• The Transactions of The Korean Institute of Electrical Engineers
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• v.60 no.1
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• pp.131-137
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• 2011

This paper analyzes EM(Electromagnetic) characteristic in the high voltage connector for the hybrid electric vehicle. The connector bridges the electrical components and helps transferring electrical power and signal through it. The necessity of the high voltage and current connector development is emphasized because the hybrid electric vehicle recently uses the high voltage and current more than 500V and 80A. So far there has not been international EMC (Electromagnetic Compatibility) standards to limit the RE(Radiation Emission) from the connector for the hybrid electric vehicle. In this paper we analyzed EM characteristic of the 288V, 65A connector to check if the RE from the high voltage connector could be within the RE limit standard of vehicle. Three-dimensional modeling and simulation was conducted by using MWS(Microwave Studio) of the CST corporation, and the result was compared with the measured RE data, which showed good coincidence each other.

• The Transactions of the Korean Institute of Electrical Engineers P
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• v.58 no.4
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• pp.541-545
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• 2009

This study evaluated the contact resistance, insulation resistance, withstand voltage characteristics and insertion force, etc., of the wire connector used inside an integrated LITE WAY lighting fixture developed for efficient installation. Since the connector connecting the lighting fixture's internal wires is housed, it is easily connected and separated and has a structure enabling a close-fitting connection. The temperature and time applied to the high temperature characteristics test of the connector are $105^{\circ}C$ and 16 hours, respectively. The measured contact resistance of the high temperature tested connector was 3.258 mV/A, and its measured insulation resistance was greater than $10\;G{\Omega}$ All specimens demonstrated uniform insulation characteristics, which could be seen to be in good condition. From the withstand voltage test results found before and after performing the high temperature operation test on the connector for cable connection, it was confirmed that the withstand voltage characteristics between all terminals were good. The insertion force of the connector connecting the internal wiring averaged 9.67 kgf. It was observed that the insertion force between the plug housing and the female terminal, and that between the plug housing and the male terminal, were 0.680 kgf and 1.27 kgf on average, respectively.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.6
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• pp.716-723
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• 2011

The battery capacity of electric/hybrid vehicle is much larger than present automobile. For that reason, the connector of Green Car should be designed to transmit the high-electric voltage. In addition, the electromagnetic wave should be shielded to protect communication and signal circuits. In this study, shielding performance of the connector was analyzed through electromagnetic shield analysis, and a connector of Green Car was designed using thermoelectrical analysis, which is capable of transmitting the high-electric power. In the design of connector structure, the improved stability and workability was considered.

• The Transactions of the Korean Institute of Electrical Engineers P
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• v.59 no.4
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• pp.462-466
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• 2010

The purpose of this study is to evaluate the safety of a wire connector fabricated for the effective installation of a lighting fixture including its contact resistance, insulation resistance, withstanding voltage characteristics, etc., and to provide the basis for the analysis and judgment of PL(Product Liability) dispute by presenting a damage pattern due to a general flame and overcurrent. This study applied the Korean Standard (KS) for the incombustibility test of the connector using a general flame and performed an overcurrent characteristics test of the connector using PCITS (Primary Current Injection Test System). The contact resistance of the housing connector was measured using a high resistance meter and the insulation resistance was measured using a multimeter. In addition, a supply voltage of AC 1,500V for testing the withstanding voltage characteristics was applied to both ends of the connector. Measurement was performed on 5 specimens and the measured values were used as a basis for judgment. Since the connector is fabricated in the form of a housing, it can be connected and separated easily and has a structure that allows no foreign material to enter. In addition, since it has a structure that allows wires to be connected only when their polarity is identical, any misconnection that may occur during installation can be prevented. When the incombustibility test was performed by applying a general flame to the connector, it showed outstanding incombustibility characteristics and the blade and blade holder connected to the housing remained firmly secured even after the insulation sheath (PVC) was completely destroyed by fire. In addition, the mechanism of the damaged connecting wire showed a comparatively uniform carbonization pattern and it was found that some residual melted insulation material was attached to both ends. In the accelerated life test (ALT) to which approximately 500% of the rated current was applied, the connector damage proceeded in the order of white smoke generation, wire separation, spark occurrence and carbonization. That is, it could be seen that the connector damaged by overcurrent lost its own metallic color with traces of discoloration and carbonization. The contact resistance of the connector at a normal state was 2.164mV/A on average. The contact resistance measured after the high temperature test was 3.258mV/A. In addition, the insulation resistance after the temperature test was completed was greater than $10G\Omega$ and the withstanding voltage test result showed that no insulation breakdown occurred to all specimens showing stable withstanding voltage and insulation resistance characteristics.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1261-1262
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• 2010

• Proceedings of the KIEE Conference
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• 2007.07a
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• pp.1488-1489
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• 2007

This paper described the current rating methodology of high voltage connectors used for high efficient vehicles. Typically, temperature rise at rated current has been used to rate power contacts in automotive connector. However, for automotive applications, they are required to meet severe environmental conditions and high connector reliability. Therefore, it is very important to rate correctly an allowable current of automotive connector. We have measured the contact characteristics through current cycling at room temperature and at high temperature, as well as temperature rising and current carrying capacity by de-rating. From the above results, we have developed high reliable contacts with about 80 Amperes.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2010.06a
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• pp.112-112
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• 2010

The purpose of development is to localize a connector for connection of cable and GIS for underground transmission system. The cable connector for GIS provides electrical insulation of GIS housing part and makes connection of ultra high voltage electrical apparatus and power cable by controlling electrical stress between electrodes of power cable termination. Generally Korean switchgear makers are using a connector for GIS made by foreign companies. We manufactured sample by best structure design of great capacity conductor connecting part and then modified the design by analysis of shape and section. We completed the suitable sample for current cycling test condition of conductor connecting part sample and ensured surge characteristics of line by short-time current test.

• Proceedings of the KSR Conference
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• 2008.11b
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• pp.1279-1284
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• 2008

This paper presents the operating characteristic of high voltage impulse(HVI) track circuit owing to the ill-contact of impedance bond lead wire. The characteristic operations of the track include rail voltage and current. Measurements are carried out using oscilloscope with current probe and it analyzed the abnormal operation due to connector of protective wire. Finally, suitable track circuit is proposed for conventional line, and operating characteristic of HVI track circuit is affected by bypass circuit.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1263-1264
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• 2010

• Corrosion Science and Technology
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• v.18 no.4
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• pp.117-120
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• 2019

Considering the tendency of development of electrification vehicles, development and verification of new evaluation technology is needed because of new technology applications. Recently, as the battery package is set outdoors of an electric vehicle, such vehicles are exposed to corrosive environments. Among major components connected to the battery package, rust prevention of high-voltage cables and connectors is considered the most important issue. For example, if corrosion of high voltage cable connectors occurs, the corrosion durability assessment of using an electric vehicle will be different from general environmental corrosion phenomena. The purpose of this study is to investigate the corrosion mechanism of high voltage cable connectors of an electric vehicle under various driving environments (road surface vibration, corrosion environment, current conduction by stray current, etc.) and develop an optimal rust prevention solution. To improve our parts test method, we have proposed a realistic test method to reproduce actual electric vehicle corrosion issues based on the principle test.