ODU Automotive - Tolerance Compensation

Camarillo, CA,

Today’s growing EV market increases the need for more connector systems with tolerance compensation. Applications such as direct connection of inverter to motor, and battery installation/swapping requires not only a robust connector solution, but one with the flexibility to compensate for tolerances.

Advantages of using tolerance compensation include; more flexibility in the production process, easier assembly of components, as well as less wear on components.

Illustration #1: Shows a common application for connecting an electric vehicle motor to an inverter. The pins compensate tolerance up to +/-1mm allowing the designer to use a rigid bus bar, thus saving costs. The ODU Docking Mate® Type 2 shown explains how the system works.

https://www.odu-usa.com/fileadmin/redaktion/images/Techbit/ODU-Docking-Mate_detail.jpg

RELIABILITY - CONTACT RESISTANCE DURING MOVEMENT

Illustration #2: (below) Shows there is very little variation in contact resistance during mating providing a more reliable contact system.

https://www.odu-usa.com/fileadmin/redaktion/images/Techbit/reliability-chart2.jpg

This connector system can not only be used in motor to inverter applications, but can also be used wherever a connection with tolerance compensation is needed. Currents up to 600 amps can be achieved using 185 mm² busbar.

Another application benefiting from tolerance compensation in electric vehicles is battery installation and swapping. Many of today’s EV batteries are extremely heavy and require mechanical installation. Using a connector system that compensates for tolerances greatly reduces the risk of damaging components prolonging the life of the battery system.

The ODU Docking Mate® is the perfect solution to this problem. Shown in illustration #3 below, the ODU Docking Mate® is a robust connector system that allows for tolerance compensation up to +-5mm in any direction. Not only does it prevent damage during installation, it also allows the user to swap batteries in and out with ease. The attached video shows this system in action. This connector system is also IP6K9K sealed, and offers 360° shielding.

https://www.odu-usa.com/fileadmin/redaktion/images/Techbit/ODU-Docking-Mate2.jpg

For more information on either of these tolerance compensation connector solutions, please call us at (805) 484-0540 or email us sales@oduautomotive.com

 

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