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Connector solutions for EV and HEV applications

Connector solutions for EV and HEV applications

Product catalog summary

Overview
FCI, a global leader in connector manufacturing, addresses the challenges of the Electric Vehicle (EV) and Hybrid Electric Vehicle (HEV) markets, focusing on high operating voltages (400V to 800V) and currents (30A to 300A). Their solutions prioritize safety, cost-effectiveness, and efficiency.

Connector Solutions
FCI provides high power connectors and charge plug solutions optimized for sealing, shielding, durability, and ergonomics. Notable products include the RCS800 and RCS890 terminals, which offer high current capacity and space efficiency. These connectors feature a patented interlock device for safety and an ErgoMate® axial mating system for user convenience.

Product Features

RCS800 Terminals: Designed for high current (up to 230A) and high voltage applications, featuring an 8mm round pin design for efficient space use.
APEX Terminals: Provide high current carrying capacity with a compact design, suitable for various automotive applications.
EV-PLUG-16/32A: Compliant with international standards, designed for both slow and fast charging, with thermal circuit breakers for safety.

Technical Specifications
- Voltage: 400-750V
- Current Capacity: Up to 230A
- Sealing Protection: IP67 & IPx9K
- Temperature Range: -40°C to +125°C
- Shielding Performance: 60 dB at 100 MHz

Collaborative Development
FCI collaborates with OEMs and system suppliers to develop customized solutions, adapting to diverse standards and requirements across regions, including different shielding technologies and connector designs.

Charge Plug Devices

Type-1 Charge Plug Device: Designed for electric and plug-in hybrid vehicles, supporting single-phase or three-phase power supply with a maximum charge performance of 43.5 kW (63 A/three phase).
Type-2 Charge Plug Device: Similar to Type-1 but with enhanced current carrying capacity up to 70 A single phase and 63 A three phase, featuring IP67 sealing and a temperature range of -40°C to +85°C.

Features & Benefits
Both charge plug types adhere to IEC62196-2-2 standards and include integrated thermal circuit breakers for overheating protection. They offer environmental features like salt spray protection and efficient fluid and dust draining, along with mechanical features such as bearing holes for locking and detection, with terminals designed for high mating cycles exceeding 10,000 cycles.

High Power Terminals and Connectors

APEX-950: Offers very high current capability (125A at 70°C) with robust mechanical strength and a temperature range of -40°C to +150°C.
RCS-890: Provides high voltage capability (400V - 750V) with a unique integrated interlock and CPA devices for safe mating and un-mating.

Application Tooling
Various tools are available for terminal extraction, crimping, and SWS positioning, with specific part numbers provided for each tool.

Conclusion
FCI is committed to advancing low emission vehicles by offering innovative and cost-effective high power interconnect and charge plug devices, ensuring safety, reliability, and durability.

Catalog excerpts

Connector solutions for EV and HEV applications-1

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:10.00pt "Arial", sans-serif; } .font1 { font:15.00pt "Arial", sans-serif; } .font2 { font:29.00pt "Arial", sans-serif; } MOTORIZED VEHICLES DIVISION Connector solutions for EV* and HEV** applications Electric Vehicles * Hybrid Electric Vehicles

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Connector solutions for EV and HEV applications-2

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:5.00pt "Arial", sans-serif; } .font1 { font:8.00pt "Arial", sans-serif; } .font2 { font:9.00pt "Arial", sans-serif; } .font3 { font:11.00pt "Arial", sans-serif; } .font4 { font:12.00pt "Arial", sans-serif; } .font5 { font:13.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } .font7 { font:7.00pt "Arial Black", sans-serif; } About FCI ith 14,000 employes in 30 countries and sales of 1.28 billion euros in 2010, FCI is a global manufacturer of connectors for various...

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Connector solutions for EV and HEV applications-4

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:8.00pt "Arial", sans-serif; } .font1 { font:11.00pt "Arial", sans-serif; } .font2 { font:12.00pt "Arial", sans-serif; } .font3 { font:16.00pt "Arial", sans-serif; } The collaborative approach to interconnect and charge plug development FCI has a long-established track record of designing and manufacturing customized solutions in partnership with major OEMs and system suppliers. This is particularly significant for the EV/HEV market where the standards are still being established. For...

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Connector solutions for EV and HEV applications-5

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:8.00pt "Arial", sans-serif; } .font1 { font:13.00pt "Arial", sans-serif; } FCI PRODUCT OFFERING FOR HIGH END INTERCONNECTION AND HIGH POWER SOLUTIONS Lighting Passive Safety Restraints Convenience & Mutimedia Modules (doors, seats) High Power Interconnect Power RCS 800 terminals Signal terminal Systems Sensors, Injectors & actuators Active safety (ABS-ESP) * EV: Electric Vehicle ** PHEV: Plug-in Hybrid Electric Vehicle EV/HEV Body & Chssis Engine Cockpit 5

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Connector solutions for EV and HEV applications-6

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:4.00pt "Arial", sans-serif; } .font1 { font:6.00pt "Arial", sans-serif; } .font2 { font:8.00pt "Arial", sans-serif; } .font3 { font:9.00pt "Arial", sans-serif; } .font4 { font:11.00pt "Arial", sans-serif; } .font5 { font:13.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } .font7 { font:24.00pt "Arial", sans-serif; } .font8 { font:27.00pt "Arial", sans-serif; } .font9 { font:9.00pt "Franklin Gothic Medium", sans-serif; } .font10 { font:4.00pt "Tahoma", sans-serif;...

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Connector solutions for EV and HEV applications-7

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:6.00pt "Arial", sans-serif; } .font1 { font:8.00pt "Arial", sans-serif; } .font2 { font:9.00pt "Arial", sans-serif; } .font3 { font:10.00pt "Arial", sans-serif; } .font4 { font:11.00pt "Arial", sans-serif; } .font5 { font:13.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } .font7 { font:19.00pt "Arial", sans-serif; } .font8 { font:24.00pt "Arial", sans-serif; } .font9 { font:10.00pt "Microsoft Sans Serif", sans-serif; } HIGH POWER INTERCONNECT P°wer,S3APEX® 2.8mm...

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Connector solutions for EV and HEV applications-8

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:6.00pt "Arial", sans-serif; } .font1 { font:8.00pt "Arial", sans-serif; } .font2 { font:9.00pt "Arial", sans-serif; } .font3 { font:11.00pt "Arial", sans-serif; } .font4 { font:13.00pt "Arial", sans-serif; } .font5 { font:14.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } .font7 { font:7.00pt "Tahoma", sans-serif; } HIGH POWER INTERCONNECT pjjl O VVE R ■ 0° RCS800 HIGH VOLTAGE - 230 A 2 way Connectors Features & benefits Electrical features High voltage 400-750...

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Connector solutions for EV and HEV applications-9

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:5.00pt "Arial", sans-serif; } .font1 { font:6.00pt "Arial", sans-serif; } .font2 { font:8.00pt "Arial", sans-serif; } .font3 { font:9.00pt "Arial", sans-serif; } .font4 { font:11.00pt "Arial", sans-serif; } .font5 { font:13.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } HIGH POWER INTERCONNECT powER.RCS800 TERMINALS Round Connection System (RCS) - High current/high voltage (400/750 V) applications Features Female terminal 8 contact blades 2-piece female terminal...

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Connector solutions for EV and HEV applications-10

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:6.00pt "Arial", sans-serif; } .font1 { font:8.00pt "Arial", sans-serif; } .font2 { font:9.00pt "Arial", sans-serif; } .font3 { font:11.00pt "Arial", sans-serif; } .font4 { font:13.00pt "Arial", sans-serif; } .font5 { font:17.00pt "Arial", sans-serif; } .font6 { font:24.00pt "Arial", sans-serif; } .font7 { font:27.00pt "Arial", sans-serif; } .font8 { font:4.00pt "Tahoma", sans-serif; } HIGH POWER CHARGE PLUG DEVICE j-j o vve r| b° EV-PLUG-16/32A - Type-1 Charge plug device - Electric...

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Connector solutions for EV and HEV applications-11

Brochure Power S3 Sept 2011.indd table.main {} tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:5.00pt "Arial", sans-serif; } .font1 { font:6.00pt "Arial", sans-serif; } .font2 { font:7.00pt "Arial", sans-serif; } .font3 { font:8.00pt "Arial", sans-serif; } .font4 { font:11.00pt "Arial", sans-serif; } .font5 { font:13.00pt "Arial", sans-serif; } .font6 { font:17.00pt "Arial", sans-serif; } .font7 { font:21.00pt "Arial", sans-serif; } .font8 { font:10.00pt "Arial Black", sans-serif; } HIGH POWER CHARGE PLUG DEVICE P2f=S?.iS3 EV-PLUG-16/32A - Type-1 Charge plug device - Electric...

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Connector solutions for EV and HEV applications

Connector solutions for EV and HEV applications

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