Browse Topic: Connectors and terminals

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Predictive Modelling of Battery Behavior for Enhanced Energy Management in Electric Vehicles2026-26-0385To be published on 01/16/2026
As electric vehicles (EVs) and smart energy systems continue to evolve, optimizing energy usage and ensuring system reliability has become critical. However, battery pack modelling remains challenging due to its highly dynamic and nonlinear behavior due to the temperature variations, aging, and variable load conditions. This paper presents a 1D digital twin framework designed for predictive monitoring of the battery parameters, including State of Charge (SoC), terminal voltage, temperature, and an indicative assessment of State of Health (SoH). The battery is modelled using a Thevenin equivalent circuit that covers both steady-state and dynamic electrical characteristics. Key parameters such as open-circuit voltage (OCV), internal resistance, and dynamic characteristics were derived through pulse testing conducted in our laboratory. A thermal modelling is done to capture the heat generation and cell temperature. SoC estimation is carried out using the Coulomb counting method and
G, Ayana, Gumma, Muralidhar
Thermal Management of High-Voltage Connectors using double-layered Phase-Change Materials (PCM)2026-26-0279To be published on 01/16/2026
Abstract: High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with
Neogi, Angshuman, Shinde, Shardul
Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.2026-26-0474To be published on 01/16/2026
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between
Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, MENON, Praveen
Preventing thermal run-away using shape memory alloy2026-26-0009To be published on 01/16/2026
Title: Preventing thermal run-away using shape memory alloy Rini Reginald, Ashish Chauhan, Saswat Rout, Venkatesh Muthukrishnan Mercedes-Benz Research and Development, India Key words: Thermal Runaway, Active and Passive Safety, Shape Memory Alloy, Nitinol, Literature Survey, Structural Simulation Abstract The present disclosure pertains to advancements in battery modules for electric vehicles (EVs). Addressing the critical issue of thermal runaway in high-voltage battery packs, this invention introduces a novel battery module designed to enhance safety of the vehicle. The battery module comprises a plurality of battery cells housed within an enclosure, electrically connected to the vehicle's circuit via busbars and innovative connectors made of Shape Memory Alloy (SMA). These connectors are engineered to transition between two states: a first state where they facilitate electrical coupling and a second state where they isolate the battery cells upon detecting temperatures exceeding a
Reginald, Rini, Rout, Saswat, VENKATESH, Muthukrishnan, Chauhan, Ashish Jitendra, Selvaraj, Elayanila
Heavy-Duty Electrical Connector Performance StandardJ2030_202511 (Current)11/21/2025
This SAE Standard encompasses connectors between two cables or between a cable and an electrical component and focuses on the connectors external to the electrical component. This document provides environmental test requirements and acceptance criteria for the application of connectors for direct current electrical systems of 50 V or less in the majority of heavy-duty applications typically used in off-highway machinery. Severe applications can require higher test levels, or field-testing on the intended application.
CTTC C2, Electrical Components and Systems
Cover Assembly, Electrical, for MS27212 Terminal Board AssemblyAS18029G (Current)10/31/2025
Scope is unavailable.
AE-8C2 Terminating Devices and Tooling Committee
Cover Assembly, Electrical, for MS27212 Terminal Board AssemblyAS18029F (Current)10/15/2025
Scope is unavailable.
AE-8C2 Terminating Devices and Tooling Committee
Edited before Publishing: CONNECTOR ACCESSORIES, ELECTRICAL, BACKSHELL, NONENVIRONMENTAL, STRAIGHT, SELF-LOCKING AND NON-SELF-LOCKING, CATEGORY 3B (FOR MIL-DTL-38999 SERIES I AND II CONNECTORS)AS85049/27C (Current)10/10/2025
Scope is unavailable.
AE-8C1 Connectors Committee
Connector Accessories, Electrical, Strain Relief, 45°, Self-Locking and Non-Self-Locking, Category 4C (MIL-DTL-38999 Series I and II Connectors)AS85049/57F (Current)10/10/2025
Testing edit capabilities prior to publishing. Scope is unavailable.
AE-8C1 Connectors Committee
Cover Assembly, Electrical, for MS27212 Terminal Board AssemblyAS18029E (Historical)10/02/2025
Scope is unavailable.
AE-8C2 Terminating Devices and Tooling Committee
Terminal Board Assembly, Molded-in-Stud, ElectricAS27212E (Current)09/29/2025
Scope is unavailable.
AE-8C2 Terminating Devices and Tooling Committee
INSTALLING AND REMOVAL TOOLS, CONNECTOR ELECTRICAL CONTACT, TYPE II, CLASS 1, COMPOSITION CAS81969/19B (Current)05/02/2025
AE-8C2 Terminating Devices and Tooling Committee
CRIMP TOOLS, TYPE 1, TERMINAL, HAND, OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 8 THROUGH 0000AS22520/23C (Current)05/02/2025
AE-8C2 Terminating Devices and Tooling Committee
SAE TOMORROW TODAY: Refining SAE J3400 for Standardized EV Charging1348010/02/2024
As most EV enthusiasts know, the Tesla-developed North American Charging System (NACS) is being standardized as SAE J3400 -- unlocking the ability for any EV supplier or manufacturer to use, manufacture, or deploy the J3400 connector on EVs and at charging stations across North America. Recently, the SAE J3400 NACS Task Force voted to establish the J3400 standard as a recommended practice, marking a significant step forward in the standardization process and demonstrating the importance of collaboration in moving the EV industry forward. To learn more, we sat down with Christian Thiele, Director, Global Ground Vehicle Standards, SAE International, and Dr. Rodney McGee, Ph.D., P.E., Chairman, SAE J3400 NACS Task Force, and Chief Engineer at the University of Delaware, to discuss how the J3400 standard is bringing industry together to build a unified and reliable EV infrastructure that supports the widespread adoption of EVs. Join the global EV ecosystem leader! The SAE EV Charging PKI
Hineman, Marcie
Simulation of Crimping Process for Electrical Contacts to ensure Structural Integrity of Crimped Joint under Static Loads2024-26-029101/16/2024
The use of electrical contacts in aerospace applications is crucial, particularly in connectors that transmit signal and power. Crimping is a widely preferred method for joining electrical contacts, as it provides a durable connection and can be easily formed. This process involves applying mechanical load to the contact, inducing permanent deformation in the barrel and wire to create a reliable joint with sufficient wire retention force. This study utilizes commercially available Abaqus software to simulate the crimping process using an explicit solver. The methodology developed for this study correlates FEA and testing for critical quality parameters such as structural integrity, mechanical strength, and joint filling percentage. A four-indenter crimping tool CAD model is utilized to form the permanent joint at the barrel-wire contact interfaces, with displacement boundary conditions applied to the jaws of the tool in accordance with MIL-C-22520/1B standard. The study identifies the
Aher, Ravi, More, Sandip Raghunath, Demarthon, Simon
Effect Analysis of Form Factor on Thermo-Electric Generator Performance2024-26-038601/16/2024
One of the major contributor for the climate change and global warming is the residual thermal energy generated from automobiles as exhaust gases in IC engine powered vehicles and batteries and fuel cell heating in green vehicles. This waste heat or the thermal energy can be converted into useful electric energy using the thermos-electric generator (TEG). TEGs are devices that can generate electricity directly from temperature difference between two surfaces. They are manufactured using semiconductor materials that exhibit Seebeck effect, generating voltage due to temperature gradient across it terminals. These devices are compact, stable and more reliable electric power generators. The main setback of TEG is its low efficiency compared to other power generators. In this paper, form factor of TEG is studied in detail with its effect on figure of merit, for commercial vehicle applications. In addition, bottlenecks in implementing these TEGs in series production is discussed.
Bali, Gaurav, Mutagi, Megha Dharnendra, PONANGI, BABU RAO
Development of a Built-in Type Dashboard Camera with Reliability and Usability 2022-01-012003/29/2022
Dashcam, which is considered essential parts of vehicles in Korea, are installed in most vehicles for reasons such as accidents, evidence of threatened driving of other vehicles, and insurance premiums. Aftermarket dashcam have been developed with many improvements such as higher resolution camera and LCD application, but still have problems in usability and durability. The first problem is a separate device mounted on the top of the windshield, which obstructs the driver's view and may injure the driver due to a collision impact. In addition, the connection of the power supply may cause a vehicle breakdown such as a fire due to a worker's mistake or a product defect. Secondly, in order to view the stored video, it is troublesome to remove the SD card and check it on the computer. Moreover, since the LCD is so small, it is difficult to search and play the desired video from the list in many saved files. The third problem is durability and reliability, when operating in the high
Jeong, DongHyuk
CONTACTS, ELECTRICAL CONNECTOR, PIN, CRIMP REMOVABLE (FOR AS81659 SERIES 2 CONNECTORS)AS39029/11C (Historical)11/09/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, PIN, CRIMP REMOVABLE (FOR AS50151 SERIES AS340X1 CONNECTORS AND AS95234 CONNECTORS)AS39029/124A (Current)10/22/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE (FOR AS50151 SERIES AS340X1 CONNECTORS AND AS95234 CONNECTORS)AS39029/123A (Current)10/06/2021
AE-8C1 Connectors Committee
115/200 Volt, 400 Hz Aircraft External Electrical Power Connector Contact Maintenance ProceduresAIR4365B (Current)09/30/2021
This SAE Aerospace Information Report (AIR) describes procedures for use in the field to determine if 115/200 Volt, 400 Hz aircraft external electrical power connectors are excessively worn, which may result in the inability of the external power plug to be retained, intermittent electrical performance and arcing.
AGE-3 Aircraft Ground Support Equipment Committee
CONNECTOR ACCESSORIES, ELECTRICAL, CAP, DUST, PLASTIC, CATEGORY 9AS85049/138C09/22/2021
SCOPE IS UNAVAILABLE.
AE-8C1 Connectors Committee
TERMINAL JUNCTION SYSTEM, TERMINAL JUNCTION BLOCKS, SECTIONAL ELECTRONIC IN-LINE JUNCTIONS, DOUBLE, INTEGRAL DIODE(S), SERIES IAS81714/24B (Current)08/26/2021
AE-8C2 Terminating Devices and Tooling Committee
CONTACTS, ELECTRICAL CONNECTORS, PIN, SOLDER, REMOVABLE, SHIELDED, SIZE 12 (FOR MIL-DTL-83723 SERIES III CONNECTORS)AS39029/74C (Current)08/23/2021
AE-8C1 Connectors Committee
CONNECTORS, ELECTRICAL, RECTANGULAR, RECEPTACLE, CRIMP CONTACTS (SINGLE INSERT, TYPE III, CLASS 1 (−65 TO +125 °C), SERIES 2, SHELL DESIGNATOR A)AS81659/61B (Current)07/30/2021
AE-8C1 Connectors Committee
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D (Current)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D-TEST-REC (Historical)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
CONNECTOR, RECEPTACLE, ELECTRIC THRU BULKHEAD, WALL MOUNTING FLANGE, SERIES I (CLASS E)AS31391 (Current)06/22/2021
AE-8C1 Connectors Committee
CONNECTOR, RECEPTACLE, ELECTRIC THRU BULKHEAD, WALL MOUNTING FLANGE, SERIES I (CLASS E)AS31391-TEST-REC (Historical)06/22/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTORS, SOCKET, SOLDER, REMOVABLE, SHIELDED, SIZE 12 (FOR MIL-DTL-83723 SERIES III CONNECTORS)AS39029/73C (Current)06/10/2021
AE-8C1 Connectors Committee
CONTACT, ELECTRICAL CONNECTOR, CONCENTRIC TWINAX, PIN, SIZE 8 (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)AS39029/113C (Current)05/28/2021
AE-8C1 Connectors Committee
Chip Detector, Electrical Connection, Remote IndicatingARP843B (Current)05/28/2021
This Aerospace Recommended Practice is applicable to the design of remote indicating magnetic chip detectors installed in the lube systems, hydraulic systems, controls systems, gearboxes, constant speed drives, etc. of Aerospace Power Plants. It is not applicable to the touch-to-test type terminal models.
E-25 General Standards for Aerospace and Propulsion Systems
CONTACT, ELECTRICAL CONNECTOR, CONCENTRIC TWINAX, SOCKET, SIZE 8, MIL-DTL-38999 SERIES I, III, AND IVAS39029/114C (Current)05/25/2021
AE-8C1 Connectors Committee
Connector Accessories, Electrical General Specification forAS85049F (Current)04/14/2021
This specification covers connector accessories for use with electrical connectors; see 6.8.
AE-8C1 Connectors Committee
Connector Accessories, Electrical General Specification forAS85049F-TEST-REC (Historical)04/14/2021
This specification covers connector accessories for use with electrical connectors; see 6.8.
AE-8C1 Connectors Committee
Aging Simulation of Electric Vehicle Battery Cell Using Experimental Data2021-01-076304/06/2021
The adoption of lithium-ion batteries in vehicle electrification is fast growing due to high power and energy demand on hybrid and electric vehicles. However, the battery overall performance changes with time through the vehicle life. This paper investigates the electric vehicle battery cell aging under different usages. Battery cell experimental data including open circuit voltage and internal resistance is utilized to build a typical electric vehicle model in the AVL-Cruise platform. Four driving cycles (WLTP, UDDS, HWFET, and US06) with different ambient temperatures are simulated to acquire the battery cell terminal currents. These battery cell terminal current data are inputs to the MATLAB/Simulink battery aging model. Simulation results show that battery degrades quickly in high ambient temperatures. After 15,000 hours usage in 50 degrees Celsius ambient temperature, the usable cell capacity is reduced up to 25%. Driving cycle simulations indicate that aggressive acceleration and
Liu, Yiqun, Liao, Y. Gene, Lai, Ming-Chia
Validation of EEPROM Chip Removal and Reinstallation for Retrieval of Electronic Crash Data - Destructive and Non-Destructive Methods2021-01-090704/06/2021
As a result of trauma to the circuit board or other damage to an airbag control module (ACM), electronic crash data recorded onto a passenger vehicle’s electronically erasable programmable read-only memory (EEPROM) chip may be inaccessible by traditional imaging methods and techniques, such as through a diagnostic link connector (DLC) or accessing the data directly from the ACM. Despite the potential damage to the subject module, electronic crash data may still be present on the module’s EEPROM chip. This paper explores and validates a methodology for the removal and reinstallation of a subject EEPROM chip using an identical undamaged exemplar airbag control module and a non-destructive clip-assisted method to gain access to the subject electronic crash data. ACMs were obtained from a 2016 BMW 740i, 2015 Toyota Corolla, 2014 Nissan 370z, 2006 Lexus IS350, 2015 Maserati Ghibli, and 2017 Audi A4. Each module was imaged prior to the chip swap procedure. Each of the six EEPROM memory chips
Zeitler, Jason P., Palmer, Jacob, Smith, Connor
TERMINAL JUNCTION SYSTEM, TERMINAL JUNCTION BLOCKS, SECTIONAL, BUSSING MODULES, FEED THRU TYPE, SIZE 22, SERIES IAS81714/6B (Current)04/01/2021
AE-8C2 Terminating Devices and Tooling Committee
TERMINAL JUNCTION SYSTEM, TERMINAL JUNCTION BLOCKS, SECTIONAL, BUSSING MODULES, FEEDBACK TYPE, SIZE 22, SERIES IAS81714/1C (Current)04/01/2021
AE-8C2 Terminating Devices and Tooling Committee
Connector Accessories, Electrical, General Specification forIEEESAE308-2020 (Current)03/12/2021
None.
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, THERMOCOUPLE (FOR AS50151 AS34501 SERIES AND MIL-DTL-83723 SERIES II CONNECTORS)AS39029/86B (Historical)02/11/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, SHIELDED, SIZE 8 (FOR MIL-DTL-38999 SERIES I, III, AND IV CONNECTORS)AS39029/59C (Historical)02/11/2021
AE-8C1 Connectors Committee
Monarch's automated, electric tractor ready for 2021 deliveries21TOFHP02_1002/01/2021
“If you want to fundamentally improve your economics,” said Monarch Tractor co-founder and CTO Zachary Omohundro to farmers and growers everywhere, “you go electric.” During a webcast with SAE International's Southern California Section featuring his startup company's battery-electric compact tractor, Omohundro offered markedly reduced operational costs as only one of many reasons for using the Monarch tractor, for which he said deliveries will start this fall for the “several hundred working farms” that have reserved the tractor that starts at $50,000.
Visnic, Bill
REMOVAL TOOLS, CONNECTOR, ELECTRICAL CONTACT, (FORK TYPE, WRAP POST/CRIMP REMOVABLE) TYPE II, CLASS 1, COMPOSITION CAS81969/4A (Current)01/26/2021
AE-8C2 Terminating Devices and Tooling Committee
INSTALLING AND REMOVAL TOOLS, CONNECTOR, ELECTRICAL CONTACT, TYPE I AND II, CLASS 2, COMPOSITION BAS81969/10A (Current)01/26/2021
AE-8C2 Terminating Devices and Tooling Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE (FOR MIL-DTL-28748/3 AND MIL-DTL-28748/13 CONNECTORS)AS39029/35C (Current)01/12/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, PIN CRIMP REMOVABLE (FOR AS81511 SERIES 3 AND 4 CONNECTORS)AS39029/18C (Current)01/12/2021
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR SOCKET, CRIMP REMOVABLE (FOR AS81511 SERIES 3 CONNECTORS)AS39029/17C (Current)12/22/2020
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET REMOVABLE (FOR MIL-PRF-6106 AND MIL-DTL-12883/40 AND /41 RELAY SOCKETS)AS39029/92B (Current)12/22/2020
AE-8C1 Connectors Committee
CONTACTS, ELECTRICAL CONNECTOR, SOCKET, CRIMP REMOVABLE, THERMOCOUPLE (FOR MIL-DTL-26482 SERIES 2, AS81703 SERIES 3, MIL-DTL-83723 SERIES I AND III, AND MIL-DTL-83733 CONNECTORS)AS39029/10C (Current)12/22/2020
AE-8C1 Connectors Committee
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