Developed in close collaboration with some of the world's leading automotive manufacturers, the Power.S3 range guarantees safety, durability, reliability, lightness, and compactness—all essential criteria for EV and HV applications. The new FCI products also offer cost competitiveness that is paramount for low-emission or zero-emission vehicles. The Power.S3 range comprises 16/32 A charging sockets and 400/600 Volt high-voltage connectors for currents up to 230 Amps, specifically designed for the new generation of hybrid and electric vehicles powered by rechargeable batteries.
The Electric Vehicle/Hybrid Electric Vehicle Market Takes Shape.
With rising oil prices, environmental concerns, and a range of government regulations and incentives, the EV and HV market has continued to grow. Major automotive equipment manufacturers are already marketing low-emission models or plan to do so in the near future. Furthermore, several large companies will begin mass production of complete EVs within the next two years.
Although the push to develop low- or zero-emission vehicles is very important, it is still unclear exactly how quickly consumers will adopt this new technology. Forecasts estimate that these vehicles will represent between 1% and 10% of the global automotive market by 2015/20. However, even based on the lower end of this range, these vehicles represent a significant new market segment, with unique challenges and opportunities for everyone involved in their design and manufacture.
Despite the commitment of major equipment manufacturers to low- or zero-emission vehicles, debates continue regarding the specific technologies that EVs and HVs should adopt. Manufacturers worldwide are pursuing different development paths. Thus, in the next two to three years, consumers will have an even wider range of EV and HV variants available. These will include a broad spectrum of hybrids, including mild hybrids (in which the conventional engine automatically shuts off when the vehicle stops and restarts when it starts), low-emission hybrids (such as the Toyota Prius), full hybrids (in which both an electric motor and a conventional engine can power the vehicle), and plug-in hybrids (i.e., full hybrids in which the battery can also be recharged independently via a charging point). The soon-to-be-released Chevrolet Volt model offers a slightly different perspective, as it features a battery with a range of 65 km, complemented by a classic combustion engine with a longer range.
Plans for large-scale production of EVs (powered exclusively by a rechargeable battery) are also well advanced. Among the models slated for release is a new Renault/Nissan, expected in 2011, with a battery range of 160 km.
Beyond the performance of the cars themselves, the shape of the EV/HV market also depends on technological improvements to batteries in terms of weight, cost, and energy efficiency, as well as on the speed and development of battery charging infrastructure. Indeed, while EVs will likely be used as second cars for relatively short trips, range anxiety remains a limiting factor for EV models. This problem will only be fully resolved if, and when, consumers have easy access to fast-charging stations. Imagine the anxiety of a driver who only had 8 liters of fuel in a traditional car, which is the equivalent range of an EV…
Facing the challenge of new demands related to interconnection and charging points
One of the common factors in these different conceptions of EVs and HVs is the use of large lithium batteries, with operating voltages of 400 V to 600 V, twenty times higher than the standard 12/14 V lead-acid batteries in traditional cars. This increase has necessitated the development of a wide range of dedicated interconnection and charging point solutions.
These new interconnections and charging points must address a number of critical challenges. Safety is paramount, given the operating voltages of 400 V to 600 V and currents of 50 A to 300 A and above. Users will inevitably need to access the motor frequently to recharge or replace the battery, making robust safety measures essential to prevent electrocution. Such power levels also create a significant problem: electromagnetic interference, in addition to the risk of arcing during connector connection and disconnection. This can cause damage not only to users but also to the terminals, electrical devices, or any interconnection components.
The presence of a large lithium-ion battery increases the risk of fire, while weight and energy efficiency remain top priorities. Indeed, improving the range of an EV and its battery autonomy must be accompanied by a reduction in the weight of all components. The concern for cost savings is also essential, as the new generation of EVs is primarily aimed at the mass market. The battery alone can cost several thousand euros, increasing the pressure and incentive to reduce manufacturing costs in every other part of the vehicle.
Collaborative Approach to Interconnection and Charging Socket Development:
FCI is ideally positioned to create new interconnection and charging socket products for the EV and HV market. The company has extensive knowledge of interconnection technology and the specific requirements of the automotive market. Furthermore, FCI also has many years of experience in designing and manufacturing new solutions in collaboration with leading automotive equipment manufacturers. This is particularly significant for the EV/HV market, where relying on established rules is not feasible. Therefore, success is linked to a truly collaborative approach. After several years of working closely with major automakers, the company can now offer, in series production, a proven range of solutions called Power.S3, consisting of charging sockets and high-voltage connectors: high-performance terminals and innovative low-profile housings.
Power.S3 16/32 A Charging Sockets.
While micro and low-emission hybrid vehicles are already on the market, the next stage in the low- and zero-emission vehicle market is the launch of EVs and plug-in hybrids. To meet the need for new charging solutions for these vehicles, FCI has collaborated with REMA, a manufacturer specializing in sockets and plugs for electric-powered forklifts. The first product launched following this collaboration is a 16/32 A single-phase charging socket and plug, fully compliant with SAE J1772 and IEC62192-1, international standards for "slow-charging" EV/HV applications. These products will allow a vehicle's lithium-ion battery to be recharged in four to eight hours, either at a public charging station or at home.
Thanks to REMA's expertise in high-voltage battery charging and FCI's knowledge of the automotive interconnection market, the products benefit from several unique and innovative features. These products include, in particular, multi-beam female terminals equipped with a calibrated spring for more precise control of coupling and uncoupling forces, enabling thousands of coupling/uncoupling cycles. The designed products offer IP67 protection against dust and water ingress, meeting high safety and insulation requirements, as well as new frost protection and special channels for fluid and dust drainage. Special attention has been paid to ergonomics to ensure comfort and ease of use.
To gain consumer acceptance of full electric vehicles and plug-in hybrids, a "fast charging" capability will also be necessary, with a full battery charge in just a few minutes using specialized charging stations. FCI and REMA are currently finalizing the development of a 16/63 A fast charging socket. This socket has been designed in accordance with IEC 62196-2-2 (although it is still being finalized). Its single-, two-, or three-phase operating capability offers integrated protection, as well as identical cycle performance to the 16/32 A device.
Power.S3 – A complete range of terminals.
FCI's range of terminals reflects the wide range of applications specific to EV/HVE design. The Apex-280 has been custom-designed to meet the 35 A requirements of subsystems such as air conditioning, heating, and vehicle charging socket interconnection, while the RCS-800 handles high-current and high-voltage DC/DC connections for the battery, junction box, and inverter, for example. The Apex-950 is positioned between the two products mentioned above and offers a maximum permissible current of up to 150 A.
Apex-280: rectangular male plug 2.8 mm 35 A at 70ºC (4 mm² cable)
Apex-950: rectangular male plug 9.5 mm 150 A at 70ºC (35 mm² cable)
RCS-800: round male plug 8 mm 230 A at 70ºC (50 mm² cable)
This range features notable innovations, such as the RCS-800 terminals, which offer a new concept in 8 mm round male plugs that allows for more efficient use of space than the equivalent square terminal. These terminals also feature a large number of contact points and can operate at up to 230 A and more, depending on the customer's exact specifications. Special surface finishes protect the product from damage caused by electric arcs, while the plastic cap offers IP2-x protection, thus preventing the risk of electric shock.
Power.S3 – Innovative Enclosure Solutions
For the APEX-280 and RCS-800 interconnects, FCI has also developed innovative enclosure solutions. The most revolutionary aspects are a patented adjustment device, which cuts the power as soon as the connector is disconnected, and a unique 2-stage disconnection process that provides ample time for the adjustment device to activate. Therefore, disconnection cannot occur while power is on: the user must perform two independent movements and has a five-second window between cutting the power and removing the connector. These innovative safety devices complement many other features. The terminals are encased in a protective plastic grid that prevents physical contact, while FCI's ErgoMate axial coupling system allows for a lower-profile solution that significantly reduces mating forces. Once connected, a connector position safety device must be activated to ensure a fully secure connection. Furthermore, the shielding (80dB) and watertightness levels are high and are accompanied by a compact design with a remarkably low profile.
Customized development remains the norm.
The EV/HV market remains fluid and is evolving rapidly. All parties involved in the design and manufacture of these new vehicles are at a crucial juncture and still have much to learn about the behavior of their products in real-world situations. FCI continues to be actively involved in the development of new products. In addition to the fast-charging sockets mentioned above, new products include:
- a 2-way/90° connector. Given the thickness of the cables typically used in EVs/HVs, this type of connector is often preferable to bending the cables;
- a 2-way test plug with an integrated isolation switch that allows the charger to be manually disconnected from the battery for servicing, repairs, or emergencies.
With the launch of the Power.S3 range, FCI has positioned itself as a global leader, offering a comprehensive portfolio of production-ready and cost-effective solutions for the EV/HVE market. However, in the near future, the market will also be characterized by a need for customized development. Since each automaker has its own strategy, FCI's willingness to collaborate with customers to create commercially viable, tailor-made solutions is therefore another key competitive advantage in this rapidly emerging technology sector. In this field, the determining success factors are customer focus, program management capabilities, and, of course, technical expertise coupled with predictive design tools. These tools and this methodology enable FCI and its partners to design high-performance connectors and predict, during the design phase, the level of performance they will achieve. In these highly innovative technology domains, this performance prediction is of paramount importance to EV and HVE designers.
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FCI
