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Definitions/Meaning
A HV connector is needed in the accumulator container to plug it and unplug it from the
charger or the vehicle. This connector must be able to withstand the maximum battery voltage and
the maximum current. Furthermore, the connector must also include an interlock (also known as
HVIL) to open the shutdown circuit when the connector is not connected.
other teams choice
Tecnun University of Navarra’s Formula Student choice
HVP800 connector from TE Connectivity This connector withstands 850 VDC
and 250A.
SRR
SRR
General Requirements
Every TS connector outside of a housing must include a interlock line connected to the shutdown circuit
All the intentional current paths must be made out of copper or aluminum (steel bolts cant be used as primary conductor)
All TS connection must not use compressible material such as plastic as fastener( zip ties)
TS connectors must be designed to be able to connect in one way (physically impossible to connect them backward or any other way than the designed configuration)
All electrical connection must be secured from unintentional loosening by the use of positive locking mechanisms
The following methods are accepted as positive locking mechanisms: (see T 10.2 in the rules for more information )
o Correctly installed safety wiring.
o Cotter pins.
o Nylon lock nuts for locations where no temperature rating above 80 °C is required.
o Prevailing torque lock nuts
o Locking plates.
o Tab washers.
Any locking mechanism based on pre-tensioning or an adhesive is not considered a positive locking mechanism.
2022:
In the 2022 vehicle we used the HVP800 2PHI connector from TE Connectivity.
This connector is rated for 850V and 250A, water resistance rating of IP67, include an HVIL and approved by the FSG.
One advantage of this choice is that it can be ordered in parts as free samples from TE.
A small disadvantage is that it has many parts that need to be bought separately.
If we wont get it for free the approximated price is 75$ for the whole assembly.
This connector is also used by the NAVARA university 2020's vehicle
PDR
PDR
Power Connector
The power connector is the connector that plug and unplug the vehicle side of the TS to the accumulator container, a second same connector connects the charger to the accumulator container.
This connector must fulfill the following requirements:
1. Be rated above the TS maximum voltage and current which (453Vdc , 200A).
2. Water resistance of at least IP67.
3. Approved for use by the FSG.
4. Include a HVIL interlock as part of the SDC (EV 4.5.1)
Industry / Other Teams:
Rosenberger HVR 200:
This connector is rated for 750V and 210A, water resistance rating of IP68, include an HVIL and approved by the FSG.
Rosenberger parts can be usually bought only by big companies but it is possible that we will get sponsorship form them, therefore this option is presented.
CDR
CDR
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