Battery Energy Storage Connector & ​High Voltage Cable

Battery storage connectors and Overmolded high-voltage wiring harnesses provide critical links between energy storage systems and energy harvesting technologies.
Battery energy storage systems have revolutionized the way we store and utilize electrical energy. Battery technology has become a key player in the global energy landscape as demand for reliable energy storage solutions continues to grow.

The rise of renewable energy sources such as solar and wind brings opportunities but also challenges to the global power grid. Because these energy sources are intermittent, storing excess energy during peak generation periods is critical to meet demand during periods of low generation. Therefore, battery energy storage systems (BESS) have emerged as a promising solution to bridge this energy gap. These systems not only stabilize the grid but also improve its overall efficiency.

High voltage battery energy storage connector

Battery energy storage systems have revolutionized the way we store and utilize electrical energy. Battery technology has become a key player in the global energy landscape as the need for renewable energy integration continues to increase and the need for reliable energy storage solutions continues to grow. A key component of these systems is the battery connector, which ensures efficient power transfer and reliable connectivity.

These connectors are critical components that facilitate the transfer of power between the battery and the application. They must be designed to handle high currents, minimize power loss, and provide safe and reliable connections. Battery connectors come in various shapes and sizes to suit different types of batteries and applications.

Renewable energy relies on energy storage
The energy transition requires support in many areas of smart energy grids and sector coupling. Starting from energy production, all the way to storage and supply, it is necessary to offer application-specific products in the areas of connectivity, electronics, automation and condition monitoring to ensure the right solution for any demanding project. Renewable energy is a technology for the future, but this energy must be stored to be optimally used.

As renewable energy becomes available, it becomes increasingly important to store it so that it can be called upon when needed. For this purpose, ESS (Energy Storage System) emerged, which in turn consists of individual battery packs. Battery connectors are critical for connecting these battery packs to each other.

Whether it’s a small storage system for home use or a large battery container, battery connectors should cover a wide range of applications. Smaller sizes are available in current capacities of 100 and 120Amp, and medium sizes in 150 and 200Amp (all of which are already available). Other options should be able to have current capabilities up to 350Amp. These connectors are designed to manage voltages up to 1500 Vdc.

High voltage battery energy storage connector cable

Characteristics of quality battery connectors
For wiring, conductor cross-sections from 16 mm² to 50 mm² are available. In the near future, conductor cross-sections of 70 mm² and 95 mm² will also be available.
In the mating part, there is a busbar that allows easy connection of the conductors to the device via cable lugs.

Battery connectors should provide several key advantages for BESS applications:
High current carrying capacity: Connectors should be designed to handle high currents, allowing for efficient energy transfer and reduced power loss.
Rugged Design: Connectors should be designed to withstand harsh environmental conditions, ensuring their reliability and longevity in demanding applications.
Easy and safe operation: Connectors should be easy to use and have mechanisms to prevent accidental disconnection, making maintenance and operation safer.
Contacts shall be made of silver-plated copper alloy and certified according to UL 4128 to guarantee optimal electrical contact after more than 100 mechanical connection and disconnection operations (no load)

Color coding is important, such as the color coding of positive connections (orange) and negative connections (black) on connectors and mating bus connections. This creates the key visuals users need to make a connection.

Both sides of the connector are critically coded to reduce the possibility of user error or inserting the wrong side into a mating bus connection. This special key coding allows the connector to be inserted in almost any orientation, thus avoiding unnecessary mechanical stress in the cable.

A locking mechanism secures the plug and socket. This mechanism is an essential safety feature given the large amounts of energy managed by this connector and the risk of arc faults with catastrophic consequences in the event of an accidental disconnection under load. Additionally, slight movement of the connector may reduce the contact area and create hot spots that can lead to BESS fires. This locking feature prevents both of these situations from happening, and the connection can be disconnected in a very practical way with the push of a button.

Energy storage connector
Battery energy storage systems are crucial in modern energy management, helping to facilitate the integration of renewable energy and enhance grid stability. Battery connectors are critical components in these systems, ensuring efficient power transfer and reliable connections.

As the world moves towards a more sustainable energy future, battery energy storage systems, along with advanced battery connectors, will continue to play an important role in shaping the way we harness and utilize electricity. Continued advances in energy storage systems and battery connector technology promise to unlock the full potential of renewable energy and accelerate the world’s move toward a cleaner, greener and more sustainable energy ecosystem.