Electric & hybrid vehicles 'face magnetic protection challenges'

Rand Wilburn, global marketing manager for automotive at Molex, said as electric and hybrid vehicles have different merits, they all face the same challenges when it comes to interconnections.
By 2018, as many as 6.5 million mild, full and plug-in hybrid vehicles could possibly be manufactured, Mr Wilburn said.
These include all-electric vehicles with petrol-driven generators, all electric plug-ins, petrol/diesel electric hybrids and conventional diesels with start-stop technology and regenerative braking.
However, Mr Wilburn said regardless of the type of electric or hybrid vehicle, they will all face similar future connector performance requirements.
"Already interconnect manufacturers are working closely with automotive OEMs to define the new requirements for connectors," he wrote.
Surge in amperage
According to Mr Wilburn, there is much dialogue in the automotive industry about how interconnect products for hybrid and electric vehicles will handle a current in-rush or spike.
In standard battery powertrains, interconnects have been used to accommodate amperage spikes for periods lasting milliseconds.
However, now manufacturers are looking for 200A products that may have to handle 250 to 300A spikes – but for minutes not milliseconds.
"From industry feedback, we estimate that the industry requirement will be for a minimum of 250A, though it is more likely going to be closer to a continuous rating of 300A," Mr Wilburn said.
"As the interconnect industry defines new test programs for these greater than 200A contact systems, it has to consider this new duty cycle."
Other challenges flagged up by Mr Wilburn include sealing and magnetic shielding properties.
Cars are hostile environments in terms of electromagnetic and radio frequency interference, making shielding from and to the rest of the electronics within the system critical.
"Consumers will persevere with their demand for greater fuel efficiency as the price of fuel continues to rise," Mr Wilburn summarised.
"The OEM (original equipment manufacturer) landscape for electric powertrains will also change as collaboration for developing batteries and recharge-related systems becomes more prevalent."