banana sockets).

Example of banana connector type, banana plug

Banana connector type – banana plug

Charging Connectors

For an electric car to be able to run for extended periods of time, its battery needs to be recharged. Charging connectors are used to connect the car to a charging station or a home charging unit. Charging connectors have a more complex build than other e-car connector types, with many bar-turned metal pins and sockets. The most common charging connector types used in e-cars are the Combined Charging System (CCS) connector, CHAdeMO connector, and Type 2 connector.

Electric car charging connector socket and charger

Electric car charging connector socket and charger

Sensor Connectors

To monitor various systems throughout the vehicle, electric cars rely on sensors such as temperature sensors, pressure sensors, motion and position sensors. With the development of advanced solutions incorporating IoT technologies, car sensors are becoming more and more elaborate and complex. Sensor connectors are used to connect the different sensors to the car’s computer system, which allows the vehicle to operate safely and efficiently. Common sensor connector types include M12 connectors, Deutsch connectors, and circular connectors.

Examples of M12 connector type

Examples of M12 connector type

As electric cars continue to grow in popularity, e-car manufacturers are working hard to design and produce ever more advanced and high-performing solutions to meet the rising demands of the consumer markets as well as the changing transportation industry regulations. Electric mobility systems are becoming more complex and require components of the highest quality of machining and surface treatments to ensure optimal performance.

At DJC, we understand the unique challenges and demands of the fast-developing automotive industry. With decades of experience and deep specialisation in manufacturing machined components for a range of industries, including electrical connectors, hydraulic and pneumatic connectors, and different automotive components, we are well equipped to supply e-car connectors of the highest-quality to electric vehicle manufacturers worldwide.

If you are an automotive parts producer in need of any type of e-car connectors, including battery connectors, motor connectors, charging connectors or sensor connectors, don’t hesitate to contact us to discuss the needs of your project.

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