Before hybrid and electric vehicles can be successfully "sent" out onto the street, all interfaces in the engine compartment must function reliably and flawlessly. And so it also all depends on the connection system that is connected to the battery.
This system must be suitable for high voltage and high current, and it must be compact and yet affordable.

ODU Automotive, the connector specialist from Mühldorf, has been working closely with battery and automobile manufacturers for many years and has now added a standard HV series to its product portfolio.

The HV series' essential data at a glance:

• 2-contact position HV system in various designs:
  - Box header connector in 90° design
  - Box header connector in 180° design
  - Connector with 180° outgoing cable
• Box header and other connectors are plug compatible
• Power transmission up to 250 A (depending on cable cross-section
  and ambient temperature)
• Voltages up to 750 V
• Outstanding shielding properties > 60 dB
• Low, constant shield contact resistance (< 10 m()
• IP 6k9k protection
• IP2XB protection against accidental contact when not inserted
• Very compact, space-saving construction - width approx. 60 mm
• Rugged aluminum die-cast housing
• Cable cross-sections from 16 mm² to 35 mm²
• Vibration protection 
• Simple assembly
• Central screw locking (without tools)

A contact system that even compensates for assembly tolerance - would this take care of your problem? Then the company ODU Automotive GmbH from Mühldorf, Germany has just the right solution for you.
 

A primary feature of the new contact system is its flexibility. Tolerance compensation of
+/- 0.3 mm radially and +/- 0.6 mm axially is no problem for the new system. The system's special geometry even compensates for thermally-induced linear expansion, so that the contacting is ensured at all times by means of the tolerance compensation.

This small contact can furthermore transmit up to 20 A. This connection system's very compact design even allows it to be used under cramped conditions, such as in vehicle steering systems (connection between engine and control unit). And the connection system can stand up to ambient temperatures of up to 125° C (260° F).

Dwindling crude oil reserves and stricter exhaust standards call for alternative drive systems. Electric, hydrogen or hybrid drive - these are the topics on everyone's minds now.
All the well-known automobile manufacturers are looking into this subject, and they are not alone. Developers and manufacturers of connector solutions are also working on connection systems suitable for use in this automotive sector.

A real-life example:
Hybrid vehicles use combustion engines and electric motors running in parallel. ODU's customized connector acts as the interface between the battery and electronics in hybrid vehicles. It guarantees reliable transmission of the drive currents during acceleration (boosting) and when recovering the braking energy (recuperation).

The connector's special technical features

• Receptacle with pin contacts at the battery
• Connector piece with 8-mm socket contacts on 2 x 16 mm² line
• Continuous current 80 A at 85° C (185° F), short-time up to 224 A
• Voltage 150 V to 500 V
• Shielding > 60 dB
• Enclosure: IP 6k9k
• Central screw locking (without tool)
• Temperature -40° to + 120°C (-40 to + 248° F)
• Chemical resistance
• Protection against accidental contact IP2X when not inserted
  
  

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Fill it up for only 2 € - this is possible with the new E-MINI from BMW company. If the rechargeable battery is empty, the E-MINI can be charged at any houshold electrical outlet. A customized connector solution of the ODU Automotive Company is responsible for the charging.

The ODU connector is located on the cable side, as the connection to the rechargeable battery in the car. Charging takes approcimately 3 hours
(240V, 40A-Outlet). Fully charged, the new E-MINI can go 250 kilometers (150 miles) and has a top speed of 152 kph (95 mph).

Technical features of the connector:

• Cylindrical connector with tear-off function, 6 position customized contact insert
  2 power contacts: 60A nominal current, 240 V AC nominal voltage
  3 x signal contacts: max. 1 A nominal current, max. 42 V nominal voltage
  1 x protective conductor: 60 A short-circuit current
• Receptacle and connector piece are packaged by ODU
• Receptacle packaged to IP 68 terminal
• IP 66 when inserted
• Ambient temperature up to 80 °C (176° F)

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Dwindling raw oil reserves and stricter exhaust standards are creating a demand for alternative drive systems. The hydrogen drive is a new technology here that also provides special protection for the environment.

As a specialist in customized connector solutions, ODU Automotive GmbH has developed and built a 100% sealed connector solution for a hydrogen tank. This forms the connection between the support system capsule and the inner tank, and also transmits signals from the filling level meter to the display instruments.

The connector's special technical features:

• Very high chemical resistance and hydrogen compatibility
• 20 contact positions, soldered connection
• Packaged on stainless steel cable, phase shift 90° - 0.1°
• Stainless steel housing
• 100% leakproof because glass-sealed
• High compressive strength: up to 1,000 bar
• High thermal stability: up to 400° C (750° F)
• Usable in low-temperature range: to -250° C (-420° F)