The most important EV charging standards differ by region, connector type, and technical specification:
ODU TURNTAC® is the ideal contact technology for all major EV charging standards. The contacts are available off the shelf as standard products or can be customized to meet specific application requirements through ODU Automotive, offering maximum flexibility for charging infrastructure and electric vehicle manufacturers.
The minimum durability requirements for EV charging connectors are defined in the relevant standards, including IEC, SAE, and GB/T. These standards specify a minimum of 10,000 mating cycles, which may be sufficient for some applications but can be limiting in others.
However, more advanced contact systems such as ODU TURNTAC® can achieve up to 20,000 mating cycles. This significantly extends the service life of charging connectors, allowing users to benefit from longer-lasting and more reliable charging solutions.
Various contact technologies are used in EV charging connectors. The most common contact types are:
Lamella contacts were widely used in the early days of EV charging but often show limitations in terms of durability. The contact element can be damaged relatively easily, which, in the worst case, may lead to connector failure due to overheating.
Turned slotted contacts such as ODU TURNTAC® and stamped contacts such as the lead-free ODU STAMPTAC® are considered particularly reliable and durable. They have proven their performance even under demanding operating conditions.
For reliably sealing charging contacts within an EV charging connector, several solutions are available. Sealing mats and potting compounds can be used, but they are often unpopular due to the additional effort required during the connector assembly process.
O-rings provide a simple and versatile sealing solution for turned slotted contacts such as ODU TURNTAC®. An even more straightforward approach is the use of stamped contacts with an overmolded seal, such as ODU STAMPTAC®, which features an integrated silicone seal and provides IPX7 protection.
Yes, lead-free charging contacts for electric vehicles are available. One example is ODU STAMPTAC®, a stamped contact system designed for the IEC Type 2 charging interface that is manufactured without lead.
Turned slotted contacts can also be produced from lead-free materials to comply with potential future RoHS lead restrictions. However, only a few highly specialized manufacturers currently offer such solutions. One example is ODU TURNTAC®, which can be manufactured completely lead-free and already meets future regulatory requirements today.
The most efficient solution is to use stamped contacts on reel-to-reel carrier strips. This enables highly automated manufacturing processes and allows large production volumes to be achieved at low cost.
ODU STAMPTAC®, the stamped contact system for the IEC Type 2 charging interface, is one of the few products on the market designed specifically for automated processing. It is fully compatible with automated assembly processes, helping manufacturers increase efficiency and reduce production costs.
An additional advantage is the integrated seal, which eliminates the need for a separate sealing step during assembly, further simplifying the manufacturing process.
Charging connectors are exposed to a wide range of environmental influences. A coating protects the contact surface and ensures stable, low-resistance electrical performance throughout the connector’s service life. As a result, coatings based on silver or silver alloys are specified by the relevant standards.
Even small amounts of precious metals can significantly increase costs, making efficient use of these materials essential.
The stamped contact system ODU STAMPTAC® is particularly cost-effective thanks to its selective plating technology, which applies precious metals only where they are needed. For turned slotted contacts such as ODU TURNTAC®, specialized solutions are also available that reduce precious metal usage while remaining fully compliant with industry standards.
Contact resistance plays a critical role in EV charging performance.
To ensure reliable and safe charging over the long term, high-quality and field-proven contact systems are essential. Examples include the stamped contact system ODU STAMPTAC® and turned slotted contacts such as ODU TURNTAC®, both of which are designed to provide consistently low and stable contact resistance throughout their service life.
Yes. At ODU Automotive, we offer a broad portfolio of standard contacts for EV charging applications, available with various conductor cross-sections and designed for all major charging standards, including IEC, SAE, and NACS.
In addition to standard products, contacts can also be customized to meet specific customer requirements. Whether you need an individual contact design, a different conductor cross-section, or an alternative termination technology, ODU Automotive can develop a tailored solution for your application.
With extensive expertise and a comprehensive product portfolio, ODU Automotive works closely with customers to identify and implement the most suitable contact solution for their EV charging systems.
Until now, 6 mm² conductor cross-sections have been the preferred choice for 32 A IEC Type 2 charging interfaces. However, volatile material prices and increasing international cost pressure are gradually driving manufacturers to adopt the smaller 4 mm² conductor cross-section.
To ensure reliable performance despite this significant reduction in conductor size, highly reliable and high-performance contact systems are more important than ever. ODU Automotive offers both the stamped contact system ODU STAMPTAC® and the turned slotted contact system ODU TURNTAC® for this purpose – available not only with 4 mm² conductor cross-sections, but also with virtually any other customer-specific conductor size.
ODU STAMPTAC® is the ideal choice for cost-effective, high-volume, and automated processing. Supplied on reel-to-reel carrier strips, the stamped contact system enables highly efficient automated assembly and helps manufacturers achieve significant cost savings in large-scale production.
A key advantage of ODU STAMPTAC® is its integrated sealing solution. By eliminating the need for a separate sealing step during assembly, manufacturers can reduce process complexity, save time, and further lower production costs.
The stamped contact system ODU STAMPTAC® is designed for 10,000 mating cycles, while the turned slotted contact system ODU TURNTAC® achieves up to 20,000 mating cycles. This exceeds the requirements of the most common EV charging standards by as much as a factor of two.
As long as the mating contact pins comply with the relevant dimensional requirements defined by the applicable standards, mating compatibility is generally ensured. However, the quality of the mating pin is critical. As the term contact system implies, performance depends on both contact partners – the socket and the pin. A low-quality pin can potentially damage the socket contact, reduce reliability, and shorten the overall service life of the system.
For optimum performance, durability, and safety, ODU pins are the ideal mating counterpart. Designed by contact technology experts, they are engineered to work perfectly with ODU contact systems and deliver maximum lifetime and reliability in EV charging applications.
ODU DOCKING MATE® is a connector system developed by ODU Automotive. Its key feature is the ability to reliably compensate for positional tolerances between fixed power connections. Typical applications include connections between the battery and battery management system (BMS) as well as between the electric motor and inverter in electric vehicles.
Another advantage is the combination of power and signal transmission in a single blind-mate interface, enabling fast and reliable assembly without the need for direct visual alignment. The connector system is fully customized to meet individual customer requirements and application needs.
In most cases, electric trucks use conventional high-voltage (HV) connectors originally developed for passenger vehicle applications. However, connectors used in commercial vehicles often need to meet higher requirements in terms of robustness, durability, and serviceability.
For the interface between the battery and the battery management system (BMS), ODU DOCKING MATE® provides a dedicated solution. This robust connector system features a blind-mate design, meaning it does not need to be directly accessible for installation or removal. It also combines power and signal contacts in a single interface, whereas conventional connector solutions typically require two separate interfaces for these functions.
Combining power and signal contacts within a single connector is common practice in industrial applications. In the automotive sector, however, such solutions are less common because power and signal wiring harnesses are typically routed separately.
In certain applications, combining power and signal transmission can offer significant benefits. For connections between the battery and battery management system (BMS) as well as between the electric motor and inverter, combined connector systems help save valuable installation space and reduce assembly time on the production line.
ODU DOCKING MATE® integrates all of these functions into a single interface. It combines power and signal contacts in one connector system, enabling compact designs, simplified assembly, and efficient integration in modern electric vehicle architectures.
Yes, both tolerance-compensating contact systems and complete connector solutions are available for automotive applications.
While conventional automotive contact systems and HV connectors can typically compensate for only very small positional deviations, the ODU DOCKING MATE® can compensate for misalignments of several millimeters. This capability is enabled by the innovative ODU LAMTAC® Float contact system.
Thanks to its integrated tolerance compensation function, interfaces such as the connection between the battery and battery management system (BMS) or between the electric motor and inverter can be connected and disconnected easily and reliably.
In modern electric motors with hairpin stators, the winding ends are typically welded to busbars. These connection points are then connected directly to the inverter, either by screw connections or plug-in connections.
Plug-in connections offer several advantages. The inverter housing can be mounted onto the motor assembly quickly and in a highly automated process. In addition, the connection interface itself no longer needs to be directly accessible, helping to save valuable installation space.
Plug-in solutions also simplify service and maintenance. Even in confined engine compartments, accessibility requirements are reduced, making inverter replacement faster, easier, and more efficient.
ODU Automotive offers connector solutions for these applications, enabling reliable and service-friendly connections between the hairpin stator and inverter in modern electric drive systems.
Both plug-in and screw connections are widely used in automotive applications and have proven their reliability over many years. In many cases, the intended application already determines the preferred connection technology, as is the case with EV charging connectors.
Where both options are feasible, it is worth considering the broader advantages of plug-in solutions. While screw connections must remain accessible for assembly and service, plug-in connections can eliminate this requirement. This can also remove the need for housing access openings, helping to save valuable installation space.
In addition, plug-in connections can reduce assembly times and simplify manufacturing processes. Advanced connector systems such as ODU DOCKING MATE® offer further benefits by compensating for assembly tolerances and the thermal expansion of busbars. Conventional screw connections are not able to provide this type of tolerance compensation.
Tolerance-compensating systems – whether the ODU LAMTAC® Float contact system for individual contact applications or the complete ODU DOCKING MATE® connector system – are specifically designed to ensure reliable and uninterrupted power and signal transmission, even under demanding operating conditions.
This is achieved through the use of advanced high-performance contact technologies such as ODU LAMTAC® Flex on the mating interface. Its robust contact design provides excellent resistance to mechanical influences, while the large number of individual contact points ensures reliable electrical performance even in harsh environments.
The integrated tolerance compensation mechanism not only compensates for positional deviations between the components being connected, but also withstands the vibration and shock loads commonly specified in LV214 and relevant ISO standards.
In electric motor-to-inverter applications, flat contact solutions are particularly popular. In many cases, housing designs and installation spaces are already defined by previous vehicle generations. To integrate more powerful electric drivetrains within these existing constraints, highly efficient and, above all, compact contact systems are required.
With ODU LAMTAC® Flat, a scalable flat contact system, ODU Automotive helps manufacturers address exactly this challenge: integrating higher performance into the smallest possible installation space.
Customers also benefit from ODU's decades of experience in developing customized contact solutions as well as its exceptionally high vertical integration of 80%, enabling maximum flexibility, quality, and application-specific optimization.
For the interface between the battery and the battery management system (BMS), the tolerance-compensating connector system ODU DOCKING MATE® is an ideal solution.
This customizable and scalable connector system combines power and signal contacts in a compact high-voltage interface and features a blind-mate design, enabling fast and efficient assembly. For power transmission, round contacts are used. Their large conductor cross-section allows high currents to be transmitted reliably, while the round contact design also supports the system's integrated tolerance compensation function.
ODU DOCKING MATE® is a scalable connector solution that can be customized to meet specific customer requirements. Based on existing applications, the system is capable of carrying continuous currents of up to 1,200 A.
The maximum current-carrying capacity depends heavily on application-specific factors, including the conductor cross-sections used by the customer and the available cooling conditions. For this reason, it is difficult to provide a universal current rating for all configurations.
To determine the optimal solution, the electrical and mechanical requirements of each application should be evaluated individually. This allows the connector system to be tailored for the required performance.
Yes, ODU DOCKING MATE® is already being used in series production.
In current production applications, the ODU LAMTAC® Flex socket serves as the core contact technology of the connector system. The next-generation ODU LAMTAC® Float socket is currently in the B-sample stage. Initial potential series production projects are already being discussed with selected customers.
ODU DOCKING MATE® is a customized solution whose configuration can vary significantly depending on the application requirements. For this reason, it is not possible to quote a fixed price for the system.
In general, however, ODU DOCKING MATE® can help reduce overall system costs by shortening assembly times, significantly improving serviceability, and enabling easy disassembly at the end of the product lifecycle.
In addition, a standardized Battery DOCKING MATE® for commercial vehicle applications is currently under development. This modular connector system is designed to be configurable according to customer requirements and will be available for different power classes in the future.
ODU DOCKING MATE® is a scalable connector solution. The amount of tolerance compensation depends on the size of the contact system, as larger contacts can provide greater tolerance compensation capabilities.
A tolerance compensation of ±1 mm can be reliably achieved across all contact sizes. With the appropriate system design and dimensioning, tolerance compensation of up to ±3 mm can also be realized.