New Requirements for New Energy Vehicle Connectors

• New Energy Vehicles: High Voltage Demands
  • New energy vehicle powertrains operate at voltages up to 800V, necessitating high-voltage wiring harness connectors. These connectors feature high voltage resistance and strong electromagnetic shielding.
• Intelligent Connectivity: Rapid Data Transmission
  • Advanced driver assistance systems require automotive connectors with stable signal transmission, high transmission speeds, and robust shielding performance.
• Lightweighting Requirements
  • For new energy vehicles, weight reduction is key to extending driving range. Wiring harness connectors must evolve toward lightweight designs while maintaining performance.

Custom Automotive Connectors: Technical Essentials

Connector performance hinges on design solutions, material selection, and manufacturing processes. When selecting manufacturers, customization capabilities are a critical consideration.

Design Elements of Custom Connectors

• Terminals: Transmit electrical signals.
• Housing: Protective layer for terminals.
• Sealing Ring: Enhances waterproof and dustproof performance.
• Latching Mechanism:
  • Primary Latch: Ensures connector engagement with audible confirmation.
  • Secondary Locking: Prevents terminals from detaching from the housing due to vibration or cable pulling.

• Misinsertion Prevention and Assist Structures:
  • Misinsertion Prevention: Asymmetric shapes ensure correct insertion.
  • Insertion/Extraction Assistance: Ensures smooth operation when connectors have numerous pins or high insertion/extraction forces.

Material Selection

Provides critical assurance for electrical connections during operation.

• Housing Material: Premium ABS plastic offering high-temperature resistance, corrosion resistance, and flame retardancy.
• Terminal Material: Copper alloy providing excellent conductivity and cost efficiency.
• Plating Material: Electroplated terminals deliver low resistance, oxidation resistance, and corrosion protection.

Testing Standards

Connectors undergo rigorous testing to meet global certification requirements.

• Electrical:
  • Contact Resistance: Evaluates terminal connection quality.
  • Insulation Resistance: Assesses insulation material performance.
  • Withstand Voltage: Measures the connector’s voltage-carrying capacity.
• Physical:
  • Insertion/Extraction Force: Ensures reliable connection.
  • Terminal Retention Force: Force required to pull out terminals, preventing pin disengagement.
  • Vibration Resistance: Maintains stable connection under automotive road vibrations.
  • Mating cycles: Maximum number of insertions/removals under operational conditions.
• Environmental:
  • Temperature cycling: Simulates temperature variations in operational environments.
  • Salt spray test: Evaluates corrosion resistance in humid, saline conditions.
  • Ingress protection rating: Verifies dust and water sealing performance.
  • Chemical resistance: Withstands chemical agent corrosion.

JinHai Professional Customization Process: From Design to Delivery

JinHai is a professional solutions provider with years of industry expertise, deeply understanding client needs in every project. JinHai maintains a closed-loop process from design to delivery, ensuring high-quality solutions for customers.

Step 1: In-depth Requirement Communication and Analysis

Our engineering team thoroughly discusses key factors including application scenarios, electrical loads, environmental constraints, driver cost targets, and project timelines.

Step 2: Solution Design and Component Selection

Design solutions based on requirements, including preliminary selection of connector types, terminal specifications, cable materials, and protection ratings.

Step 3: 3D Modeling and Simulation Validation

Utilize CAD/CAE software for 3D modeling and virtual assembly, performing simulation analysis on critical performance metrics to identify and resolve potential issues before prototyping.

Step 4: Prototype Fabrication and Testing

Rapidly produce functional prototypes and subject them to comprehensive electrical, mechanical, and environmental testing in our ISO/TS 16949-certified in-house laboratory to ensure 100% compliance with design specifications and industry standards.

Step 5: Automated Mass Production and Quality Control

Proceed to batch production upon prototype validation. We possess automated capabilities for wire cutting, terminal crimping, assembly, and 100% electrical continuity testing, supplemented by visual inspection systems and pull-out tests.

Step 6: Delivery and Full-Cycle Technical Support

We offer flexible global logistics solutions and commit to providing continuous technical support and rapid response services throughout the product’s entire lifecycle.

JinHai: Your Trusted Custom Wire Harness and Connector Manufacturer

An outstanding manufacturer should possess the following attributes:

• Industry Certification Standards: ISO 9001, UL, RoHS, and other certifications.
• R&D and Testing Capabilities: Independent design team, mold development expertise, and fully equipped in-house laboratory.
• Automation Level: Automated processes ensure consistent product quality and stability.
• Project Experience & Success Stories: Proven track record in cutting-edge fields like new energy and autonomous driving.
• Supply Chain & Rapid Response: Partners with stable raw material supply and swift customer response mechanisms.

Conclusion

JinHai is dedicated to being a trusted global manufacturer of customized wire harness solutions. We not only possess advanced manufacturing equipment and rigorous production/process workflows but also strictly adhere to IATF16949 and ISO9001 quality management systems.

Choose JinHai to accelerate your project’s success—JinHai grows alongside your projects!