High-reliability 60KW Module Power Connector Assembly: The Core Choice for Enabling Stable Operation of Charging and Energy Storage Equipment

In the current era of rapid development of the new energy industry, the stable operation of power supply modules, charging piles, charging arrays and energy storage systems cannot be achieved without the reliable support of core connectors and their accompanying components. These seemingly small components directly determine the energy transmission efficiency, safety performance and service life of the equipment. Today, we will introduce a set of components that have undergone rigorous testing and verification. With excellent performance, they can adapt to various scenarios and become a high-quality selection solution in the industry.

As the key interface for energy transmission of the equipment, the performance of the rectangular connector directly affects the operational quality of the entire system. The two core models precisely cover the mainstream scenarios of AC input and DC output:

Specification model: Plug YHR MPC60-4TJW-2 (50-903-50031), Socket YHR MPC60-4ZKY-2 (50-913-50050)

Core performance advantages: Supports 115A working current and 1000V AC working voltage, perfectly matching the AC input requirements of medium and large power charging modules; Initial contact resistance ≤ 0.5mΩ, low power transmission loss, facilitating efficient operation of the equipment; Normal insulation resistance ≥ 5000MΩ, withstands 3000V AC (sea level) voltage, effectively avoiding leakage risks in high-voltage scenarios and ensuring usage safety.

Reliability performance guarantee: Mechanical life up to 200 times, capable of withstanding 10Hz to 2000Hz strong vibration and 490m/s² impact, instantaneous disconnection time ≤ 1μs, maintaining stable connection even under high-frequency plugging and complex working conditions; Contact components undergo 48-hour neutral steady-state salt spray test, with excellent corrosion resistance; Insulation body uses PA66 flame-retardant material, contact terminals use copper-plated gold, fixed brackets use brass-plated nickel, balancing structural strength and conductivity.

Structural upgrade highlights: Upgrade from machined parts to injection-molded parts, without changing the installation dimensions, adding groove design between plug terminals to enhance creepage distance, and optimizing the shell and pressure plate cooperation structure of the socket to further enhance safety and stability.

2. 14-pin 60KW module power rectangular connector: All-round choice for DC output and signal transmission

Specification model: Plug YHR MPC60-14G12TJW-2 (50-903-50032), Socket YHR MPC60-14G12ZKY-2 (50-913-50111)

Core performance advantages: Adopting a power port and signal port separation design to achieve "energy transmission + signal feedback" dual functions. Power port supports 115A working current and 1000V DC working voltage, contact resistance ≤ 0.5mΩ, ensuring efficient transmission of high-power DC electrical energy; Signal port works with a current of 3A and a voltage of 24V DC, contact resistance ≤ 12mΩ, capable of accurately transmitting equipment operation status, fault warnings, etc.; Power port withstands 3000V DC, signal port withstands 300V DC, insulation resistance ≥ 5000MΩ, effectively isolating power signals and control signals, avoiding mutual interference.

Reliability performance guarantee: Also has 200 mechanical life, excellent vibration and impact resistance, contact components undergo 48-hour salt spray test without abnormalities; Power port terminals use copper-plated gold, signal port is copper alloy-plated gold, socket sleeve undergoes stainless steel passivation treatment, positioning claws use铍 copper heat treatment process， suitable for long-term stable use in complex environments.

Practical design details： Clearly mark the installation restrictions of 9# and 12# holes to avoid installation errors； After structural upgrade， the creepage distance is improved， batch production consistency is better， suitable for large-scale application needs.

II. Key supporting components： φ6 hole component and M4 screw —— Strengthening the stable foundation of the equipment

The stable operation of the connector is inseparable from the support of high-quality supporting components. The following two core accessories perfectly match the rectangular connector and ensure the overall reliability of the equipment from details：

Specification Model: YHR8.571.50083 (60-571-50083)

Core Performance Advantages: Adopting a technologically advanced crown spring structure, the rear sleeve is made of copper, the crown spring is made of beryllium copper, and the surfaces are all treated with gold plating. The dynamic contact reliability is strong; the working current reaches 115A, perfectly matching the rectangular connector, the separation force of the socket is controlled between 8N and 20N, ensuring smooth insertion and extraction while avoiding connection loosening.

Process and Installation Assurance: Adopting a crimping terminal connection form, compatible with 25mm²/3AWG, 4AWG specification cables. The crimping stripping length is standardized, the tensile strength of the crimped connection head is ≥1350N (compression ratio 80%~90%) and ≥1000N (compression ratio 70%~80%), with no loosening after vertical pulling tests; after installation, the component can be firmly fixed by the positioning claws, avoiding detachment during use.

Environmental Adaptability: Working temperature range covers -55℃ to +125℃, no abnormalities after 48-hour salt spray test, capable of meeting the usage requirements of outdoor charging piles, battery swap stations, etc., in complex scenarios.

2. M4 Screw: The Solid Foundation of the 60KW Module Power Connector

Specification Model: YHR8.222.1034 (80-222-01034)

Core Performance Advantages: Specifically designed for the module power connector of the series, made of carbon steel with a surface of zinc-nickel alloy plating, with high mechanical strength and superior corrosion resistance, far exceeding ordinary screws. After 240-hour neutral stable salt spray test, there is no rusting, effectively avoiding rusting and loosening in outdoor environments.

Process Parameter Assurance: The recommended torque for M4×0.7 specification screws is 1.5N・m, with a minimum breaking torque of 3N・m, sufficient fixing force, capable of withstanding vibration and impact during equipment operation, ensuring the stability of the connector installation; the working temperature range covers -55℃ to +125℃, perfectly matching the working environment of charging and energy storage equipment, with strong adaptability.

Three, Full Scene Adaptation + Core Value: The Key to Becoming an Industry Preferred Solution

Charging Pile / Charging Cluster Scenarios: Compatible with AC chargers, integrated chargers, and split chargers, featuring wide temperature operation, high salt spray protection, and anti-vibration and shock resistance, ensuring the equipment operates stably in complex outdoor environments such as sun exposure and temperature fluctuations;

Energy Storage System Scenarios: Compatible with large-scale storage, industrial and commercial storage, and household storage systems and charging equipment for coordinated operation, low contact resistance and high insulation performance ensure efficient and safe energy transmission, in line with the green and low-carbon development trend;

Power Module Scenarios: Perfectly matching the AC input and DC output interface requirements of module power, standardized design enhances equipment compatibility, helping simplify product development and production processes.

2. Core Value Highlighted

Safe and Reliable: All product series pass rigorous salt spray, vibration, and impact tests, key components use high-quality materials and advanced processes, reducing equipment failure risks from the source;

Efficient and Energy-Efficient: Low contact resistance design reduces power transmission loss, helping the equipment improve overall energy efficiency and reduce operating costs;

Compliance Adaptation: Compliant with RoHS and REACH environmental requirements, meeting industry policies and market demands, suitable for global application scenarios;

Complete Compatibility: From screws to socket components to rectangular connectors, forming a complete supporting system, avoiding compatibility issues when combining different brand components, improving equipment assembly efficiency.

In the context of the rapid development of the new energy charging and energy storage industry, the stability and safety of the equipment are the key to core competitiveness. This high-reliability module power connector component, with complete model specifications, excellent core parameters, and wide scene adaptability, provides solid support for various power equipment. Whether it is the development of new equipment or the upgrading of old equipment, choosing this proven component combination will effectively enhance product quality and market competitiveness, helping the enterprise gain an advantage in the industry competition.

Conclusion: Reliability is the result of countless details.

In the era of rapid advancement in fast-charging infrastructure, true technical strength is not merely reflected in the power figures, but is also hidden in the coating of each screw, the contact surface of each terminal, and the smoothness of each insertion and removal. Choosing high-specification connection solutions that have been verified through engineering is like taking out an insurance policy for the operational stability in the next ten years.

If you need the detailed specification sheet, 3D model or sample of the above products, please feel free to contact:

Xu Sheng | +86 199 2527 9918

Email: mailto:leo@yonghaorun.com

(Shenzhen YHRise Technology Co., Ltd. | Specializing in high-reliability connector solutions)