E-mobility: higher currents, higher power and compact design — PerforMore

The automotive industry's delivery specification LV 215 for high-voltage contacts sets the bar high for connector suppliers, with good reason

PerforMore – a key link for high power transfer (PresseBox) ( Allschwil, )
In addition to the current carrying capacity, withstand voltage, shielding, contact resistance and class IP69 degree of protection, it features further important safety specifications. These include touch protection when unmated, plug coding, reverse polarity protection and insulation. This document was the golden opportunity for the connector manufacturer Stäubli Electrical Connectors, with its many years of industry experience. The Swiss specialist’s response is the redesigned connector system PerforMore.

Environmental influences such as dirt, vibrations, extreme temperature peaks and impact loads, as well as the effects of oils and fuels, are increasing in commercial vehicles. These loads must be taken into account when developing connection technology. Gone are the days when conventional electrical systems with 12 or up to 48 volts and a few amps of electricity were enough. Today, cables and connectors must handle several hundred volt loads, both DC and AC, and currents well over 300 amps.

The two-pole PerforMore connector’s angled version is based on LV 215 and gives vehicle developers the greatest possible freedom: Due to its compact design and high degree of tightness (protection class IP69), the connector can be used at various interfaces in the drive train such as batteries, inverters or high-voltage distribution units. The powerful 10 mm contacts transmit high continuous currents with minimal power loss. High-quality 360° shielding guarantees sufficient damping even at high frequencies. The use of resistant MULTILAM contact elements ensures that the connectors are resistant to the demanding requirements of the electric drive train, such as vibrations and high operating temperatures. The two-step interlock release, , allows easy and quick installation and at the same time providing a safe and delayed disconnection process.

The Stäubli developers have succeeded in reducing the distance between the pins to a level that is usually only possible for connectors with significantly lower current carrying capacity. As a result, PerforMore is smaller and easier to install. Despite its compact design and comfortable handling during the connection process, no compromises must be made on the power transmission. On the contrary: The integrated MULTILAM contact technology ensures highly efficient power transmission and a long lifespan — even under the most extreme conditions, such as in the use of utility vehicles. Therefore, the PerforMore system is ideal as a high-current connector for powerful electric cars e.g. sports cars or racers and larger commercial vehicles such as buses, trucks and specialty vehicles. The mechanical and color coding is modular in design, and offers additional flexibility and greater safety when using multiple, otherwise identical plugs within a vehicle, since this prevents any risk of confusion.

Stäubli Electrical Connectors specializes in the development of customized contact solutions. Whether special geometric requirements, the need for higher performance values or innovative designs. This expertise offers significant added value for customers who cannot rely on standard market products due to special constraints or requirements. Thanks to many years of experience as a supplier of tailor-made products with extraordinary requirements, Stäubli Electrical Connectors also provides targeted support in putting process optimizations into practice, such as implementing easy-to-install systems and converting to components that have a positive impact on total cost of ownership in the long term. Thus, a specific solution adapted to individual requirements may be more cost-effective overall than a standard product.
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