Electrical connectors are an important part of EV technology, serving as a critical link between various systems that allow for efficient power transfer and communication. EVs rely on complex electrical designs for electric motors, charging batteries and supporting onboard electronics, and reliable connectors ensure seamless system integration. Their role goes beyond performance. Connectors influence the vehicle's cost, safety, energy efficiency and overall performance. With the push for compact designs, fast charging and low costs, link solutions have become a key factor in overcoming challenges in modern EV development.
It has been charged recently spoke with Stäubli connector experts David Rababy and Michael Domzalski to learn more about cutting-edge connector technology.
For more than 130 years, Stäubli has been at the forefront of industrial solutions, covering fields as diverse as robotics, textiles, and connectors.
A standout innovation from Stäubli is the ZeroBolt solution. As the name suggests, it is designed to reduce the need for wired connections. This plug-in system is ideal for applications with limited design space, such as electric motors, batteries and inverters. By eliminating bolted joints, manufacturers can save time during assembly and improve maintenance efficiency, making disassembly much easier. The solution also improves durability by reducing the risks of loosening due to vibration, providing a robust alternative to high-performance designs.
Stäubli's modular connector CombiTac system empowers manufacturers with a choice of options. Whether electrical signals, pneumatics, or fiber optics, these connectors can be quickly configured using Stäubli's online programmer. Designed for high mating cycles and rigorous industrial use, these systems are ideal for both prototyping and mass production.
Stäubli is also a leader in high-power connectors, such as the Megawatt Charging System (MCS) that pushes the boundaries of EV charging technology, achieving faster, more efficient power transfer for truck, off-highway, and heavy-duty applications.
Additionally, Stäubli is exploring solutions to support the growing demand for lightweight and cost-effective construction materials, such as aluminum for buses, which can reduce weight and cost in electric vehicles. Another area of innovation focuses on integrated cooling systems for indoor applications, addressing challenges such as heat management and optimizing space.
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