Automotive connectors are classified into high and low voltage types based on the voltage they operate under. Among them, the working voltages of low voltage connectors are mainly 12V, 24V, or 48V. The working voltage of high-voltage connectors can reach 60 to 800 volts, or even higher.

Automotive high and low voltage connectors are important components of the automotive electrical system. They undertake the key tasks of transmitting electrical signals and supplying power between different circuits. The main differences between high and low voltage connectors are reflected in the functions they undertake in vehicle electrical systems, working principles, structural designs, and applicable scenarios, etc. In this article, we will delve into the main differences between automotive high and low voltage connectors and provide a detailed analysis of them.

Functional differences

High-voltage connectors: High-voltage connectors are typically used to transmit high-voltage power sources, such as in ignition systems, fuel injection systems, etc. They need to have good insulation performance and high withstand voltage capacity to ensure the stable operation and safety of the circuit.

Low-voltage connectors: Low-voltage connectors are mainly used for transmitting low-voltage power supplies and signals, such as connections between lighting systems and control units. Compared with high-voltage connectors, low-voltage connectors may be more complex in structural design because they need to take into account more signal transmission and control functions.

Working principle

High-voltage connectors: High-voltage connectors typically employ special materials and structural designs to ensure that no breakdown or arc occurs under high voltages. They may adopt waterproof and dustproof designs to protect the circuit from interference from the external environment.

Low-voltage connectors: Low-voltage connectors are typically required to have good contact performance and reliability as they are often used to transmit complex signals and control circuits. In addition, for low-voltage connectors, the number of insertions and the impact of connection stability on system performance also need to be taken into account.

Structural design

High-voltage connectors: High-voltage connectors usually have a relatively simple structure, mainly considering insulation performance and withstand voltage capacity. It is generally composed of terminals, insulators, plastic shells, shielding rings, seals, covers, etc. Compared with low-voltage connectors, high-voltage connectors have added inner and outer shielding rings. After the high-voltage connector is assembled, the shielding ring will come into contact with the shielding layer on the connector housing. Eventually, the shielding layer of the high-voltage conductor will be grounded, thereby achieving 360° shielding protection for the high-voltage conductor.

Low-voltage connectors: The structural design of low-voltage connectors needs to take into account the stability and reliability of signal transmission. This type of connector usually has more contact points and conductive materials to ensure good connection performance even in complex working environments. The structural composition of a low-voltage connector is shown in the figure below. Generally, it consists of a pull rod, a sealing ring, a housing, a TPA, and other structures.

Differences in applicable scenarios

High-voltage connectors: High-voltage connectors are typically used in scenarios where high-voltage power supply needs to be transmitted, such as ignition systems, fuel injection systems, etc. They need to have a high withstand voltage capacity and insulation performance to ensure the safe operation of the circuit.

Low-voltage connectors: Low-voltage connectors are widely used in scenarios where low-voltage power supplies and signals are transmitted, such as connections between lighting systems and control units. Wire harness terminals usually have a rather complex structural design to meet the requirements of complex signal transmission and control.

The future development direction of low-voltage connectors is bound to be high-speed data transmission, lightweight, miniaturization and integration. However, with the increase in car functions and the widespread application of electronic control technology, there are more and more electrical components and wires. The number of circuits and electricity consumption in cars have significantly increased, and the wiring harnesses have become thicker and heavier. How can a large number of wiring harnesses be more effectively and reasonably arranged in the limited space of a car to enable the new energy wiring harnesses to play a greater role? This is a major problem that car manufacturers need to solve.

In terms of wire harness terminals: Throughout the entire development and even mass production process, suppliers are required to have the ability to respond quickly and handle engineering changes. However, with the rapid rise of the new energy vehicle market, some enterprises in the current low-voltage wire harness terminal market are unable to meet market demands due to their technological levels and delivery capabilities. Because automotive wiring harness terminals are no longer merely for connecting devices, but have become higher-level components that integrate devices and control systems.