EV and EV Charging

Total Connections already supplies some of the leading names in electric vehicle and electric vehicle charging. As charging points are installed across the UK and beyond, our electrical terminals and earthing solutions for charging station technology will service the infrastructure needs into the future.

Charging station manufacturers have been not only been incorporating our standard terminal and earthing products into their infrastructure, but there has been a demand on our in-house design and manufacturing capabilities. We have provided bespoke solutions, including custom lattice earth mats designed to specifications and we have even supplied the grounding substrate (Marconite) to complete the installation.

EV and EV Charging Case Study

Total Connections was approached by a customer to manufacture a busbar that was designed for the rear wheel motors on a McLaren P1 hybrid hyper car. We prototyped the customer busbar designs, but there were design flaws in the original right-angled sheet terminal that would have affected the performance and achievable tolerances of the busbar.

Our in-house design team redesigned it, allowing it to be manufactured quicker and more economically, and to a tighter tolerance. A half moon profile was cut into the busbar, with tube brazed to the busbar. Full radii were cut onto every edge to allow the busbar to be powder-coated.

The new busbar increased the cross-section of the brazed joint allowing it to carry the required 10A/sqmm. Due to the high current, the busbar is fluid cooled. The prototype was accepted for use and manufacturing was initiated for installation in this prestige electric vehicle.

For more information on how we can serve your needs in the EV and EV Charging sector, contact our in-house design & manufacture team.