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Battery charging connectors for fast charging applications

Battery charging connectors for fast charging applications

Fast Charging is rapidly becoming a mainstream charging technology due to cost savings, increased productivity, and safety. While Fast Charging of batteries is not a new technology (used in many handheld devices in the past), it really started to take off to reduce charging time of on-road electric vehicles.

Fast Chargers are different from conventional chargers in many ways. First off, the power rating can be 3-4 times the rating of a conventional charger often requiring the use of dual cables and connectors for charging rates in excess of 300A.  In addition, Fast chargers incorporate advance controls that maximize the battery’s’ acceptance of the charge while monitoring the battery temperature rise to avoid overheating.  In order to achieve this information transfer, you will need connectors that include auxiliary contacts.

The common two types of connectors used are the SBE® style and the Din 43589-1 style connectors. Both connector styles offer robust housings and contacts that will handle 5000 or more mating cycles. In addition, they offer four or more auxiliary contacts for applications such as battery monitoring. Both connector types are rated to EN1175:1998 and have attributes that make them the right choice depending on your application needs. Key attributes to consider when choosing one or the other are:

SBE® Connectors

  • Genderless one piece housings (80 amp, 160 amp, and 320 amp versions available) fully compliant with EN1175-1, UL and CSA
  • Color and mechanically keyed for 10 different voltages
  • One piece housings for simple assembly
  • Touch safe housings minimize potential contact with live circuits per IEC 60950 and IEC60529
  • Provides two flat wiping power contacts and up to eight auxiliary contacts (Pin and socket style)
  • The 1x4 auxiliary system uses contacts that will also reach 10,000 cycles and allows sequencing within the auxiliary contacts.
  • The eight position auxiliary system uses contacts that will achieve 5,000 cycles but do not allow sequencing.
  • All auxiliary contacts are mate last/break first in relationship to the power contacts.
  • Higher mating/unmating force than EBC that minimizes the need for secondary latches. However, a manual assist bracket may needed to reduce the force required to make the connection.
  • Air tube availability but replaces auxiliary contacts

EBC (Din 43589-1)

  • Distinct Male and Female housings – (80 amp, 160 amp, and 320 amp versions available). Fully compliant with DIN 43589-1, EN1175-1, UL/CSA
  • Removable voltage key with six voltage positions and color-coded for Dry Cell Battery (Green), Wet Cell Battery (Grey), and Universal (Yellow) applications
  • Pin and socket style contacts (Power and auxiliary) that provide a minimum of 5,000 mating cycles. Auxiliary contacts are Mate last/break first in relationship to the power contacts. Sequencing is not available.
  • Lower mating and un-mating forces that reduce effort to mate and unmate connectors. However, a secondary latch to ensure the connection may be required in high vibration applications
  • Up to four auxiliary contacts
  • Air tube availability and housing can use the upper auxiliary contacts

Both connector styles offer standard accessories such as cable clamps, handles, latches, and manual assist brackets to meet individual application needs.

The SBE®/EBC connectors are both ideal for rugged, high mating cycle applications and the markets served include Material Handling Equipment, Industrial Maintenance equipment, Electric utility vehicles, Electric Motorcycles/Scooters amongst many others. When assembled correctly using the proper tools both products will provide years of excellent performance.

This article is kindly sponsored by Anderson Power Products® 

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