HYBRID AND
ELECTRIC VEHICLE
CONNECTION SYSTEM
SELECTOR GUIDE
A world of
transportation
Aptiv has been a trusted automotive supplier for decades, introducing practical
innovations in the areas of safety, efficiency, and connectivity. The transportation
market has been advancing in these same areas and Aptiv can offer product
solutions upgraded to its tougher operational and environmental requirements.
Did you
Know?
Hybrid and electric vehicles are creating a host of
challenges, including the demand for a new generation of
high performance, high power connectors and charging
solutions. Many additional power electronics devices
are added to the vehicle architecture including lithium-
ion (Li-ion) batteries, inverters and DC (Direct Current)
converters. Their impact on connector design results in
handling operation voltages that range from 400V up to
1000 V and carrying currents as high as 250A.
Commercial and recreation vehicles,
such as trucks, buses, construction,
agriculture equipment and
motorcycles, are often exposed to
higher levels of environmental forces,
including vibration, duct, water,
debris, and temperatures. To protect
the integrity of the electrical system,
high performance connection
systems are often required.
To deliver superior performance, a
number of complex factors in the
electrical system must be addressed
in the component design, including
sealing, locking features, and
materials.
Aptiv
is ready when and where you need us
About
Aptiv
Aptiv is a global technology
company that develops safer,
greener and more connected
solutions, which enable the
future of mobility. Headquartered
in Dublin, Aptiv has 147,000
employees and operates 14
technical centers, as well as
manufacturing sites and customer
support centers in 45 countries.
Image Source : PSA
Wuppertal, Germany
Tatabanya, Hungary
Épernon, France
Épernon, France
Saltillo, Mexico
Anting, China
Anting, China
Warren, USA
APTIV’S MAJOR HV
DESIGN CENTERS &
MANUFACTURING SITES
Design center
Manufacturing site
Visit
aptiv.com
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Why is
vehicle electrification
now a reality?
GOVERNMENT
REGULATIONS
AND INCENTIVES
RISING
FUEL
COSTS
Aptiv is currently driving the innovations required for future multi-voltage
architectures. Our research and development teams have leveraged the
lessons learned from the collaboration with OEM’s to focus on technological
excellence and to provide real-life electrification performance.
With a unique expertise in architecture optimization and systems
integration, the company has created one of the most comprehensive
portfolios of the high power connection systems.
ENVIRONMENTAL
CONCERNS
Superior
Sealing
Performances
All of our connection systems feature external IP67 sealing performance.
To ensure optimum sealing performance, our connectors are designed for
the harshest conditions due to a back sealing feature.
Driven by rising fuel costs, environmental concerns and a
combination of government regulations and incentives, the market
for EVs (Electric Vehicles) and HEVs (Hybrid Electric Vehicles) is
now becoming a reality. Vehicle specifications and infrastructure
deployment have reached a certain level of industrialization.
Standards have already been established for vehicle charging
interfaces used on plug-in HEVs and EVs.
There are three standards used throughout the world including SAE
J1772 in North America and Japan, IEC62196 Type II in Europe and
GB/T 20234 in China. In addition, SAE has established a common
footprint for DC (Direct Current) fast charging in North America and
Europe. Aptiv offers a complete line of all global charging standards.
Superior
Shielding
Performance
EV and HEV electrical and electronic systems generate unwanted
electromagnetic interference (EMI) which radiate from the interconnecting
cables. The connection systems are designed by minimizing the paths
along which these signals can escape. Our connectors and cabling
designs provide high levels of shielding effectiveness to ensure EMI free
performance of the complete system.
Superior
Safety
Performances
Our connectors provide finger-proof, touch safe and 2-step disconnection
technologies to guarantee optimum safety during all handling operations.
They continue to meet with changing requirement of the OEM’s in regard
to HVIL on a vehicle system and connection system level. Additionally, the
company’s ErgoMate™ axial mating system helps achieve a lower profile
solution while reducing mating forces. Once connected, a CPA (Connector
Position Assurance) device must be activated to ensure a 100% safe mating
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A
comprehensive
product portfolio
Product
Applications
High Voltage
Auxiliary
Modules
High Voltage connection systems designed specifically for the voltage
and current needs of auxiliary modules, such as A/C compressor,
heater, coolant control module, on board-board charger, DC
converter, and battery accessory output.
Page 9
E-Heater, DC Converter, Charger, Air
Conditioning, Coolant Heater Control
High Voltage
Power
Conversion
High Voltage connection systems designed specifically for the
voltage and current needs up to 250A. Power conversion modules
consist of inverters, drive motors/generators, and High Current/
High Voltage battery outputs.
Page 23
HV battery, E-motor, Inverter, junction box,
power electric box
High Power 12, 24,
48 Volt
Solutions
Growing requirements and a quickly increasing market for
48 Volt applications drive our technology for innovative solutions.
Two key characteristics define these solutions: High current
carrying capabilities and high sealing protection.
Page 35
48V Inverter, 48V Battery, Power Distribution
boxes, E-charger (e-booster), 12 V battery, DC/
DC converter, 12V Electrical Distribution Center
Charging
Solutions
Unique technologies to help facilitate a global charging
infrastructure, from Aptiv’s Portable Electric Vehicle Charger and
Charge Coupler pigtails for integration into Electric Vehicle Supply
Equipment (EVSE). With Aptiv products, hybrid and electric vehicles
can be powered safely and efficiently at home or away.
Page 43
On-vehicle charging inlets
Grid-to-vehicle charging
Charging infrastructure-to-vehicle
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Performance key &
Aptiv
design indicators key
Selector Guide
Application
Description
Page #
Image
Auxiliary Modules Solutions
Temperature
Vibration
Class
# Ways
orientation
Amperage
Sections
Shielding
Voltage
e
Voltage
Range
12V – 1000V
Amperage
Range
10A – 250A
10-13
On-board
charger
applications
(Level 1 and 2)
On-board
charger female
On-board
charger male
inline
On-board
charger header
Battery pack
(Aux)
DC/DC
converter
On-board
charger
PTC Electric
Heater
Electric air
conditioning
Electric power
Steering
AK class 1 3way
female (no HVIL)
AK class 1 2way
female (HVIL
pass-through)
AK class 1 2way
female
(HVIL shunt)
T3
V1
Not
shielded
32A
at
85°C
600V
2 to 4
power
lines /
180°
2 to
5 mm²
Temperature
Class
Ambient Temperature Range
-40˚C to +85˚C
-40˚C to +100˚C
-40˚C to +125˚C
Sealing
Class
S1
S2
Common Name
14-15
Performance
T1
T2
T3
T4
Unsealed
Sealed
Sealed
(w/high pressure spray)
16-17
Temperature:
Level 4/
Vibration
Shielded
Level 2
multicore
(LV 215)
cable
T4
V1
32A
at
85°C
1000V
2 to 3
power
lines /
180°
2.5 to
4 mm²
S3
-40˚C to +150˚C
APEX280
2way female
T3
V1
Electric air
conditioning
PTC Electric
Heater
Charger
APEX280
2way header
Vibration
Class
Common Name
Typical Application
Shielded
with
metal
braid
Inner connector
HV280 with
inner connector
header
HV280 female
Shielded
individual
cables
35A
at
70°C
1000V
2 power
2.5 to
lines /
5 mm²
180°
V1
V2
V3
V4
Chassis Profile
Engine Profile
Severe On-Engine
Extreme Vibration
Components on sprung portions
of vehicle not coupled to Engine
Components coupled to Engine
with severe vibration possible
Components subject to severe vibration
Used as needed to correlate to extreme
vibration areas
18-19
T3
V1
20-21
On-board
charger
APEX 950 On-
Board Charger
Connector
(HVIL shunt)
T3
V1
Not
shielded
125A
at
70°C
750V
4 power
10 to
lines /
16 mm²
180°
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