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Electric Vehicle Integrated Controller Connectors

Engineers designing electric vehicle (EV) controllers require high-power, automotive-grade connectors that deliver reliable operation in harsh environments. Molex offers a range of interconnect solutions that are tested and certified to meet stringent industry standards, providing integrated signal, low-power and high-power capabilities while reducing package sizes, optimizing manufacturability and improving design flexibility.

Designing EV Controllers

For designers of EV controllers, the complexity of the integrated 4-in-1 design presents unique challenges. EV controller connectors must meet the diverse requirements of a DC/DC controller, power distribution unit (PDU), motor control unit (MCU) and onboard charger (OBC). In addition to ensuring efficient power management, interconnects must optimize space and weight, support thermal regulation, operate reliably in harsh conditions and meet automotive industry standards.

Handling complex power management tasks in high-output systems subject to a range of challenging environmental conditions requires rugged and specialized solutions. Molex offers a range of high-power connectors and cables designed for automotive applications like DC/DC controllers, PDUs, MCUs and OBCs. A modular approach provides scalability, making it easier for designers to adapt designs to different vehicle models and evolving technologies.

With the increasing importance of advanced driver assistance systems (ADAS) and vehicle-to-everything (V2X) communication, high-speed data connections are critical to vehicle safety and performance. Robust, high-speed interconnects and custom EV controller solutions from Molex enable seamless integration with V2X and autonomous vehicle technologies.

These connectors are rigorously tested for safety and durability, ensuring compliance with industry standards and regulatory requirements while enhancing vehicle safety and long-term system reliability. Molex delivers global manufacturing capabilities to provide a consistent and secure supply along with a collaborative engineering approach to help customers optimize EV controller designs.

Featured Products

Connectors Inside the EV Controller

EV controller designers must incorporate a variety of connections inside the box that meet requirements for smaller package sizes, efficient thermal management, high-speed connectivity and resistance to shock and vibration. Molex automotive-grade connectors help address these needs with a diverse selection of circuit counts and connector styles for wire-to-board and board-to-board applications.

  Stack Height Circuits Potting Capable Wire-to-Board Board-to-Board
SlimStack Connectors 0.60 to 16.00mm 6 to 240     X
FFC/FPC Connectors   2 to 120   X  
Micro-Lock Plus Connectors   2 to 42 Up to 6.00mm X  

Premo-Flex Flat-Flexible Cable (FFC)

Reliable board-to-board connectors available in standard off-the-shelf and custom solutions that enable designers to maximize PCB space and reduce device weight.

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Flexible Printed Circuits

Rugged, durable and resistant to shock and vibration, Flexible Printed Circuits (FPCs) meet the small package requirements of inside-the-box connectors. Their high-speed connectivity helps address the needs of EV controllers.

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Connectors Outside the EV Controller

Design a compact 4-in-1 EV controller that meets automotive demands by seamlessly integrating motor control, DC/DC conversion, onboard charging, and inverter functions into one unit with Molex high-performance connectors. These connectors ensure high-voltage connectivity, optimize space and guarantee long-term reliability and performance in harsh conditions, making them essential for creating efficient and durable EV controllers.

  Terminal Size Circuits Sealed Wire-to-Board Wire-to-Wire
CMC / CMX Connectors 0.64, 1.50, 2.80mm 22 to 154 X  X  
Compactus Connectors 0.50, 1.00, 2.80mm 48 to 186 X X  
ConnTAK50 Connectors 0.50mm 2 to 22    X  
DuraClik Connectors 2.00mm 2 to 15   X  
Mini50 Connectors 0.50, 1.20mm 2 to 38 X X X
MX150 Connectors 1.50mm 2 to 26 X X X
MX-DaSH Connectors 0.50, 0.64, 1.20, 2.80 4.80mm Multiple, modular, hybrid X X X

EV Controller Power Distribution

Optimizing power distribution, which is essential to EV efficiency, can make a significant difference in vehicle performance. When compared with traditional wiring harnesses, rigid, flexible and laminated busbars provide reduced weight, space savings, streamlined assembly processes and improved electrical conductivity compared with traditional wiring harnesses. Busbars can handle higher currents for more effective power distribution, while robust, vibration-resistant busbar interconnects and mounting systems reduce failure points and improve reliability.

  Voltage Rating Material Capabilities
Busbars 30.0 to 200.0A Copper, Tin, Mylar, Nomex, rigid plastic and FR4 Flexible grounding jumpers, flexible busbars, rigid busbars and laminated busbars