Many analysts are now recalibrating projections for near term sales growth of full battery electric vehicles (BEVs) and a resurging demand for Plug-in Hybrid Electric Vehicles (PHEVs). To take advantage of this shift, automakers are looking for improved agility to fill the PHEV demand. At the same time, they need to keep a strategic eye on long-term larger market opportunities as BEV range and price reductions reignite that market segment.
To succeed in this dynamically shifting environment, automotive manufacturers need vendor partnerships that can span the full range of powertrain electrification solutions for PHEVs, while also supporting the eventual shift back toward BEVs.
Building on over 60 years of serving the automotive industry, ENNOVI is designing and delivering end-to-end solutions for PHEVs alongside our sustained commitment to supporting the ongoing evolution of BEVs and the EV market in general.
As shown below, the various applications span two major areas:
- Power Electronics – including inverters/converters and controllers
- Powertrain – including battery interfaces, charging systems and electric motors
The following sections provide a deeper look at these key areas and the ENNOVI solutions that apply to each one.
Power Electronics
Systems such as inverters, DC/DC converters, on-board chargers, and controller modules are all becoming more complex and at the same time need to be smaller and more compact.
ENNOVI’s extensive range of busbar technologies are important for optimizing robust power interfaces that are customizable, compact, and cost-effective. These technologies include:
- Rigid non-insulated busbars
- Molded busbars
- Pluggable, small-footprint Power Busbar PCB Connector: ENNOVI-BusMate
Electrical Motors
Compact electrical motors in PHEVs require highly efficient, cost-effective alternatives that are optimized for current flow, form factors, thermal performance, faster assembly, and overall lower cost of deployment.
ENNOVI’s custom motor stator busbars are designed to accommodate hairpin windings and to provide a range of flexible multi-phase connections. They can handle a full range of high-voltage current requirements and use high-performance copper integrated with specially selected polymer materials for optimal dielectric isolation and improved thermal characteristics.
Low-Voltage Connectors for the Powertrain
As the global leader in Press-Fit solutions for the automotive industry, ENNOVI has also pioneered using this solderless technology across a wide range of applications. Key among these are fully integrated, custom configurable low voltage connectors. Not only is solderfree, Press-Fit technology more efficient and reliable than soldering; it is also more environmentally friendly due to elimination of solder paste and flux.
For automotive manufacturers and Tier 1 partners, this one-stop, complete solution reduces overall manufacturing costs for a variety of PHEV power electronics and powertrain applications. Options include IndiCoat™ plating for whisker mitigation and integrated sealing rings for waterproofing, along with a wide range of custom pin lengths, densities, and spacing configurations.
Battery Pack Junction Boxes
An PHEV’s high-voltage junction box (BJB) is responsible for managing high-voltage connections for the battery pack, inverter/motor, and charging system. It acts as a gateway to send battery power to the high voltage systems in the vehicle.
ENNOVI’s technologies in this area include:
- Rigid and flexible busbars
- Molded busbars
Battery Pack
The battery pack is the heart of the PHEV, providing high voltage to the powertrain and other systems. In contrast to larger BEV batteries, power packs in PHEVs typically consist of one or two battery modules, which need to be internally connected and then other systems via high voltage interfaces.
ENNOVI’s technologies in this area include:
- Rigid and flexible busbars
- High voltage extruded busbars
- Cell contacting systems
Summary
ENNOVI is addressing the shift toward a resurgence in PHEV demand by leveraging our long history of innovative technologies for automotive electronics and EV power solutions, combined with the agility and commitment to quickly adapt to changing needs of automakers.
Our wide range of products, including rigid and flexible non-insulated and insulated busbars, motor stator busbars, pluggable busbar connectors, and cell contacting systems provide a solid foundation of customizable solutions that offer enhanced performance, reliability, and efficiency.
We have a proven track record with the top Tier-1s and OEMs, along with a global and local strategy that includes a vast engineering network covering key regions such as Europe, North America, and China. This leveraging of local production and design support has consistently demonstrated success in exceeding customer expectations through early engagement, tailored solutions, and ramp up to high volume production.
Underscoring it all is ENNOVI’s unwavering commitment to sustainability through innovative product designs that reduce environmental impact.
In case you missed it, read the previous article for more information on PHEV market trends.
