News Room Press & media contacts Technology magazin tec.news
How to Buy Configurators Download Manager (Download Product Data) Technical Support
HARTING Careers

Industrial connectors / Han®


Overview
Rectangular connectors
Rectangular connectors
Industrial circular connectors
Industrial circular connectors
Connectors & cable assemblies for specific applications
Connectors & cable assemblies for specific applications

Circular connectors


Overview
Metric circular connectors
Metric circular connectors
Industrial circular connectors
Industrial circular connectors

Device connectivity


Overview
PCB connectors
PCB connectors
Panel feed throughs
Panel feed throughs
Cable connectors and cable assemblies
Cable connectors and cable assemblies

Industrial Ethernet Switches


Overview
Industrial Ethernet Switches
Industrial Ethernet Switches

Operator interfaces


Overview
Operator interfaces
Operator interfaces

Charging equipment for Electromobility


Overview
Charging equipment for Electromobility
Charging equipment for Electromobility

Tools


Overview
Tools
Tools

Cable assemblies & bulk cables


Overview
Power and signal
Power and signal
Data
Data
Bulk cables
Bulk cables

Industries


Automation
Automation - Hero Image
Data Centers
Data Centres
Energy
Energy - Grid Hero Image
Machinery
Machinery Americas - Hero Image
EV Charging
E-Mobility with NACS.jpg
Railway
Railway Overview
Robotics
2024-08_GettyImages-1333855916_Robotics.jpg
Semiconductor Manufacturing
2024-09_probsystem_RF_test_seiconductor_silison_wafers_GettyImages-1162146044.jpg
Smart Infrastructure
2024-09_Cooling_Heating_System_GettyImages-1002890486.jpg

The Technology Group


About HARTING Technology Group
HQT Building, Espelkamp
The future needs the past
The Future needs the Past
The Harting family
A family-run Company
Awards & recognition
We are proud about our awards
Facts & figures
Facts and Figures

About HARTING Americas


HARTING Americas
HARTING North America
Manufactured in America
website_Elgin-production-floor.png
Industry Partnerships
Industry Partnerships

Sustainability


Our Responsibility
Our Responsibility
Our Corporate Culture
Our Corporate Culture
Our Environment
Our environment
Our Technologies
Our technologies
Our Social Commitment
Our Social Commitment
Environmental Statement
Road with painted yellow arrow line
Whistleblower System
Protect by Seeing and Acting - BKMS Whistleblower System
Sustainability Certificates
CSR Certificates
Human Rights
HARTING Statement Human Rights Due Diligence - Declarations

Customer Service


myHARTING
Website Advanced Stage
Customer Service
Customer Service - Hero.png
Customer Information
Customer Support - Front of HARTING plant 1 HQT
Product Change Notifications
hero_Han-Industriesteckverbinder.tif
Website Training Center
Website Training Center

Contact


Contact Us
HARTING North America
HARTING Worldwide
HARTING Worldwide - Flags

Alternatives:

Search by series
Configurators
  1. Home
  2. News
  3. Optimised current carrying capacity: Bridge to the electric future
tec.news
March 31, 2025
3 min

Optimised current carrying capacity: Bridge to the electric future


Improving the efficiency and performance of electrical connectors for the manufacturing industry
Optimised current carrying capacity

The manufacturing industry is faced with the challenge of adapting its systems to increasing performance requirements – without claiming more space. Find out here how we at HARTING are improving the efficiency and performance of electrical connections through targeted design optimisations and advanced, leading-edge technologies.

The All Electric Society requires electrical energy, which is supplied by way of the power core both between and within the sectors. In many cases, the transition to electrified systems will entail higher performance levels or new systems with more power will have to be created.

The gains in on-board power in automobiles is an illustrative example from everyday life. This measure simplifies the implementation of so-called "break by wire" and "steer by wire" applications. The former refers to an electric braking system in which the braking forces are transmitted electronically and not mechanically, in other words by way of brake lines. The second refers to an electronic steering system in which the connection between the steering wheel and the wheels is also not mechanical, as with steering rods, but is executed via electrical signals. These performance gains also optimise the charging process for electric cars. Here, large amounts of energy have to be transferred to the vehicle by way of a connector in a short time so that the electric car is as powerful as a combustion engine when "refuelling". Similar examples can also be found in other sectors.

Despite the higher energy requirements, the available space remains unchanged. At the same time, the efficient installation, maintenance or operation calls for the use of connector, which must therefore be able to offer higher current-carrying capacity while retaining the same size.

»

There are three key starting points to improving current carrying capacity: the cable connection, the contact material and the contact point itself.

Stephan Middelkamp

Stephan Middelkamp

General Manager for Qualität and Technologien

The key to boosting efficiency


This is where current carrying capacity enters the picture. It indicates the maximum current that a connector can transmit for a specific cable diameter. This capacity results from the balance between the heat generated due to the electrical resistance and the heat dissipated. The latter is dissipated both by radiation and by way of the cable. While higher current-carrying capacities can be realised more easily with larger connectors and cables, this is not an option in many applications. In some cases, active cooling of the connectors or the use of alternative plastic materials that allow higher temperatures will provide a solution.

Reducing electrical resistance is another alternative, which prevents heat from developing. This also improves energy efficiency. Ultimately, there are three key starting points for improving current carrying capacity: the connection of the cable, the contact material and the contact point itself.

There are various solutions for the cable connection. So-called "crimping", i.e. making a mechanical connection that provides both electrical contact and mechanical strength is a common technique in the energy sector.

A well-executed crimp considerably reduces the contact resistance due to the plastic deformation of the cable and the contact area. The right crimping tool and the correct parameters are crucial factors here. In terms of the contact material, the alloy selected is also of particular interest, as it can significantly increase conductivity. Copper alloy is generally used as the base material.

The resistance in the mating area is influenced by various factors. The number and size of the contact points can be optimised by the specific design: The larger the contact surface, the lower the resistance. The normal force – in other words, the force with which the mating parts are pressed together – also plays a major role in this context. A higher normal force increases the effective contact surface, meaning that more current can flow per contact point, whereby the choice of surface supports this effect. A higher normal force also entails greater insertion force, however, which in turn can increase wear.

Ultimately, it is evident that the optimised design of many parameters improves the overall current carrying capacity. State of the art simulation tools enable us to optimise the current carrying capacity as early as the design phase, meaning that different designs and materials can be selected and adapted accordingly.

Discover all articels of tec.news issue 48
Stephan Middelkamp

Dr Stephan Middelkamp

Position: General Manager Quality & Technologies

  • Department: SSU QT
  • Company: HARTING Stiftung & Co. KG

Related news


“If you can make it there, you’ll make it everywhere”
June 4, 2025

“If you can make it there, you’ll make it everywhere”

The All Electric Society faces the challenge of ensuring a reliable and efficient energy supply based on renewable sources.
read more
Technological key
March 31, 2025

Interoperability: a key aspect of the AES

Innovative connectivity solutions for the interplay between of electrification, digitalisation and decarbonisation
read more
I got the power - electrical energy as a driving force
March 31, 2025

I got the power

Important questions about the role of electrical energy as the driving force of the AES
read more

Social Media


© HARTING Technology Group

  • Imprint
  • Privacy Policy
  • Cookie Policy
  • Terms of Use
  • Customer Information