E-mobility is set to change the way we travel and transport goods, offering a cleaner, more efficient alternative to traditional fossil fuel-powered systems. From electric vehicles (EVs) and eVTOL aircraft to industrial automation and outdoor power equipment, the rapid adoption of electrification presents new challenges for engineers and manufacturers. One critical but often overlooked component in this transition are the connector solutions, ensuring seamless power and data transfer in demanding environments. Here, we explore the key applications of e-mobility and how choosing the right connectors can enhance reliability, performance and safety.
Charging infrastructure
The rapid expansion of charging networks is fundamental to supporting the growing adoption of EVs. A well-designed charging network requires robust and efficient connectors to handle high power loads and endure frequent mating cycles all while withstanding exposure to harsh environmental conditions.
High-power connectors are key to ensuring safe and efficient energy transfer. Many EV connectors are designed to handle voltages up to 1,500 V and currents ranging from 70 A to 500 A, making them suitable for high-power applications. These connectors must feature advanced thermal management and low-contact resistance to minimise energy loss and prevent overheating during fast-charging cycles.
Another major consideration is ingress protection. Many EV connectors are designed with IP67 or even IP69K ratings, ensuring complete protection against dust, moisture and high-pressure water jets. This level of durability is essential for outdoor charging stations that must operate in diverse weather conditions. Additionally, electromagnetic interference (EMI) shielding ensures that charging systems remain stable and do not suffer from signal degradation.
The Amphenol SurLok Plus™ Compression Lugs are a prime example of high-power connectors for EVs, energy storage and industrial equipment. These connectors are designed for durability in harsh conditions, ensuring reliable operation used in more than just outdoor charging situations – more likely on the battery pack size.
EV charging connectors must be safe. The high currents and voltages involved create conditions where electrical arcing can occur, leading to contact damage or overheating. Advanced charging connectors incorporate safety mechanisms such as pilot signals that immediately cut off power in case of a fault, reducing the risk of overheating and improving overall reliability.
EV transportation
EVs like passenger cars, buses, trucks and industrial vehicles rely on high-performance connectors for efficient power transmission and system integration. As this sector grows, the demand for durable and efficient connectors becomes even more pressing.
EV connectors are subject to stringent electrical and mechanical requirements. They must handle high voltage and current levels while maintaining minimal power loss to optimize vehicle range. Power transmission efficiency is critical, as losses in connectors can impact battery performance and overall energy consumption. Many connectors use copper or silver alloys for high electrical conductivity and low resistance, helping to maintain efficiency and prevent excessive heat generation.
With vehicles being subjected to constant vibrations, shocks and, sometimes, extreme temperatures, EV connectors must have a high degree of structural integrity. Connectors must, therefore, feature durable housings made from high-quality plastics or metal alloys to resist mechanical stress and prevent corrosion. They must also comply with industry standards, ensuring they meet strict safety and environmental requirements.
Innovative connector designs are shaping the EV landscape. For example, Amphenol’s SurLok Plus series offers compact, high-voltage connectors specifically designed for EV battery packs. These connectors feature a unique integral latching system that ensures a secure mechanical and electrical connection while maintaining IP67-rated environmental protection. Furthermore, the inclusion of Amphenol’s patented RADSOK technology enables high current flow while minimizing insertion force and maintaining excellent conductivity.
eVTOL / aviation
Electric vertical take-off and landing (eVTOL) aircraft are transforming urban mobility, offering rapid, sustainable alternatives to traditional transport. These aircraft require lightweight, high-power connectors capable of handling extreme operational conditions while ensuring safety and efficiency.
One of the greatest challenges in eVTOL design is power transmission. These aircraft rely on high-voltage battery systems that require connectors capable of delivering high current loads while maintaining minimal power loss. Amphenol’s Raptor series connectors are specifically engineered for high-power aviation applications, featuring silver-plated copper contacts and advanced insulation geometry to prevent arcing and overheating.
Connector design must also consider environmental factors. eVTOL aircraft are subjected to extreme temperatures, humidity and EMI. Connectors must have robust sealing technologies, such as IP67 and IP68-rated enclosures and EMI shielding, to ensure uninterrupted performance. Like in other types of EV, connectors must be resistant to vibration and shock as rapid take-offs and landings exert immense mechanical stress on electrical systems.
Weight optimization is another key consideration. Unlike traditional aircraft that rely on liquid fuel, eVTOLs are heavily dependent on battery efficiency, meaning every component must be as lightweight as possible. High-strength aluminium and composite connectors reduce overall weight while maintaining structural integrity. Multi-functional connectors that consolidate power and signal paths into a single interface further enhance efficiency and reduce excess weight.
Regulatory compliance is essential for integrating eVTOLs into commercial airspace. Connectors must meet stringent aerospace standards, ensuring arc resistance, fire retardancy and fail-safe mechanisms to prevent electrical faults. Safety redundancy is also important as, if a failure occurs, critical flight systems must remain operational to ensure passenger safety.
Material handling
The material handling industry is increasingly adopting automation and robotics. The integration of automated systems and AI-driven logistics is improving efficiency in sorting, packaging and transporting goods in warehouses and distribution centres. Human-robot collaboration is enhancing productivity and workplace safety, while remote monitoring and control systems enable predictive maintenance and reduce downtime.
Connectors in material handling equipment must support high-speed data transmission and robust power delivery while withstanding industrial conditions. Ruggedised circular connectors, like those from SureSeal®, with hybrid power and signal capabilities ensure reliable communication between sensors, actuators and control systems, maintaining seamless operations. Additionally, modular and quick-connect solutions allow for efficient battery swaps and system upgrades, maximizing uptime in fast-paced industrial environments.
Process control
Process control systems play a key role in industrial automation by ensuring that manufacturing operations run smoothly and efficiently. The rise of Industry 4.0 has increased connectivity, allowing for real-time monitoring and control through IoT integration.
Advanced analytics, including AI-driven predictive maintenance, facilitate the anticipation of equipment failures and the optimization of process parameters, reducing operational downtime. Deploying edge computing brings data processing closer to the source, enabling faster decision-making in critical control applications.
Reliable connectors must facilitate high-speed data transfer and robust power connections while enduring industrial conditions. RF connectors enable seamless wireless communication within process control networks, while sensor connectors provide reliable interfaces for data acquisition devices. The use of modular, field-replaceable connector designs enhances system flexibility, allowing manufacturers to adapt quickly to changing requirements.
For these demanding environments, Sure-Seal® USB 2.0 Connectors provide IP67-rated protection while facilitating high-speed data transfer and robust power connections. Their modular, field-replaceable design enhances system flexibility, allowing manufacturers to adapt quickly to changing requirements.
Outdoor power equipment
The transition to electrified outdoor power equipment, such as electric lawnmowers, chainsaws, leaf blowers and golf carts, is driven by the need for quieter, emission-free, and low-maintenance alternatives to traditional petrol-powered tools. However, these devices must withstand harsh environments, including exposure to moisture, dirt, extreme temperatures and mechanical vibrations.
For these applications, the Anderson Power Products™ SBS®X-75A Series connectors are ideal. They operate at 600 V/140A, withstand extreme temperatures from -20°C to 105°C, and have an IP68 rating when mated, providing complete protection against dust, water and shock. Their robust construction ensures reliable operation in outdoor environments, making them suitable for garden tools, agricultural machinery and recreational vehicles.
As the world transitions to an electrified future, the role of high-quality, application-specific connectors cannot be overstated. Whether enabling ultra-fast EV charging, ensuring secure in-flight power delivery or supporting automated logistics, the right connector solution makes all the difference. By selecting robust, future-proof connectors, manufacturers can enhance reliability, reduce downtime and optimize efficiency across e-mobility applications.
For more information on how PEI-Genesis can support your e-mobility project, get in touch with our team today.
