Connectors - The Unsung Heroes of EV Industry

Electric vehicle charging receptacles come in several forms, just as the home videocassette market saw warring VHS and Betamax formats vying for supremacy. These are still relatively early days for EVs, so what’s hot today may be passé tomorrow. That said, the easiest way to understand current charging standards is to break them down by speed.

Where Connectors Come In

All the electrons in the world can’t do a thing for your electric vehicle if it’s not equipped with a matching connector. Here’s a rundown of the major charging connectors you’ll find on virtually every modern electric vehicle.

J1772 is the standard Level 2 charging connector you’ll find on most vehicles. While capable of charging at Level 1 speeds, J1772 chargers are typically running at Level 2 in most residential, commercial, and retail settings.

CHAdeMO is an early form of DC quick charging that was established by a consortium of Japanese carmakers. Short for CHArge de MOve, or “move using charge,” CHAdeMO connectors appear alongside J1772 connectors in order to maximize charging options. However, these chargers have been waning in popularity and are unlikely to hold significant market share in the future.

CCS Type 1 / CCS Type 2 connectors, short for Combined Charging System, enable both AC and DC charging using the same port, offering Level 2 or Level 3 charging via the same connector because it incorporates a J1772 outlet. European and American carmakers have embraced the CCS format.

Tesla uses proprietary connectors that link any Tesla vehicle to Level 3 charging. With over 23,000 Tesla Superchargers in the world, there’s a remarkably robust infrastructure open to those who choose to join Elon’s side. (Ed. note: Tesla is opening up access to its Superchargers for all EVs in late 2021.)

How Adapters Fit Into the Picture

If the conversation about EV charging has gotten uncomfortably complicated, don’t worry: It gets easier to navigate these waters once you’ve established a groundwork for how charging standards work with each other.?

While some carmakers have chosen to wall themselves in by their charging standards, adapters can enable two otherwise incompatible connectors to charge a vehicle. However, many of these compatibilities seem to occur without rhyme or reason.?

For instance, Tesla’s connectors are primarily proprietary, though CHAdeMO, J1772, and/or CCS adapters can be fitted for alternative charging sources.

However, it doesn’t currently work the other way around at a Tesla Supercharger, which is why you’ll only see Teslas there. Rather than relying on an adapter between, say, CCS and CHAdeMO units, most charging venues instead offer both connectors in order to optimize their use.?

E-2W Connectors

Electric two-wheelers, like e-bikes and e-scooters, rely heavily on their batteries for power. The battery is often the most delicate and susceptible part of the vehicle, often suffering damage due to improper handling and careless cleaning. Water can seep into the internal components, leading to humidity and moisture buildup. Additionally, extreme temperatures can adversely affect the battery and its connectors. If the temperature is either too high or too low, it can negatively impact the components of the electric bike battery connectors.

One of the most crucial elements that require attention is the EV battery connectors. These connectors, which come in various types, significantly impact the battery and performance of your E-bike. While people often perceive them as simple mechanisms, robust electric bike battery connectors are necessary due to their frequent plugging and unplugging. This continuous operation can put a strain on the connectors and they can even spark.

When choosing electric bikes battery connectors, factors such as ease of use, reliability, durability, water resistance, and size should guide your decision. Price is a significant concern for many people. The choice of connector can also affect the current and voltage requirements of your e-bike’s battery and motor, ensuring efficient and safe power delivery.

There are several types of electric bike battery connectors, including:

- Anderson Connectors: These are the most common ones and are mostly used in DIY E-bikes. They are economical and never charge more than 7 amperes. They come in two versions, and their shape and housing case allow them to be installed side by side.

- Deans Plug: These are popular among the RC modelers and these can charge at high amperes as well. They are extremely cost-effective and compact. However, they are difficult to solder and provide poor protection against moisture.

- XLR Connectors: These have heavy-duty metal shells. These are fastened by a latch, making them hard to break or come apart. They offer good protection against moisture but require some skills to install.

- XT60: These are highly recommended and easy to solder. They require high skills for installation but are easy to plug in. They offer a high life cycle and are compact.

There are several other electric bike battery connectors such as XT90, bullet connectors, JST balance connectors, QR connectors, etc. Each has its own pros and cons, and the choice should be based on the specific needs and preferences of the user.

In addition to these, there are also different types of charging connectors used in electric two-wheelers. These include AC Charging connectors like IEC60309 and Type 2 Connectors, DC Charging Connectors like GB/T Connector, CHAdeMO connector, and CCS1 and CCS2 connector.

- IEC60309: These connectors are popular in open-air settings as they are weatherproof to IP44. They are often utilized in situations when a high current rating or three-phase capabilities were not required.

- Type 2 Connectors: The IEC 62196 Type 2 connector (Mennekes) is mostly used in Europe for charging electric vehicles. It is also recommended at countries like New Zealand. The circular connector has a flattened top edge and was designed to charge battery electric vehicles at 3–50 kilowatts.

- GB/T Connector: GB/T connectors are mainly used in China. The GB/T standard allows for charging power of up to 250 kW, allowing electric vehicles to charge even faster.

- CHAdeMO connector: The CHAdeMO EV Connector Specifications are used to create DC-based EV Connectors that offer up to 62.5 kW by 500 V with 125 Amperes, direct current for fast charging of battery electric vehicles.

- CCS1 and CCS2 connector: Combined Charging System (CCS) charging sockets use shared communications pins to combine AC and DC inlets. As a result, the CCS charging socket occupies less space than CHAdeMO and other AC plugs.

In conclusion, there are numerous electric battery connectors from various manufacturers, each with different shapes and sizes but similar prices and functionality.

The key is to choose the most compatible plug for your EV.