CONTACT EXPERTISE FOR THE FUTURE OF MOBILITY

Transcription

1 CONTACT EXPERTISE FOR THE FUTURE OF MOBILITY Contact technologies and connectors from ODU.

2 THE FUTURE IS IN THE CONNECTION The emobility market is already a key market of the future with enormous development potential. This applies both to numerous applications and almost all industries. The contact technologies and transmission systems used are an important foundation for the successful implementation of sustainable emobility applications. As an established specialist in high-performing contact technology and connections in many industries, development work at ODU has been focusing on innovative approaches and optimizations in emobility for several years. This makes ODU a strong and experienced development partner for you including for application-specific and customized solutions in current and future emobility technology. All dimensions are in mm. Some figures are for illustrative purposes only. Subject to change without notice. Errors and omissions excepted. We reserve the right to change our products and their technical specifications at any time in the interest of technical improvement. This publication supersedes all prior publications. This publication is also available as a PDF file that can be downloaded from 2 3

3 CONTACT TECHNOLOGY DYNAMIC MARKETS REQUIRE FUTURE-ORIENTED CONTACTS HIGH NUMBER OF MATING CYCLES ODU contact systems provide for an extremely high number of mating cycles. They also offer long-term stable mechanical and electrical properties over the entire service life. More than 10,000 mating cycles for loading applications High reliability, e.g. with the ODU SPRINGTAC Today's emobility applications primarily demand the reliable and stable transmission of high currents, both for efficient charging technology and for the actual electric drive power. In this context, there is a demand for robust contacts and connectors that can withstand both harsh environmental conditions and heavy use. ODU already commands application-specific contact technology that is designed for the challenges of emobility. LOW MATING FORCES With very low mating forces, ODU contacts are designed for easy and smooth connection operations and a high degree of user-friendliness. A secure connection is guaranteed at all times. Quick and easy handling in all connection operations Safe contacting, even with mating at angles of up to 5 e.g. with the ODU TURNTAC HIGH CURRENT-CARRYING CAPACITY The special contact design, material selection and optimal termination technology play a crucial role in contact systems for efficient charging technology and connectors for high drive power. Reliable transmission quality Temperature resistance and long-lasting relaxation resistance, even at very high currents, e.g. with the ODU LAMTAC LOW CONTACT RESISTANCE To guarantee high transmission power and long-term stability, ODU contacts also offer low contact resistances. The application-specific, optimal contact design is identified by using targeted FEM simulation in the mechanical design. Ideal contact design for lasting high performance Reliable, proven termination technology for permanently secure connection HIGH WEAR RESISTANCE This is to ensure lasting maximum conductivity, including under heavy use and with high numbers of mating cycles. To achieve this, ODU implements precisely coordinated combinations of design, surface and base material. Special coating systems for high conductivity and wear resistance Targeted FEM simulation during the development stage for optimally coordinated mechanical and electrical contact properties 4 5

4 CONTACT TECHNOLOGY PROVEN ODU CONTACT TECHNOLOGY IN INNOVATIVE DESIGNS The mature contact technology, which is used in very diverse fields, offers a full range of modification and optimization options for emobility applications. As a result, the specially developed contact designs are already being used successfully in small-scale and large-scale production for high-quality, economical solutions. THE MARATHON RUNNER: Outstanding reliability, lifetime and durability with up to 1 million mating cycles Contact with springwire technology Very high contact security Low mating and demating forces Very high vibration resistance Low contact resistances High current-carrying capacity THE RUGGED ONE: Suitable even for harsh environments Turned, slotted sockets > 10,000 mating cycles Low and stable mating and demating force Contact diameter dimensions from 1.5 mm possible Mating at an angle of up to 5 possible ODU TURNTAC ODU SPRINGTAC Robust contact technology for efficient charging operations. This ODU TURNTAC design has been specially developed for charging technology. THE HIGH-PERFORMANCE CONTACT: Maximum current-carrying capability and temperature resistance Contact with lamella technology Current-carrying capacity of up to 2,400 amperes > 10,000 mating cycles Application temperature up to 180 C High vibration resistance Low contact resistances Automated lamella assembly High contact security ODU LAMTAC ODU STAMPTAC THE HIGH-VOLUME CONTACT: Economical contact system for automatic processing Stamped, rolled contact > 10,000 mating cycles Standard contact for use in (IEC standard) charging connectors Cost-efficient alternative for high volumes Sealing of the IP 67 protection class 3 mm and 6 mm stamped contact 6 7

5 PRODUCT SOLUTIONS HIGH PERFORMANCE NEEDS RELIABLE CONNECTIONS ODU offers high-performance, 2-pole high-voltage connector systems that meet all requirements for installation in vehicles. The ODU GEN2, as a compact power connector, guarantees the stable transfer of high currents and is designed as a simple assembly in standard processes. Housing 2-PIN HV CONNECTOR SYSTEM ODU GEN2 For durably high current-carrying capacity in a limited assembly space. Combined with the ODU LAMTAC high voltage contact, it is the perfect connector solution. Compact: Connector width < 60 mm Variable: 16/25/35 mm² cable cross-section possible Secondary locking Radial seal Contact spring (EMC) Interlock cable assembly Contact plate (EMC) Termination bolts Robust: Aluminum housing Reliable: Central screw-locking system Insulating body Sealing mat Trouble-free: Shielding attenuation > 60 db Tested: as per the requirements of LV215 Sealing: IP 6K9K sealing class Easy: Assembly using standard processes Controlled: with HV interlock Typical fields of application of the ODU GEN2 connector system are connections to high-voltage batteries and inverters. Pin contact Insulating sleeve 8 9

6 TECHNOLOGICAL EXPERTISE MULTIPHYSICS FEM SIMULATION MATING CYCLES TEST INNOVATION BEGINS WITH EXPERTISE Mature contact and connection technology that meets additional requirements and offers innovative solutions. This drives ODU development work forward and continuously opens new technical approaches for further development and optimization. The special expertise at ODU is based on over 70 years of experience and skills as well as on the latest technologies and procedures. To benefit from reliable forecasting models at the earliest possible time, ODU has opted for targeted FEM simulations to run alongside development. ALTERNATING THERMAL STRESS TEST Mating cycle tests are conducted over the entire service life under a variety of environmental conditions and demands for example mating at angles, heavy pollution and damp conditions. EMC ANALYSIS In this test, the test specimens are subjected to a variety of temperature cycles in the -40 C to +130 C range. Components are artificially aged by the thermal movements this causes. Representation of the electric field strength magnitude for testing the connector plug housing for EMC leakage or points of failure. In this case, the housing is ideally sealed. No radiation is escaping. STEAM JET TEST DERATING This IP X9K protection type testing makes special demands on the sealing system. An 80 bar high-pressure jet at a water temperature of 80 C acts on the test specimen from all three spatial axes at a distance of 100 mm to 150 mm. The measurement to determine the derating curve is performed in the laboratory. A derating curve describes the permissible current load of a contact system depending on the ambient temperature

7 ODU IN USE HIGH-TECH CONTACTS AND CONNECTIONS IN PRIVATE AND PUBLIC TRANSPORT The future is already on the road with special contact and connection technology from ODU. Including connections installed in vehicles and in special contacts for use in charging plugs. For high drive power and ultra-fast loading: ODU has the skill, manufacturing capabilities and special expertise for present and future emobility requirements. ENDURING HIGH PERFORMANCE Efficient loading and high drive power in electric buses, high performance connectors and contact systems that are optimally designed for high current transmission are essential. HIGH-QUALITY CHARGING TECHNOLOGY With high-quality ODU contact systems, which are available in different versions for the markets of Europe, China and the United States: extremely high mating cycles, outstanding robustness and easy handling

8 THE ODU GROUP INGENIOUS IDEAS PERFECT SOLUTIONS ODU S PRODUCT PORTFOLIO. Versatile connector solutions for transmission of power, signals, data, or media ODU never fails to offer the right interface when quality and absolute reliability are the top priorities. COMPACT MODULAR CONNECTOR SOLUTIONS PUSH-PULL CIRCULAR CONNECTORS ELECTRICAL CONTACTS HEAVY-DUTY & DOCKING AND ROBOTIC CONNECTOR SOLUTIONS APPLICATION AND CUSTOMER-SPECIFIC SOLUTIONS CABLE ASSEMBLY Application-specific hybrid interface For manual mating and automatic docking The highest packing density Flexible modular construction Multitude of data transmission modules Variety of locking options available For the transmission of signals, power, high current, high voltage, coax, high-speed data, fiber optics and other media such as air or fluid. Mating cycles scalable as required from 10,000 to over 100,000 (1 million) Circular connector series in robust metal or plastic housing Contacts for soldering, crimping and PCB termination Optional selectable Push-Pull locking ensuring a secure connection at all times as well as easy to release Break-Away function 2 up to 55 contacts IP 50 to IP 69 Autoclavable for medical applications Hybrid inserts for combined transmission Versatile connector technologies Outstanding reliability, lifetime and durability Up to 1 million mating cycles Current-carrying capacity of up to 2,400 amperes and more Rugged contact systems, suitable even for harsh environments Economical solutions for automatic processing Extremely durable even under extreme / harsh environments Interference-free and secure connection, even under vibration Up to 500 A (higher currents upon request) High contact security due to the springwire technology High pin density due to a minimum contact diameter Low contact resistance Contacts, connectors and assemblies for the highest technical requirements as well as special applications First-class implementation expertise High level of vertical manufacturing all competences and key technologies under one roof Expert advice based on mutual partnership Fast development and production Complete systems from a single source based on years of assembly expertise State-of-the-art production facilities with 100% end testing, high-voltage testing, component testing and pressure testing up to 100 bar Cleanroom production Hot-melt and high-pressure injection molding Customer-specific labeling Rapid prototyping of samples 14 15

9 ODU GROUP WORLDWIDE HEADQUARTERS ODU GmbH & Co. KG Pregelstraße 11, Mühldorf a. Inn, Germany Phone: , Fax: , SALES SUBSIDIARIES ODU Denmark ApS Phone: ODU Japan K.K. Phone: sales@odu.co.jp ODU-UK Ltd. Phone: sales@odu-uk.co.uk ODU France SARL Phone: odu@odu.fr ODU Scandinavia AB Phone: sales@odu.se ODU-USA, Inc. Phone: sales@odu-usa.com ODU Italia S.R.L. Phone: sales@odu-italia.it ODU (Shanghai) International Trading Co., Ltd. Phone: oduchina@odu.com.cn Further information and specialized representatives can be found at: PRODUCTION AND LOGISTICS SITES Germany China Mexico Romania USA Otto Dunkel GmbH ODU (Shanghai) Connectors Manufacturing Co. LTD ODU Mexico Manufacturing S.R.L. de C.V. ODU Romania Manufacturing S.R.L. ODU-USA, Inc. ODU North American Logistics Simply scan the QR code to download the entire brochure. EMOBILITY / B / 0218 / E > Stempelfeld nicht lackieren <