DC power connectors designed for EV applications

TME's product range has been extended to include PowerLok power connectors from Amphenol GEC. This is a new offering from a renowned supplier, primarily designed for manufacturers and electrical engineers specialising in the EV and hybrid automotive industries. Furthermore, the presented products are also suitable for renewable energy installations, particularly energy storage systems.

Although all introduced products belong to the same family, this offering should be divided into two groups: PowerLok G2 plugs and sockets and PowerLok 4.0 G2 connectors.

PowerLok G2
These products are high-performance electrical connectors constructed using aluminium alloy. They can conduct currents up to 300A at a nominal voltage of 1kV DC. They provide a wide range of configurations, including straight and angled versions. The assortment includes wire-mounted plugs (cross-sections up to 150mm2) and panel-mounted plugs. A single connector can have one, two, or three pins. At the same time, the body design provides complete insulation and shielding of contacts to protect operators and minimise interference.

The primary applications of these products are in power trains of hybrid and fully electrified vehicles, including passenger cars, trucks, and buses, as well as agricultural machinery and off-road vehicles. Given such demanding applications, the products are designed to a protection class of IP67, i.e., high water resistance and full dust tightness that can prevent the conductivity of connections from being impaired. Complete water resistance is accomplished when the connectors are mated.

PowerLok 4.0 G2
Unlike the connectors described above, the PowerLok 4.0 G2 sub-series is intended for powering accessories and components in vehicles (sensors, actuators, servomechanisms, etc.). Their electrical parameters are, therefore, slightly lower (currents 5…60A, wires up to 10mm2), but their bodies are also smaller in size. Here, too, the high protection class reaches IP69 after the connection is ensured. It is worth noting that all PowerLok connectors also provide wide thermal tolerance and can operate in temperatures ranging from -40C to 125C.