The electrical systems of electric vehicles (EVs) are characterized by high voltages (typically exceeding 300V) and high currents (ranging from 100A to several hundred amperes), and they operate within complex environments:
Electrical Performance: Components such as battery packs and motor controllers require terminal contact resistance of less than 10 mΩ to minimize heat generation and energy loss; simultaneously, they must withstand instantaneous surge currents (which can exceed 500A during fast charging).
Environmental Adaptability: The vibrations experienced during vehicle operation (reaching accelerations of 50G), temperature fluctuations (-40°C to 125°C), and waterproofing requirements (IP67 rating) far exceed the standards typically found in general industrial settings.
Safety: High-voltage systems must prevent electrical arcing; terminals are required to possess flame-retardant properties (UL94 V-0 rating), and insulating materials must be resistant to electrochemical corrosion.
